SEBM027706

MACHINE MODEL SERIAL No.

PC1800-6 10011, 11002 and up

• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.

• PC1800-6 mounts the SAA6D140E-3 engine.

For details of the engine, see the 140-3 Series Engine Shop Manual.

© 2004
All Rights Reserved
Printed in Japan 12-04 (01)
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GENERAL

CONTENTS

No. of page
01 GENERAL ............................................................................................................................ 01-1

10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1

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

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

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

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 LIST OF REVISED PAGES

The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Page to be newly added Add

Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

or made additions.

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

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00-1 (6) 01-1 10-14 10-43 10-72
00-2 (2) 01-2 10-15 10-44 10-73
00-2-1 (6) 01-3 10-16 10-45 10-74
00-2-2 (6) 01-4 10-17 10-46 10-75
00-2-3 (6) 01-5 10-18 10-47 10-76
00-2-4 (6) 01-6 10-19 10-48 10-77
00-2-5 (6) 01-7 10-20 10-49 10-78
00-2-6 (6) 01-8 10-21 10-50 10-79
00-3 01-9 10-22 10-51 10-80
00-4 01-10 10-23 10-52 10-81
00-5 01-11 10-24 10-53 10-82
00-6 01-12 (4) 10-25 10-54 10-83
00-7 01-13 10-26 10-55 10-84
00-8 10-28 10-56 10-85
00-9 10-29 10-57 10-86
00-10 10-1 (5) 10-30 10-58 10-88
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00-17 10-9 10-37 10-66 10-95
00-18 10-10 (6) 10-38 10-67 10-96
00-19 10-12 10-39 10-68 10-97
00-20 10-13 10-40 10-69 10-98
00-21 10-13-1 (5) 10-41 10-70 10-99
00-22 10-13-2 (5) 10-42 10-71 10-100

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10-103 10-148 10-193 20-124 (1) 20-160 (1)
10-104 10-149 10-194 20-125 (1) 20-161 (1)
10-106 10-150 (2) 20-126 (1) 20-162 (1)
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10-119 10-165 20-138 (1) 20-174 (1)
10-120 10-166 20-101 (3) 20-139 (1) 20-175 (1)
10-122 10-167 20-101-1 (6) 20-140 (1) 20-176 (1)
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20-238 (2) 20-318 (6) 20-356 (1) 20-429 (1) 20-469 (1)

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20-476 (1) 20-519 (1) 20-560 (2) 20-601 (1) 20-731 (1)
20-477 (1) 20-520 (1) 20-561 (2) 20-602 (1) 20-732 (1)
20-478 (1) 20-521 (1) 20-562 (2) 20-603 (1) 20-733 (1)
20-479 (1) 20-522 (1) 20-563 (2) 20-604 (1) 20-734 (1)
20-480 (1) 20-524 (1) 20-564 (1) 20-605 (1) 20-735 (1)
20-481 (1) 20-525 (1) 20-565 (1) 20-606 (1) 20-736 (1)
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20-512 (1) 20-553 (1) 20-593 (1) 20-724 (1) 20-811 (1)

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Time of Time of Time of Time of Time of

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revision revision revision revision revision
20-812 (1) 20-920 (1) 30-9-20 (6) 30-46 (2) 30-86 (2)
20-813 (1) 20-921 (1) 30-9-21 (6) 30-47 (2) 30-87 (2)
20-814 (1) 20-922 (1) 30-9-22 (6) 30-48 (2) 30-88 (2)
20-815 (1) 20-923 (1) 30-9-23 (6) 30-49 (2) 30-89 (2)
20-816 (1) 20-924 (1) 30-10 (2) 30-50 (2) 30-90 (2)
20-817 (1) 20-925 (1) 30-11 (2) 30-51 (2) 30-91 (2)
20-818 (1) 20-926 (1) 30-12 (2) 30-52 (2) 30-92 (2)
20-819 (1) 20-927 (1) 30-13 (2) 30-53 (2) 30-93 (2)
20-820 (1) 20-928 (1) 30-14 (2) 30-54 (2) 30-94 (2)
20-821 (1) 20-929 (1) 30-15 (2) 30-55 (2) 30-95 (2)
20-822 (1) 30-16 (2) 30-56 (2) 30-96 (2)
20-823 (1) 30-17 (2) 30-57 (2) 30-97 (2)
20-824 (1) 30-1 (6) 30-18 (2) 30-58 (2) 30-98 (2)
20-826 (1) 30-2 (6) 30-19 (2) 30-59 (2) 30-99 (2)
20-827 (1) 30-3 (2) 30-20 (2) 30-60 (2) 30-100 (2)
20-828 (1) 30-4 (2) 30-21 (2) 30-61 (2) 30-101 (2)
20-829 (1) 30-5 (3) 30-22 (2) 30-62 (2) 30-102 (2)
20-830 (1) 30-6 (2) 30-23 (2) 30-63 (2) 30-103 (2)
20-831 (1) 30-7 (6) 30-24 (2) 30-64 (2) 30-104 (2)
20-832 (1) 30-8 (6) 30-25 (2) 30-65 (2) 30-105 (2)
20-833 (1) 30-9 (6) 30-26 (2) 30-66 (2) 30-106 (2)
30-9-1 (6) 30-27 (2) 30-67 (2) 30-107 (2)
20-901 (1) 30-9-2 (6) 30-28 (2) 30-68 (2) 30-108 (2)
20-902 (1) 30-9-3 (6) 30-29 (2) 30-69 (2) 30-109 (2)
20-903 (1) 30-9-4 (6) 30-30 (2) 30-70 (2) 30-110 (2)
20-905 (1) 30-9-5 (6) 30-31 (2) 30-71 (2) 30-111 (2)
20-906 (1) 30-9-6 (6) 30-32 (2) 30-72 (2) 30-112 (2)
20-907 (1) 30-9-7 (6) 30-33 (2) 30-73 (2) 30-113 (2)
20-908 (1) 30-9-8 (6) 30-34 (2) 30-74 (2) 30-114 (2)
20-909 (1) 30-9-9 (6) 30-35 (2) 30-75 (2) 30-115 (2)
20-910 (1) 30-9-10 (6) 30-36 (2) 30-76 (2) 30-116 (2)
20-911 (1) 30-9-11 (6) 30-37 (2) 30-77 (2) 30-117 (2)
20-912 (1) 30-9-12 (6) 30-38 (2) 30-78 (2) 30-118 (2)
20-913 (1) 30-9-13 (6) 30-39 (2) 30-79 (2) 30-119 (2)
20-914 (1) 30-9-14 (6) 30-40 (2) 30-80 (2) 30-120 (2)
20-915 (1) 30-9-15 (6) 30-41 (2) 30-81 (2)
20-916 (1) 30-9-16 (6) 30-42 (2) 30-82 (2)
20-917 (1) 30-9-17 (6) 30-43 (2) 30-83 (2) 90-1 (6)
20-918 (1) 30-9-18 (6) 30-44 (2) 30-84 (2) 90-2-1 (6)
20-919 (1) 30-9-19 (6) 30-45 (2) 30-85 (2) 90-2-2 (6)

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LIST OF REVISED PAGES

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90-2-3 (6)
90-2-4 (6)
90-2-5 (6)
90-2-6 (6)
90-2-7 (6)
90-2-8 (6)
90-2-9 (6)
90-2-10 (6)
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90-2-13 (6)
90-2-14 (6)
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90-2-18 (6)
90-2-19 (6)
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00-2-6 PC1800-6
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SAFETY SAFETY NOTICE

SAFETY
SAFETY NOTICE

IMPORTANT SAFETY NOTICE

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

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

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.

00-4
FOREWORD GENERAL

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

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

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.

TESTING AND ADJUSTING

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

DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.

MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

NOTICE

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

00-5
FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:

Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.

SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):

2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204

00-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4

• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.

★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.

2) Sling wire ropes from the middle portion of the

hook.

00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.

k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.

Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.

2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.

Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.

00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly

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

• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection

00-9
FOREWORD COATING MATERIALS

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

Category Komatsu code Part No. Q'ty Container Main applications, features

• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container

Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case

00-10
FOREWORD COATING MATERIALS

Category Komatsu code Part No. Q'ty Container Main applications, features

• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI

SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA

Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load

SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass

• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container

SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT

00-11
FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

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

mm mm Nm kgm

6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5

16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100

27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370

Tightening torque
Thread diameter Width across
of bolt flats

mm mm Nm kgm

6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5

00-12
FOREWORD STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

00-13
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22

2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51

3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –

00-14
FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

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

CLASSIFICATION BY THICKNESS

Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication

Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue

Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White

Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow

Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black

Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n

00-15
FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE

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

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

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-16
FOREWORD CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound
1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-17
FOREWORD CONVERSION TABLE

Liter to U.S. Gallon

1l = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon

1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-18
FOREWORD CONVERSION TABLE

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

0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-19
FOREWORD CONVERSION TABLE

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

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-20
FOREWORD CONVERSION TABLE

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

°C °F °C °F °C °F °C °F

–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

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

00-21
FOREWORD UNITS

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}

00-22 10-04
 01 GENERAL

SPECIFICATION DRAWINGS...................................................................................................................... 01- 2

SPECIFICATIONS ........................................................................................................................................ 01- 4
WEIGHT TABLE ........................................................................................................................................... 01- 8
FUEL, COOLANT AND LUBRICANTS......................................................................................................... 01- 12

PC1800-6 01-1
GENERAL SPECIFICATION DRAWINGS

SPECIFICATION DRAWINGS
BACK HOE

A B C D E F G H

Dimension mm 17,185 6,745 6,015 810 6,510 6,235 7,436 5,780

A B C D E F

Dimension mm 15,780 9,265 13,380 2,740 8,620 15,305

01-2 PC1800-6
GENERAL SPECIFICATION DRAWINGS

LOADING SHOVEL

A B C D E F G H

Dimension mm 13,230 7,435 5,410 810 6,510 6,140 7,445 5,780

A B C D E F

Dimension mm 13,170 11,940 14,420 3,220 7,090 7,500

PC1800-6 01-3
GENERAL SPECIFICATIONS

SPECIFICATIONS
BACK HOE

Machine model PC1800-6

Serial Number 10011, 11002 and up
3
Bucket capacity m 12.0
Weight of machine kg 180,000
Max. digging depth mm 9,265
Working ranges

Max. vertical wall depth mm 2,740

Max. digging reach mm 15,780
Max. reach at ground level mm 15,305
Max. digging height mm 13,380
Performance

Max. dumping height mm 8,620

Max. digging force kN {kg} 626 {63,800}
Swing speed rpm 4.5
Swing max. slope angle deg. 10.0
Travel speed km/h 2.7
Gradeability deg. 35
Ground pressure kPa {kg/cm2} 166.71 {1.7}
[standard double grouser shoe width] [810 mm]
Overall length mm 17,185
Overall width mm 6,015
Overall width of track mm 5,410
Overall height mm 6,745
Overall height to top of machine mm 6,510
Dimensions

Ground clearance of upper structure mm 2,080

Min. ground clearance mm 730
Tail swing radius mm 6,235
Min. swing radius of work equipment mm 7,300
Height of work equipment at min. swing radius mm 11,855
Length of track on ground mm 5,780
Track gauge mm 4,600
Height of machine cab mm 4,535

01-4 PC1800-6
GENERAL SPECIFICATIONS

Machine model PC1800-6

Serial Number 10011, 11002 and up
Model SAA6D140E-3 x 2
4-cycle, water-cooled, in-line, vertical, direct injec-
Type
tion, with turbocharger and aftercooler (air cooled)
No. of cylinders – bore x stroke mm 6 – 140 x 165
Piston displacement l {cc} 15.24 {15,240}
kW/rpm
Flywheel horsepower 338/1,800 {454/1,800}
{HP/rpm}
Performance

Nm/rpm
Engine

Max. torque 2,138/1,350 {218/1,350}

{kgm/rpm}
Max. speed at no load rpm 1,980 ± 50
Min. speed at no load rpm 825 ± 25
g/kWh
Min. fuel consumption 192.5 {143.63}
{g/HPh}
Starting motor 24V, 11 kW
Alternator 24V, 50A
Battery 12V, 170 Ah x 2
Radiator core type CWX-4
Carrier roller 3 on each side
carriage
Under-

Track roller 8 on each side

Track shoe Assembly-type double grouser, 49 on each side
Variable displacement piston type:
Hydraulic pump

Type HPV160, HPV95 + 95 x 2

Gear type: SAL63 + 8
Delivery l/min Piston type: 419 x 4 + 314 x 2, gear type: 157 x 2
MPa
Set pressure Piston type: 29.6 {300}, gear type: 2.96 {30}
{kg/cm2}
Type x No. 2-spool + 4-spool type x 2, + 5-spool type x 2
Control
valve

Control method Hydraulic

Piston type (with brake valve):

Hydraulic

Travel motor
Hydraulic system

x 4 (KMF160ADT-2)
motor

Piston type (with safety valve):

Swing motor
x 2 (KMF160AB-2)
Boom Arm Bucket
Double-acting Double-acting Double-acting
Hydraulic cylinder

Cylinder type piston piston piston

Inside diameter of cylinder mm 280 250 200
Outside diameter of piston rod mm 190 160 140
Stroke mm 2,660 2,142 2,170
Max. distance between pins mm 6,480 5,342 5,420
Min. distance between pins mm 3,820 3,200 3,250
Hydraulic tank Box-shaped, with breather
Hydraulic filter Line: Pump outlet side, Returen: Tank return side
Hydraulic cooler Air cooled (J4)

PC1800-6 01-5
GENERAL SPECIFICATIONS

LOADING SHOVEL

Machine model PC1800-6 loading shovel

Serial Number 10011, 11002 and up
3
Bucket capacity m 11.0
Weight of machine kg 180,000
Max. digging depth mm 3,220
Working ranges

Max. vertical wall depth mm —

Max. digging reach mm 13,170
Max. reach at ground level mm 11,940
Max. digging height mm 14,420
Performance

Max. dumping height mm 9,635

Max. digging force kN {kg} 755 {77,000}
Swing speed rpm 4.5
Swing max. slope angle deg. 10.0
Travel speed km/h 2.7
Gradeability deg. 35
Ground pressure kPa {kg/cm2} 166.71 {1.7}
[standard double grouser shoe width] [810 mm]
Overall length mm 13,230
Overall width mm 6,015
Overall width of track mm 5,630
Overall height mm 8,180
Overall height to top of machine mm 6,510
Dimensions

Ground clearance of upper structure mm 2,080

Min. ground clearance mm 730
Tail swing radius mm 6,235
Min. swing radius of work equipment mm 7,500
Height of work equipment at min. swing radius mm 10,890
Length of track on ground mm 5,780
Track gauge mm 4,600
Height of machine cab mm 4,535

01-6 PC1800-6
GENERAL SPECIFICATIONS

Machine model PC1800-6 loading shovel

Serial Number 10011, 11002 and up
Model SAA6D140E-3 x 2
4-cycle, water-cooled, in-line, vertical, direct injec-
Type
tion, with turbocharger and aftercooler (air cooled)
No. of cylinders – bore x stroke mm 6 – 140 x 165
Piston displacement l {cc} 15.24 {15,240}
kW/rpm
Flywheel horsepower 338/1,800 {454/1,800}
{HP/rpm}
Performance

Nm/rpm
Engine

Max. torque 2,138/1,350 {218/1,350}

{kgm/rpm}
Max. speed at no load rpm 1,980 ± 50
Min. speed at no load rpm 825 ± 25
g/kWh
Min. fuel consumption 192.5 {143.63}
{g/HPh}
Starting motor 24V, 11 kW
Alternator 24V, 50A
Battery 12V, 170 Ah x 2
Radiator core type CWX-4
Carrier roller 3 on each side
carriage
Under-

Track roller 8 on each side

Track shoe Assembly-type double grouser, 49 on each side
Variable displacement piston type:
Hydraulic pump

Type HPV160, HPV95 + 95 x 2

Gear type: SAL63 + 8
Delivery l/min Piston type: 419 x 4 + 314 x 2, gear type: 157 x 2
MPa
Set pressure Piston type: 29.6 {300}, gear type: 2.96 {30}
{kg/cm2}
Type x No. 2-spool + 4-spool type x 2, + 5-spool type x 2
Control
valve

Control method Hydraulic

Piston type (with brake valve):

Hydraulic system

Hydraulic

Travel motor
x 4 (KMF160ADT-2)
motor

Piston type (with safety valve):

Swing motor
x 2 (KMF160AB-2)
Boom Arm Bucket Bottom dump
Hydraulic cylinder

Cylinder type Double-acting piston

Inside diameter of cylinder mm 280 200 225 180
Outside diameter of piston rod mm 180 150 160 100
Stroke mm 1,930 2,170 2,050 600
Max. distance between pins mm 5,655 5,400 5,550 1,990
Min. distance between pins mm 3,725 3,230 3,500 1,390
Hydraulic tank Box-shaped, with breather
Hydraulic filter Line: Pump outlet side, Returen: Tank return side
Hydraulic cooler Air cooled (J4)

PC1800-6 01-7
GENERAL WEIGHT TABLE

WEIGHT TABLE
★ This weight table is a guide for use when transporting or handling components
BACK HOE
Unit: kg
Machine model PC1800-6
Serial Number 10011, 11002 and up
Engine assembly 2,670 x 2
• Engine 1,720 x 2
• PTO (Including lubricating piping) 490 x 2
• Main piston pump 441 (157 + 147 + 137) x 2
• Tandem gear pump 17.7 x 2
Radiator assembly (Excluding radiator guard) 260 x 2
Oil cooler assembly 200 x 2
Hydraulic oil tank (Excluding hydraulic oil) 1,500
Fuel tank (Excluding fuel) 1,459
Revolving frame (Including L.H. and R.H. platform) 40,410
Operator’s cab 1,230
Swing machinery 1,044 x 2
Swing motor 126 x 2
Travel motor 180 x 4
Swing control valve 108
L.H. 5-spool control valve 245 x 2
R.H. 4-spool control valve 240 x 2
Center swivel joint assembly 69
Counterweight (Excluding mounting bolts) 21,300
Track frame assembly
• Track frame 6,950 x 2
• Carrier roller 70 x 6
• Track roller 280 x 16
• Idler cushion assembly 885 x 2
• Idler 1,110 x 2
• Final drive assembly 2,810 x 2
• Swing circle assembly 3,610
• Center frame assembly 15,000

01-8 PC1800-6
GENERAL WEIGHT TABLE

Unit: kg
Machine model PC1800-6
Serial Number 10011, 11002 and up
Track shoe assembly
• Standard shoe (810 mm) 17,020
• Optional wide shoe (1,010 mm) 21,040
Boom assembly (Excluding piping) 16,500
Arm assembly (Excluding piping) 7,570
Bucket assembly 9,985
Boom cylinder assembly 1,929
Arm cylinder assembly 1,288
Bucket cylinder assembly 921
Link (Large) 386 x 2
Link (Small) 206 x 4
Boom pin 88 x 2
Arm pin 330
Bucket pin 81.5 x 2
Link pin 81.5 x 2 + 70.5 x 6

PC1800-6 01-9
GENERAL WEIGHT TABLE

LOADING SHOVEL

Unit: kg
Machine model PC1800-6 loading shovel
Serial Number 10011, 11002 and up
Engine assembly 2,670 x 2
• Engine 1,720 x 2
• PTO (Including lubricating piping) 490 x 2
• Main piston pump 441 (157 + 147 + 137) x 2
• Tandem gear pump 17.7 x 2
Radiator assembly (Excluding radiator guard) 260 x 2
Oil cooler assembly 200 x 2
Hydraulic oil tank (Excluding hydraulic oil) 1,500
Fuel tank (Excluding fuel) 1,895
Revolving frame (Including L.H. and R.H. platform) 40,410
Operator’s cab 1,230
Swing machinery 1,044 x 2
Swing motor 126 x 2
Travel motor 180 x 4
Swing control valve 108
L.H. 5-spool control valve 245 x 2
R.H. 4-spool control valve 240 x 2
Center swivel joint assembly 69
Counterweight (Excluding mounting bolts) 21,300
Track frame assembly
• Track frame 6,950 x 2
• Carrier roller 70 x 6
• Track roller 280 x 16
• Idler cushion assembly 885 x 2
• Idler 1,110 x 2
• Final drive assembly 2,810 x 2
• Swing circle assembly 3,610
• Center frame assembly 15,000

01-10 PC1800-6
GENERAL WEIGHT TABLE

Unit: kg
Machine model PC1800-6 loading shovel
Serial Number 10011, 11002 and up
Track shoe assembly
• Standard shoe (810 mm) 17,020
• Optional wide shoe (1,010 mm) 21,040
Boom assembly (Excluding piping) 13,200
Arm assembly (Excluding piping) 6,850
Bucket assembly 14,315
Boom cylinder assembly 2,330
Arm cylinder assembly 1,100
Bucket cylinder assembly 1,496
Bottom dump cylinder assembly 309
Front and rear bucket connecting pin 41 x 2
Bottom dump cylinder rod pin 41 x 2
Bottom dump cylinder bottom pin 26 x 2
Boom top pin 99 x 2
Boom foot pin 110 x 2
Boom cylinder rod pin 61 x 2
Boom cylinder bottom pin 87 x 2
Arm top pin 105 x 2
Arm cylinder rod pin 28 x 2
Arm cylinder bottom pin 28 x 2
Bucket cylinder rod pin 51 x 2
Bucket cylinder bottom pin 68 x 2

PC1800-6 01-11
GENERAL FUEL, COOLANT AND LUBRICANTS

FUEL, COOLANT AND LUBRICANTS

AMBIENT TEMPERATURE CAPACITY ( )
KIND OF
RESERVOIR 22 4 14 32 50 68 86 104
FLUID Specified Refill
30 20 10 0 10 20 30 40

SAE 30
SAE 10W
Engine oil pan (each side) 58 53
SAE 10W-30
SAE 15W-40

SAE 30
PTO case (each side) Engine oil 20 20
SAE 10W
Swing machinery case
(each side) 30 30
SAE 30
Final drive case (each side) 85 85

Hydraulic system SAE 10W 2400 1500

Idler (1 each) 1–1.1 1–1.1

Track roller (1 each) Gear oil GO 140B 0.86–0.94 0.86–0.94

Carrier roller (1 each) 1.05–1.15 1.05–1.15

ASTM D975 No.2

Fuel tank Diesel fuel 2,750
ASTM D975 No.1

Cooling system (each side) Coolant Add antifreeze 85

01-12 PC1800-6
(4)
GENERAL FUEL, COOLANT AND LUBRICANTS

NOTE:

(1) When fuel sulphur content is less than 0.5%,

change oil in the oil pan every periodic mainte-
nance hours described in this manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.

Change interval of oil

Fuel sulphur content
in engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval

(2) When starting the engine in an atmospheric

temperature of lower than 0°C, be sure to use
e n g i n e o i l o f S A E 1 0 W, S A E 10 W - 3 0 a nd
SAE15W-40, even though an atmospheric tem-
perature goes up to 10°C more or less in the day
time.
(3) Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
(4) There is no problem if single grade oil is mixed
with multigrade oil (SAE10W-30, 15W-40), but
be sure to add single grade oil that matches the
temperature in the table on the left.
(5) We recommend Komatsu genuine oil which has
been specifically formulated and approved for
use in engine and hydraulic work equipment
applications.

ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute

Specified capacity: Total amount of oil including oil

for components and oil in piping.
Refill capacity: Amount of oil needed to refill system
during normal inspection and main-
tenance.

PC1800-6 01-13
 10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD

PTO ..........................................................10- 2 TRAVEL MOTOR..................................... 10- 92

PTO LUBRICATION SYSTEM .................10- 4 TRAVEL BRAKE VALVE.......................... 10- 94
POWER TRAIN........................................10- 6 PILOT RELIEF VALVE............................. 10- 96
SWING MACHINERY ..............................10- 8 SAFETY LOCK VALVE ............................ 10- 98
SWING CIRCLE.......................................10- 10 ACCUMULATOR ..................................... 10-100
FINAL DRIVE ...........................................10- 12 PPC VALVE ............................................. 10-102
SPROCKET .............................................10-13-1 SOLENOID VALVE .................................. 10- 110
IDLER.......................................................10- 14 HYDRAULIC CYLINDER......................... 10- 112
HIC SYSTEM ...........................................10- 16 AIR SYSTEM ........................................... 10- 116
TRACK ROLLER......................................10- 18 AIR GOVERNOR..................................... 10- 117
CARRIER ROLLER..................................10- 19 AIR TANK................................................. 10- 117
TRACK SHOE..........................................10- 20 AUTO-DRAIN VALVE .............................. 10- 117
HYDRAULIC COMPONENT LAYOUT .....10- 24 SAFETY VALVE....................................... 10- 118
HYDRAULIC TANK ..................................10- 26 SOLENOID VALVE
HYDRAULIC PUMP .................................10- 28 (FOR LUBRICATION, HORN) ............ 10- 118
SWING PUMP..........................................10- 55 GREASE PUMP ...................................... 10- 119
CONTROL AND PTO LUBRICATING GREASING SYSTEM .............................. 10-122
PUMP .................................................10- 60 WORK EQUIPMENT ............................... 10-130
LINE OIL FILTER .....................................10- 62 DIMENSIONS OF WORK EQUIPMENT . 10-134
PILOT OIL FILTER...................................10- 62 ENGINE CONTROL ................................ 10-138
RETURN OIL FILTER ..............................10- 63 MACHINE CONTROL SYSTEM .............. 10-145
DRAIN OIL FILTER ..................................10- 64 ELECTRONIC COMPONENTS OF
ELECTRONIC OLSS ...............................10- 66 AUTOMATIC WORK EQUIPMENT
CONTROL VALVE....................................10- 68 CONTROL SYSTEM .......................... 10-172
SWING CONTROL VALVE ......................10- 84 MONITOR SYSTEM ................................ 10-178
SWING MOTOR.......................................10- 88
CENTER SWIVEL JOINT ........................10- 91

PC1800-6 10-1
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO

PTO

20 l (Engine oil CLASS-CD SAE30).

Volume of lubricating oil :
1. Driven gear (No. of teeth: 46)
2. PTO case Reduction ratio:
3. Drive gear (No. of teeth: 51) 43
4. Input shaft HPV95 + 95 pump shaft = = 0.843
51
5. Connection plate 46
6. Driven gear (No. of teeth: 41) HPV160 pump shaft = = 0.902
51
7. Driven gear (No. of teeth: 43) 41
SAL63 + 8 pump shaft = = 0.804
51

Unit: mm
No. Check item Criteria Remedy
Backlash between drive gear and Standard clearance Clearance limit
8
driven gear (HPV160) 0.23 – 0.74 —
Backlash between drive gear and Repair or
9 0.23 – 0.74 — replace
driven gear (HPV90 + 90)
Backlash between driven gear (SAL63
10 0.23 – 0.74 —
+ 8) and driven gear (HPV90 + 90)

10-2 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO

PC1800-6 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO LUBRICATION SYSTEM

PTO LUBRICATION SYSTEM

1. PTO case OUTLINE

2. Lubrication piping The lubrication oil from lubrication oil tank (5) goes
3. Dividing block to tandem gear pumps (4). The oil passing through
4. Control and PTO lubricating pump (SAL63+8) gear pump SAL8 is sent to the upper dividing block
5. Oil tank (3), and from here it is divided and sent to all parts of
the PTO to lubricate and cool all parts of the gear.

10-4 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN

POWER TRAIN

10-6 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN

1. Idler 8. Final drive, sprocket 15. P4 pump (HPV95+95)

2. Center swivel joint 9. Travel motor (KMF160ADT-2) 16. Swing pump (HPV160)
3. Swing motor (KMF160AB-2) 10. Engine (SAA6D140E-3) 17. Control, PTO lubricating pump
4. 5-spool control valve (V2) 11. PTO 18. Swing brake solenoid valve
5. 5-spool control valve (V4) 12. P1 pump (HPV95+95) 19. Swing machinery
6. 4-spool control valve (V1) 13. P2 pump (HPV95+95) 20. Swing circle
7. 4-spool control valve (V3) 14. P3 pump (HPV95+95) 21. Swing valve

PC1800-6 10-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY

SWING MACHINERY

10-8 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY

1. Swing pinion (No. of teeth: 16)

2. Cover
3. Case
4. Coupling
5. No. 2 planetary gear (No. of teeth: 32)
6. No. 2 ring gear (No. of teeth: 83)
7. No. 1 ring gear (No. of teeth: 83)
8. Cover
9. Dipstick
10. Swing motor
11. No. 1 sun gear (No. of teeth: 23)
12. No. 1 planetary carrier
13. No. 2 sun gear (No. of teeth: 17)
14. No. 2 planetary carrier
15. Drain plug

Specifications
23 + 190 17 + 83
Reduction ratio: x
23 17
= 54.4757

Unit: mm
No. Check item Criteria Remedy
Backlash between swing motor shaft Standard clearance Clearance limit
16
and No. 1 sun gear 0.07 – 0.18 —
Backlash between No. 1 sun gear
17 0.15 – 0.38 —
and No. 1 planet gear
Backlash between No. 1 planet gear
18 0.21 – 0.58 —
and ring gear
Backlash between No. 2 planet gear
19 0.06 – 0.24 —
and coupling
Backlash between No. 1 planet car-
20 0.47 – 0.72 —
rier and No. 2 sun gear
Replace
Backlash between No. 2 sun gear
21 0.15 – 0.38 —
and No. 2 planet gear
Backlash between No. 2 planet gear
22 0.23 – 0.67 —
and ring gear
Backlash between coupling and
23 0.09 – 0.25 —
swing pinion
Backlash between swing pinion and
24 0.41 – 2.02 —
swing circle
Clearance between plate and cou-
25 0.15 – 1.0 —
pling
Standard size Repair limit Repair hard
Wear of swing pinion oil seal contact
26 chrome plating
surface 185 — or replace

PC1800-6 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CIRCLE

SWING CIRCLE

1. Swing circle inner race Specifications

2. Swing circle outer race (Upper end) 131
3. Roller Reduction ratio: = 8.1875
16
4. Swing circle outer race (Lower end) Amount of grease: 170 l (G2-LI)
a. Inner race soft zone S position
b. Onner race soft zone S position

Unit: mm
No. Check item Criteria Remedy
Axial clearance of bearing Standard clearance Clearance limit
5 Replace
(When mounted on machine) 0.5 – 1.5 2.0

10-10 PC1800-6
(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE

FINAL DRIVE

1. Hub Specifications
2. Sprocket 65 13 + 80 15 + 69
3. Floating seal Reduction ratio: x x
11 31 15
4. No. 1 ring gear (80 teeth)
Amount of lubricating oil: Each 85 l (EO30-CD)
= 236.727
5. No. 1 planetary gear (33 teeth)
6. Drive gear (11 teeth)
7. Input shaft
8. Motor case
9. Travel motor
10. Driven gear (65 teeth)
11. Case
12. No. 1 sun gear (13 teeth)
13. No. 1 planetary carrier
14. Housing
15. Housing
16. No. 2 ring gear (69 teeth)
17. No. 2 planetary gear (26 teeth)
18. No. 2 sun gear (15 teeth)
19. No. 2 planetary gear carrier

10-12 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE

Unit: mm
No. Check item Criteria Remedy
Backlash between No. 1 sun gear and Standard clearance Clearance limit
20
No. 1 planetary gear 0.25 – 0.46 —
Backlash between No. 1 planetary gear
21 0.28 – 0.67 —
and No. 1 ring gear
Backlash between drive gear and
22 0.20 – 0.51 —
driven gear Replace
Backlash between No. 2 planetary gear
23 0.36 – 0.81 —
and No. 2 ring gear
Backlash between No. 2 sun gear and
24 0.24 – 0.62 —
No.2 planetary gear
25 Clearance of cases 7.7 —
Thickness of shim at cover mounting
26 2.0 Adjust
part

PC1800-6 10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET

SPROCKET

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

1 Wear of tooth tip
482.7 470.7
Build-up welding
2 Thickness of tooth root 40 34
or replace
3 Width of tooth 140 137
4 Wear of tooth shape Repair limit: 6 (measure with sprocket tooth shape)

10-13-1 PC1800-6
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET

SPROCKET TOOTH SHAPE OF REAL DIMENSION

a The above drawing is reduced to 41%. Enlarge it to 244% to return it to the full scale and make a copy on
an OHP sheet.

PC1800-6 10-13-2
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER

IDLER

10-14 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER

Unit: mm
No. Check item Criteria Remedy
Outside diameter Standard size Repair limit
1
of protruding part 1072 —
Outside diameter Rebuild
2 1030 1016
of tread surface or
3 Depth of tread 21 — replace
4 Overall width 311 —
5 Width of tread 85 —
Standard Tolerance Standard Clearance
Clearance size clearance limit
Shaft Hole
6 between shaft
and bushing –0.060 +0.520 0.540 –
140 —
–0.120 +0.480 0.640 Replace
Standard Tolerance Standard Interference bushing
Interference size interference limit
Shaft Hole
7 between idler and
bushing +0.090 –0.123 0.165 –
150 —
+0.042 –0.175 0.265

PC1800-6 10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIC SYSTEM

HIC SYSTEM

1. Idler 7. Relief valve with check valve 13. R.H. travel motor
2. Yoke 8. Accumulator 14. Brake valve
3. Plunger A 9. Check valve 15. Center swivel joint
4. Plunger B 10. Stop valve 16. R.H. travel control valve
5. Cylinder 11. Reducing valve 17. Line oil filter
6. Stop valve 12. Check valve 18. Front pump

OPERATION
• The area between yoke (2) and plunger (3) is • When idler (1) returns to the front, the gas pres-
filled with grease. In addition, the area between sure inside accumulator (8) makes the pressur-
plunger (4) and cylinder (5) is filled with hydrau- ized oil pass through the check valve of the
lic pressure at a constant pressure 17.7 MPa relief valve with check valve (7) and return to the
{180 kg/cm 2}. This hydraulic pressure is con- inside of cylinder (5). As idler (1) moves forward,
nected to accumulator (8) through relief valve the cushion force is reduced and the system
with check valve (7). returns to the original condition.
• If idler (1) tries to move to the rear under exter-
nal force, plunger (4) is pushed and the pres-
sur e ins ide cy linder (5) ris es. When this
pressure exceeds the set pressure, relief valve
with check valve (7) opens and the pressure
goes to accumulator (8).
• The volume of the nitrogen gas inside accumu-
lator (8) is reduced by an amount equal to the
pressurized oil pushed by plunger (4). However,
the gas pressure rises, so the cushion force
becomes larger as plunger (4) moves.

10-16 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIC SYSTEM

• ACCUMULATOR

Volume: 32,500 cc
1. Valve Operating pressure: 29.4 MPa {300 kg/cm2}
2. Body
3. Plug
4. Check valve

PC1800-6 10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER

TRACK ROLLER

Unit: mm
No. Check item Criteria Remedy
Outside diameter Standard size Repair limit
1
of flange 360 —
Outside diameter
2 300 288
of tread surface
Thickness of Rebuild
3 82.5 — or
tread
replace
4 Overall width 394 —
5 Inside width 141 —
6 Width of tread 85 —
7 Width of flange 41.5 —
Standard Tolerance Standard Clearance
Clearance size clearance limit
Shaft Hole
8 between shaft
and bushing –0.060 +0.460 0.300 –
125 —
–0.120 +0.240 0.580 Replace
Standard Tolerance Standard Interference bushing
Interference size interference limit
Shaft Hole
9 between roller
and bushing +0.090 +0.025 0.017 –
135 —
+0.042 –0.015 0.105

10-18 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER

CARRIER ROLLER

Unit: mm
No. Check item Criteria Remedy
Outside diameter of Standard size Repair limit
1
flange 275 —
Outside diameter of
2 240 220
tread
3 Width of tread 85 —
4 Thickness of tread 47 37
5 Width of flange 25 —
Standard Tolerance Standard Interference
Interfer- size Shaft Hole interference limit
ence
–0.060 +0.360 0.280 – Replace
6 between OUTER 95 —
bearing –0.120 +0.220 0.480
and roller –0.060 +0.390 0.205 –
INNER 125 —
–0.015 +0.145 0.405
Interfer- +0.087 +0.035 0.022 –
OUTER 102.6 —
ence +0.057 0 0.087
7 between
bearing +0.180 +0.053 0.027 –
INNER 135 —
and shaft +0.080 –0.010 0.190

Play of roller in Standard size Clearance limit

8
axial direction 0 – 0.18 0.18

PC1800-6 10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

TRACK SHOE

★ P portion shows the link of bushing press fitting end.

10-20 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch
317.75 320.75
Reverse or
When turned
Standard size replace
2 Bushing outside diameter Normal load Impact load
117 — 112
Standard size Repair limit Reverse or
3 Link height
195 182 replace
Thickness of link metal
4 49.5
(bushing press-fitting portion)
5 274 Replace
6 Shoe bolt pitch 96
7 33
8 Inside width 148
Repair or
9 Link Overall width 83
replace
10 Tread width 78
11 Protrusion of pin 2.9
12 Protrusion of regular bushing 2
13 Overall length of pin 353 Adjust or
14 Overall length of bushing 226 replace
15 Thickness of bushing metal 23
16 Thickness of spacer —
17 Bushing 245 – 686 kN {25 – 70 ton}
Press-fitting
18 Regular pin 921.2 – 2312.8 kN {94 – 236 ton} —
force
19 Master 529.2 – 872.2 kN {54 – 89 ton}
: Dry type track link

PC1800-6 10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

Unit: mm
No. Check item Criteria Remedy
Tightening torque Additional tightening
a. Regular (Nm {kgm}) angle (deg.)
link
Shoe 686.5 ± 68.6 {70 ± 7} 120 ± 10
Retighten
bolt Tightening torque Additional tightening Lower limit torque
20 b. Master (Nm {kgm}) angle (deg.) (Nm {kgm})
link
— — —
No. of shoes (each
49 —
side)
Tolerance Standard
Standard size
Interference between Shaft Hole interference
21
bushing and link +0.652 +0.087
113 0.435 – 0.652
+0.522 0
Interference between +0.496 –0.126
22 70 0.522 – 0.696
regular pin and link +0.396 –0.200
Tolerance Standard
Clearance between Standard size
Shaft Hole clearance
23 regular pin and bush-
ing +0.496 +1.136 Adjust or
70 0.240 – 0.740
+0.396 +0.736 replace
Tolerance Standard
Standard size
Interference between Shaft Hole interference
24
master pin and link +0.216 –0.126
70 0.302 – 0.416
+0.176 –0.200
Tolerance Standard
Clearance between Standard size
Shaft Hole clearance
25 master pin and bush-
ing +0.050 +1.436
69.8 0.886 – 1.486
–0.050 +0.936

: Dry type track link

10-22 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

DOUBLE SHOE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height
23 2
2 Height 70 —
3 Thickness 38
Rebuild or replace
4 81
Length at bottom
5 —
6 50
Length at top
7 44

PC1800-6 10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC COMPONENT LAYOUT

HYDRAULIC COMPONENT LAYOUT

10-24 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC COMPONENT LAYOUT

1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Return oil filter
6. No. 3 control valve (4-spool)
7. No. 4 control valve (5-spool)
8. Oil cooler
9. No. 1 control valve (4-spool)
10. No. 2 control valve (5-spool)
11. No. 2 swing pump
12. No. 4 main pump
13. No. 3 main pump
14. No. 1 swing pump
15. No. 2 main pump
16. No. 1 main pump
17. Line oil filter
18. Swing control valve
19. Swing motor

PC1800-6 10-25
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK

HYDRAULIC TANK

1. Hydraulic tank BREATHER

2. Filler cap Relief cracking pressure:
3. Strainer 68.6 ± 6.9 Pa {0.7 ± 0.07 kg/cm2}
4. Oil level sensor Suction cracking pressure:
5. Suction strainer
1.96 ± 0.2 Pa {0.02 ± 0.002 kg/cm2}
6. Breather

10-26 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

HYDRAULIC PUMP
1. No. 2, 4 PUMP ASSEMBLY
(HPV95 + 95 WITH TVC VALVE AND CO•NC VALVE ASSEMBLY)

1. Front pump Pecn (F). CO•NC valve output PSV. Pilot pressure port
2. Front pump servo pressure OUT port Pe. TVC valve output pressure port
unit assembly Pecn (R). CO•NC valve output Pd. Jet sensor downstream pres-
3. Rear pump servo unit pressure OUT port sure IN port
assembly PA3. Swing pump discharge Pt. Jet sensor upstream pressure
4. Rear pump pressure IN port IN port
PPL. L.H. travel main pressure
port
PPR. R.H. travel main pressure
port

10-28 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

2. No. 1, 3 PUMP ASSEMBLY

(HPV95 + 95 WITHOUT TVC VALVE AND CO•NC VALVE ASSEMBLY)

1. Front pump Pecn (F). CO•NC valve output pressure IN port

2. Front pump servo valve Pecn (R). CO•NC valve output pressure IN port
3. Rear pump servo valve Pecn (FP). CO•NC valve output pressure pick-up port
4. Rear pump Pecn (RP). CO•NC valve output pressure pick-up port
PSV. Pilot pressure port

PC1800-6 10-29
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

3. FRONT PUMP, REAR PUMP AND IMPELLER PUMP

No. 2, 4 PUMP

PA1. Pump discharge PSV1A. Servo valve output Pd (V1, V3). Discharge port
pressure port port (To V1 or V3 control valve)
PA2. Pump discharge PSV1B. Servo valve output Pd (V2, V4). Discharge port
pressure port port (To V2 or V4 control valve)
PSV1. Control pump pressure PSV2A. Servo valve output
PS. Suction port
port port
PSV2. Control pump pressure PSV2B. Servo valve output
port port

10-30 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

1. Front shaft 6. Cylinder 11. Rear end cap

2. Front cradle 7. Valve plate 12. Rear case
3. Front case 8. Front end cap 13. Rear cradle
4. Rocker cam 9. Impeller 14. Rear shaft
5. Piston 10. Coupling 15. Servo piston

PC1800-6 10-31
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

4. FRONT PUMP, REAR PUMP AND IMPELLER PUMP

No. 1, 3 PUMP

PA1. Pump discharge PSV1A. Servo valve output Pd (V1, V3). Discharge port
pressure port port (To V1 or V3 control valve)
PA2. Pump discharge PSV1B. Servo valve output Pd (V2, V4). Discharge port
pressure port port (To V2 or V4 control valve)
PSV1. Control pump pressure PSV2A. Servo valve output
PS. Suction port
port port
PSV2. Control pump pressure PSV2B. Servo valve output
port port

10-32 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

1. Front shaft 6. Cylinder 11. Rear end cap

2. Front cradle 7. Valve plate 12. Rear case
3. Front case 8. Front end cap 13. Rear cradle
4. Rocker cam 9. Impeller 14. Rear shaft
5. Piston 10. Coupling 15. Servo piston

PC1800-6 10-33
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

5. SERVO UNIT ASSEMBLY

• No. 2, 4 FRONT PUMP SERVO UNIT ASSEMBLY

1. TVC valve PSV. Control pump pressure IN port

2. CO•NC valve assembly Pac. Servo actuator port
3. Connector Pe. TVC valve output pressure F-R connecting port
4. Servo valve Pd. Jet sensor downstream pressure F-R connecting port
Pt. Jet sensor downstream pressure IN port
PA1. Pump discharge pressure IN port Pdr. Servo valve drain OUT port
PA2. Pump discharge pressure IN port
PA3. Swing pump discharge pressure IN port

10-34 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

• No. 2, 4 REAR PUMP SERVO UNIT ASSEMBLY AND SWING PUMP SERVO UNIT ASSEMBLY

1. CO•NC valve assembly PSV. Control pump pressure IN port

2. Servo valve Pac. Servo actuator port
Pe (P). TVC valve output pressure pick-up IN port
Pe. TVC valve output pressure F-R connecting port
PA1. Pump discharge pressure IN port Pd. Jet sensor downstream pressure IN port
PA2. Pump discharge pressure IN port Pt. Jet sensor downstream pressure IN port
Pdr. Servo valve drain OUT port

PC1800-6 10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

• SERVO VALVE • The diagram shows the servo valve for the
For No. 2, 4 PUMP and SWING PUMP No. 2 front pump.

Pac. Servo actuator port Pdr (OUT).Servo valve drain port

PSV (IN). Control pump pressure IN port Pdr. CO•NC valve drain port
PSV (OUT). Control pump pressure OUT port Pecn. CO•NC valve output pressure IN port
PA1. Pump discharge pressure IN port
PA2. Pump discharge pressure IN port

10-36 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

1. Locknut 7. Pin 13. Sleeve

2. Cover 8. Control piston 14. Guide spool
3. Plug 9. Lock nut 15. Spring
4. Spring 10. Plug 16. Plug
5. Body 11. Locknut 17. Cover
6. Arm 12. Cover 18. Locknut

Function
• Delivery amounts of two main piston pumps are
controlled separately by the respective servo
valve.
• The stroke of the actuator (servo piston) which
changes the delivery of the variable displace-
ment pump, is controlled by the pump servo
valve.
The relationship between the delivery amounts
q1 (or q2) of the pump and the input signal pres-
sure Pecn to the servo valve is as shown in the
graph on the right. The stroke of the actuator
(servo piston) is proportional to the oil pressure
from TVC valve, in other words, delivery
amounts q1 (or q2) vary in direct proportion to
Pecn.

PC1800-6 10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

For No. 1, 3 PUMP

Pac. Servo actuator port PSV. Control pump pressure IN port

PA2. Pump discharge pressure IN port Pecn. CO•NC valve output pressure IN port

10-38 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

1. Plug 7. Spring 13. Plug

2. Locknut 8. Plug 14. Spring
3. Body 9. Cover 15. Guide spool
4. Control piston 10. Locknut 16. Sleeve
5. Arm 11. Locknut 17. Cover
6. Pin 12. Cover 18. Locknut

PC1800-6 10-39
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

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

• The control pump pressure Psv is taken to port • When guide spool (13) moves, port a and port d
a. are closed and port d is connected to drain
Signal pressure Pecn from the NC valve is chamber e. As a result, servo piston chamber f
taken from port b to chamber c. is also interconnected with chamber e through
• When signal pressure Pecn rises, control piston port g and port d.
(8) is pushed to the left by the hydraulic pres- At the same time, port a is interconnected with
sure in chamber c, and stops at a point where it port h, so the oil flows through port i to servo
balances the pressure of springs (4) and (4A). piston chamber j, pushes servo piston (19) to
At the same time, arm (6) uses servo piston (19) the left, increases the swash plate angle in the
as a fulcrum and sways to the left in the same main piston pump and increases the pump dis-
way as control piston (8). This moves guide charge amount.
spool (13) to the left. • When servo piston (19) moves, arm (6) rotates
clockwise with its center at pin (7). Guide spool
(13) is moved to the right and closes port a, port
d and port h, so the discharge increases by an
amount that matches signal pressure Pecn.

10-40 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

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

• When signal pressure Pecn goes down, control • When servo piston (19) moves, arm (6) rotates
piston (8) moves to the right and stops at a point counterclockwise with its center at pin (7). Guide
where the hydraulic pressure in chamber c bal- spool (13) is moved to the left and closes port a,
ances the pressure of springs (4) and (4A). port d and port h, so the discharge decreases
At the same time, arm (6) uses servo piston (19) by an amount that matches signal pressure
as a fulcrum and sways to the right in the same Pecn.
way as control piston (8). This moves guide
spool (13) to the right.
• When guide spool (13) moves, port a and port h
are closed and port h is connected to drain
chamber e. As a result, servo piston chamber j
is also interconnected with chamber e through
port i and port h.
At the same time, port a is interconnected with
port d, so the oil flows through port g to servo
piston chamber f, pushes servo piston (19) to
the right, decreases the swash plate angle in the
main piston pump and decreases the pump dis-
charge amount.

PC1800-6 10-41
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

• TVC VALVE

Psv. Control pump pressure IN port 1. Spring 5. Sleeve

PA1. Pump discharge pressure IN port 2. Spool 6. Piston
PA2. Pump discharge pressure IN port 3. Piston 7. Body
Pdr. TVC valve drain OUT port 4. Piston 8. Solenoid
Pe. TVC valve output pressure OUT port

10-42 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

OPERATION AND FUNCTION OF TVC VALVE

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

Function Operation
• When the power mode is at DH mode or H • The command current sent from the controller
mode, the pump discharge amount is controlled actuates solenoid push pin (9) and spool (2)
to the optimum amount by the command current moves. When this happens, the piston stops at
sent from the controller in accordance with the a point where it balances the total of the force of
variation in the engine speed. spring (1), the force of push pin (9), and the
• In G mode or when the pump prolix switch is force of TVC output pressure Pe acting on pis-
ON, the pump discharge amount is controlled ton (3). The command current at this point is
according to the pump discharge pressure small, so spool (2) is balanced at the bottom.
(load) by hydraulic sensing which follows a con- As a result, port a and port b are almost com-
stant pump absorption torque. pletely open, so the pressure oil from the control
pump is almost all output as TVC output pres-
★ For details, see MACHINE CONTROL SYSTEM. sure Pe.
In thi s way, th e p ump di s cha r ge amou nt
becomes the maximum.

PC1800-6 10-43
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

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

Operation
• The command current sent from the controller
actuates solenoid push pin (9) and spool (2)
moves. When this happens, the piston stops at
a point where it balances the force of spring (1).
The command current at this point is large, so
spool (2) is balanced at the top.
As a result, the flow of oil from the control pump
at port a and port b is throttled. At the same
time, the area of the opening at port b and port c
(drain port) becomes larger.
In this way, TVC output pressure Pe goes down,
and the pump discharge amount decreases.

10-44 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

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

• When G mode is selected (pump prolix switch

ON), solenoid push pin (9) is pushed up,
increases the set pressure of spring (1), and this
condition is maintained.
• As a result, the pump absorption torque
becomes constant, so TVC output pressure Pe
(= pump discharge amount) is controlled by the
pump discharge pressure.
• Main pump discharge pressures PA1 and PA2
are low, so spool (2) is pushed down fully by
spring (1). As a result, control pump discharge
pressure Psv and TVC valve output pressure
Pe are equal.
At this point, TVC valve output pressure Pe
becomes the maximum, and the main pump dis-
charge amount is also the maximum.

PC1800-6 10-45
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

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

• When main pump discharge pressure PA1 (or

PA2) increases, spool (2) is moved up by piston
(4) or piston (6). As a result, the flow of oil from
port a to port b is throttled by the notch in the
spool. At the same time, the area of the opening
at port b and port c (drain port) becomes larger.
In this way, TVC output pressure Pe goes down,
and the pump discharge amount decreases.

10-46 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

6. CO•NC valve
• Front

PA1I. Pump discharge pressure IN port Pc. CO selector pilot port

PA2I. Pump discharge pressure IN port Pecn. CO•NC valve output pressure detection port
PA1o. Pump discharge pressure OUT port Pt. Jet sensor upstream pressure IN port
PA2o. Pump discharge pressure OUT port Pd. Jet sensor downstream pressure IN port
Psv1. Control pump pressure IN port Pdr1. Servo valve drain IN port
Psv2. Control pump pressure OUT port Pdr2. Servo valve drain OUT port
Pe1. TVC valve output pressure detection port
Pe2. TVC valve output pressure front, rear inter-
connection port

PC1800-6 10-47
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

• Rear

PA1I. Pump discharge pressure IN port Pd. Jet sensor downstream pressure IN port
Pe1. TVC valve output pressure front, rear intercon- Pt. Jet sensor upstream pressure IN port
nection port Pdr2. Servo valve drain OUT port
Pe2. TVC valve output pressure detection port Pecn. CO•NC valve output pressure detection port
Pc. CO selector pilot port

10-48 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

CO valve NC valve
1. Plug 7. Plug
2. Piston 8. Sleeve
3. Spring 9. Piston
4. Spool 10. Spool
5. Piston 11. Spring
6. Plug 12. Plug

PC1800-6 10-49
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

FUNCTION AND OPERATION OF CO VALVE

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

Function Operation
• When the load becomes large during operations • Spool (4) is being pushed down fully by spring
and the main pump discharge pressure rises to (3).
a point close to relief pressure, the cut-off func- As a result, port a and port b are fully open and
tion of the CO valve acts to reduce the pump TVC valve output pressure Pe and CO valve
discharge in order to reduce relief loss. output pressure Pec are equal.
• At the same time, it has a cut-off cancel function In this way, CO valve output pressure Pec
actuated by the pilot pressure from the heavy-lift becomes the maximum and the main pump dis-
solenoid valve. charge amount also becomes the maximum.
• The CO valve is controlled by balancing the
spring with the total of main pump discharge
pressure PA and CO valve output pressure Pec.

10-50 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

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

• If the load increases and main pump discharge

pressure PA comes close to the relief pressure,
main pump discharge pressure PA pushes pis-
ton (5). At the same time, CO valve output pres-
sure Pec pushes piston (5), and spool (4)
moves up.
As a result, the flow of oil from port a to port b is
throttled by the notch in the spool, and the area
of the opening at port b and port c (drain port)
becomes larger.
In this way, CO valve output pressure Pec goes
down, and the pump discharge amount
becomes the minimum.

PC1800-6 10-51
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

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

• When the heavy-lift solenoid valve is excited

and is switched, pilot pressure Pc is sent to the
port, and piston (2) is pushed down fully.
For this reason, seat (6) contacts seat (7) and
spool (4) is locked.
As a result, main pump discharge pressure PA
goes up, but even when it reaches the relief
pressure, spool (4) is not actuated, so CO valve
output pressure Pec remains at the maximum.

10-52 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

FUNCTION AND OPERATION OF NC VALVE

1) When control valve is at neutral

Function Operation
• The NC valve controls the main pump discharge • Jet sensor differential pressure (Pt – Pd)
amount according to the amount that the control becomes the maximum, and the force of jet sen-
valve spool is operated. This flow control func- sor output pressure Pt pushing piston (10)
tion reduces the neutral loss and fine control becomes larger than the total of the force of
loss. spring (12) and the force of jet sensor output
• The NC valve is controlled by balancing the total pressure Pd pushing the bottom of spool (11).
of the jet sensor output pressure Pt and the NC As a result, spool (11) is pushed down, so the
valve output pressure Pecn with the total of the flow to port c and port b is throttled, and the
force of NC valve spring (12) and the jet sensor area of the opening of port b and port a (drain
output pressure Pd. port) becomes larger. In this way, NC valve out-
• The jet sensor picks up the flow of oil returning put pressure Pecn becomes the minimum, and
to the tank through the control valve and takes the main pump discharge amount also becomes
them as Pt and Pd of the NC valve. the minimum.

PC1800-6 10-53
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

2) When control lever is operated

• When the control valve is moved, the jet sensor

differential pressure (Pt – Pd) goes down in
accordance with the movement of the control
valve. Spool (11) is pushed up, and the area of
the opening of port c and port b becomes larger.
In this way, NC valve output pressure Pecn
becomes larger and the discharge amount from
the main pump increases. In other words, the
pump discharge amount increases according to
the amount the control lever is operated.

10-54 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING PUMP

SWING PUMP

★ For details of the structure and operation of the

servo valve, see HYDRAULIC PUMP.

1. Main pump PA3. Discharge port Pe. TVC valve output pressure IN port
2. Servo valve PSV. Control pump pressure supply Pe (P). TVC valve output pressure pick-up
3. CO•NC valve port port
Pd. Jet sensor downstream pres- PS. Suction port
sure IN port Pd2. Drain port
Pt. Jet sensor upstream pressure
IN port

PC1800-6 10-55
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING PUMP

1. MAIN PISTON PUMP (HPV160)

PA3. Pump discharge pressure port

PSV. Control pump pressure port
PSVA. Serve valve output port
PSVB. Serve valve output port

10-56 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING PUMP

1. Shaft 7. Valve plate

2. Cradle 8. End cap
3. Case 9. Impeller
4. Rocker cam 10. Block
5. Piston 11. Servo piston
6. Cylinder block

PC1800-6 10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING PUMP

2. CO•NC VALVE ★ For details of the operation of the CO•NC valve,

see HYDRAULIC PUMP.

PA1i. Pump discharge pressure IN port Pd. Jet sensor downstream pressure IN port
Pe1. TVC valve output pressure front, rear intercon- Pt. Jet sensor upstream pressure IN port
nection port Pdr2. Servo valve drain OUT port
Pe2. TVC valve output pressure detection port Pecn. CO•NC valve output pressure OUT port

10-58 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING PUMP

CO valve NC valve
1. Plug 10. Plug
2. Cover 11. Sleeve
3. Seat 12. Piston
4. Spring 13. Spool
5. Seat 14. Body
6. Spool 15. Seat
7. Piston 16. Spring
8. Sleeve 17. Plug
9. Plug 18. Cover

PC1800-6 10-59
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL AND PTO LUBRICATING PUMP

CONTROL AND PTO LUBRICATING PUMP

SAL63 + 8

1. Drive gear OUTLINE

2. Bracket In this tandem gear pump, the SAL63 is for the PPC
3. Gear case and OLSS charging, and the SAL8 is for PTO lubri-
4. Cover cation.
5. Coupling
6. Drive gear
7. Bracket SPECIFICATIONS
8. Gear case Theoretical delivery: SAL63 63.1 cc/rev.
9. Cover SAL8 8.5 cc/rev.
10. Driven gear
Max. delivery pressure: 20.6 MPa {210 kg/cm2}
11. Driven gear

10-60 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL AND PTO LUBRICATING PUMP

Unit: mm
No. Check item Criteria Remedy
Clearance Standard clearance Clearance limit
between gear SAL63
12 0.10 – 0.15 0.19
case and side
plate SAL8 0.10 – 0.15 0.19
Replace
Clearance SAL63 0.06 – 0.149 0.20
between bearing
13
I.D. and gear SAL8 0.06 – 0.144 0.20
shaft O.D.
Discharge
Standard Discharge
Pump speed pressure
Performance discharge volume limit
SAL63 (rpm) (MPa
14 EO10W-CD (l/min) (l/min)
{kg/cm2})
45 – 55°C
2,500 2.9 {30} 151 138
SAL8 2,500 2.9 {30} 18 16

PC1800-6 10-61
 LINE OIL FILTER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT OIL FILTER

LINE OIL FILTER

1. Body
2. Element
3. Cover

PILOT OIL FILTER

1. Bracket
2. Cartridge
3. Element

10-62 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETURN OIL FILTER

RETURN OIL FILTER

1. Cover OUTLINE
2. Spring There are six return oil filter sets installed at the rear
3. Bypass valve of the hydraulic tank. They act to remove the dirt and
4. Bypass valve spring other matter in the return oil.
5. Element
6. Housing • Bypass valve set pressure:
0.103 ± 0.02 MPa {1.05 ± 0.2 kg/cm2}

PC1800-6 10-63
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRAIN OIL FILTER

DRAIN OIL FILTER

1. Bracket OUTLINE
2. Safety valve This filter is installed between the swing motor,
3. Cartridge travel motor, and hydraulic tank. It acts to remove
4. Element the dirt and foreign matter in the oil coming from the
drain port of each motor.

• Safety valve set pressure:

0.1 MPa {1.0 kg/cm2}

10-64 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC OLSS

ELECTRONIC OLSS
1. OUTLINE
1) Whole of machine

The electronic OLSS (Open center Load Sensing

1. Mode selector switch System) is a hydraulic system which reduces vari-
2. 4-spool control valve ous hydraulic losses made during operation and
3. 5-spool control valve improves the fine controllability by controlling the
4. Potentiometer swash plate angle, or the discharge, of the swash
5. Engine speed sensor plate-type variable-capacity pumps and which
6. No. 2 swing pump reduces the fuel consumption by matching the
7. No. 4 main pump engine best to the pumps.
8. No. 3 main pump The pump absorption torque can be set to one of the
9. No. 1 swing pump DH, H, and G modes. When the load is small, the
10. No. 2 main pump fuel consumption is reduced by selecting the G
11. Safety lock valve
mode.
12. Charging and PTO lubrication pump
13. No. 1 main pump
14. Swing control valve
15. Control box (for front engine)
16. Control box (for rear engine)
17. Prolix circuit resistor
18. Prolix circuit switch

10-66 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC OLSS

2) Detail of pumps

The diagram shows the front engine.

1. PTO 9. No. 2 rear pump servo valve

2. Swing pump CO•NC valve assembly 10. No. 2 rear pump
3. Swing pump servo valve 11. No. 2 front pump
4. Swing pump 12. Charging and PTO lubrication pump
5. TVC valve 13. No. 1 rear pump
6. No. 2 front pump servo valve 14. No. 1 rear pump servo valve
7. No. 2 front pump CO•NC valve assembly 15. No. 1 front pump
8. No. 2 rear pump CO•NC valve assembly 16. No. 1 front pump servo valve

PC1800-6 10-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

CONTROL VALVE
• V1 CONTROL VALVE

10-68 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

1. Main relief valve 9. Jet sensor relief valve

2. Spool (R.H. travel) 10. Check valve
3. Spool (Boom-Lo) 11. Check valve spring
4. Spool (Bucket-Hi) 12. Straight-travel valve
5. Spool (Arm-Hi) 13. Suction valve
6. Spool return spring 14. Safety-suction valve (for boom head)
7. Body 15. Safety-suction valve
8. Jet sensor orifice

PC1800-6 10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

10-70 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Main relief valve Free length Installation Installation Installation
Free length
1 pilot poppet x O.D. length load load
spring 330.3 N 292 N
34.8 x 10.4 32.9 —
{33.7 kg} {29.8 kg}
Main relief valve 5.7 N 4.5 N
2 16 x 16 12 —
main valve spring {0.58 kg} {0.46 kg}
Jet sensor relief
30.4 N 24.5 N
3 valve pilot pop- 34.5 x 8.8 29.4 — Replace
{3.1 kg} {2.5 kg}
pet spring spring if any
Jet sensor relief damages or
49 N 39.2 N deformations
4 valve main valve 37.4 x 11.4 33 —
{5.0 kg} {4.0 kg} are found
spring
Spool return 431.2 N 345 N
5 69.9 x 57 63 —
spring {44 kg} {35.2 kg}
Spool return
6 75 x 37 75 — — —
spring
Check valve 18.8 N 14.7 N
7 78.2 x 26.6 52 —
spring {1.92 kg} {1.5 kg}
Check valve 18.8 N 14.7 N
8 53.6 x 31 39 —
spring {1.92 kg} {1.5 kg}

PC1800-6 10-71
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

• V2, V4 CONTROL VALVE

10-72 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

1. Main relief valve 9. Jet sensor orifice

2. Spool (Service) 10. Jet sensor relief valve
3. Spool (Boom-Hi) 11. Check valve
4. Spool (Arm-Lo) 12. Check valve spring
5. Spool (Bucket-Lo) 13. Check valve (with orifice)
6. Spool (L.H. travel) 14. Safety-suction valve
7. Spool return spring 15. Suction valve
8. Body

PC1800-6 10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

10-74 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Main relief valve Free length
1 x O.D. length load load
pilot poppet spring
330.3 N 292 N
34.8 x 10.4 32.9 —
{33.7 kg} {29.8 kg}
Main relief valve 5.7 N 4.5 N
2 16 x 16 12 —
main valve spring {0.58 kg} {0.46 kg}
Jet sensor relief Replace
30.4 N 24.5 N
3 valve pilot poppet 34.5 x 8.8 29.4 — spring if any
{3.1 kg} {2.5 kg}
spring damages or
Jet sensor relief deforma-
49 N 39.2 N tions are
4 valve main valve 37.4 x 11.4 33 —
{5.0 kg} {4.0 kg} found
spring
431.2 N 345 N
5 Spool return spring 69.9 x 57 63 —
{44 kg} {35.2 kg}
6 Spool return spring 75 x 37 75 — — —
1.0 N 0.8 N
7 Check valve spring 31.8 x 7.6 26.5 —
{0.1 kg} {0.08 kg}
18.8 N 14.7 N
8 Check valve spring 78.2 x 26.6 52 —
{1.92 kg} {1.5 kg}

PC1800-6 10-75
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

• V3 CONTROL VALVE

10-76 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

1. Main relief valve 9. Jet sensor relief valve

2. Spool (R.H. travel) 10. Check valve
3. Spool (Boom-Lo) 11. Check valve spring
4. Spool (Bucket-Hi) 12. Straight-travel valve
5. Spool (Arm-Hi) 13. Suction valve
6. Spool return spring 14. Safety-suction valve (for boom head)
7. Body 15. Safety-suction valve
8. Jet sensor orifice

PC1800-6 10-77
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

10-78 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Main relief valve Free length
1 x O.D. length load load
pilot poppet spring
330.3 N 292 N
34.8 x 10.4 32.9 —
{33.7 kg} {29.8 kg}
Main relief valve 5.7 N 4.5 N
2 16 x 16 12 —
main valve spring {0.58 kg} {0.46 kg}
Jet sensor relief
30.4 N 24.5 N Replace
3 valve pilot poppet 34.5 x 8.8 29.4 —
{3.1 kg} {2.5 kg} spring if any
spring
damages or
Jet sensor relief deforma-
49 N 39.2 N
4 valve main valve 37.4 x 11.4 33 — tions are
{5.0 kg} {4.0 kg}
spring found
Spool return 431.2 N 345 N
5 69.9 x 57 63 —
spring {44 kg} {35.2 kg}
Spool return
6 75 x 37 75 — — —
spring
Check valve 18.8 N 14.7 N
7 78.2 x 26.6 52 —
spring {1.92 kg} {1.5 kg}
Check valve 18.8 N 14.7 N
8 53.6 x 31 39 —
spring {1.92 kg} {1.5 kg}

PC1800-6 10-79
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

STRAIGHT-TRAVEL VALVE

P. From port PF
PP. From pump
PT. Drain
P1. From port PR
P2. To L.H. travel
P3. To bucket, boom
P4. To arm

10-80 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

1. Orifice
2. Check valve
3. Spring
4. Spool return spring
5. Body
6. Spool
7. Cover

PC1800-6 10-81
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

STRAIGHT-TRAVEL VALVE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Spool return Free length Replace
1 x O.D. length load load
spring spring if
156.9 N damaged or
117.5 x 27.9 68 — —
{16 kg} deformed
Throttle valve 0.98 N
2 31.8 x 7.6 26.5 — —
spring {0.1 kg}

10-82 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

Function
• When the travel is operated at the same time as
the boom, arm, or bucket, the pressure oil flow-
ing to the left and right travel circuits is divided
and sent to the boom, arm, or bucket circuit. If
the oil in one travel circuit is divided off, the
amount of oil supplied to the travel motor will be
less than in the travel circuit which is not divided,
so the drop in the supply of oil to the travel
motor will cause the machine to deviate.
• To prevent this, the straight-travel valve is
switched to interconnect the left and right travel
circuits. This ensures that the amount of oil sup-
plied to the left and right travel motors is equal,
so the left and right travel motors both rotate at
the same speed, and this prevents any travel
deviation.

Operation
When travel is operated independently (straight-
travel solenoid valve de-energized)
• The straight-travel solenoid valve is de-ener-
gized, so no pilot pressure flows, and spool (6)
remains pushed to the left.
• Because of this, port P2 (left travel circuit) and
port P1 (right travel circuit) are not intercon-
nected, and each circuit remains independent.

When travel and work equipment are operated at

same time (st raight -travel solenoid valve
excited)
• The straight-travel solenoid valve is excited, so
the pilot pressure flows and spool (6) is pushed
to the right.
• Because of this, port P2 and port P1 are inter-
connected, so the amount of oil supplied to the
left and right travel motors is the same. As a
result, the left and right travel motors both rotate
at the same speed, so there is no travel devia-
tion.

PC1800-6 10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CONTROL VALVE

SWING CONTROL VALVE

a. PA1 port (From L.H. PPC valve) g. T port (To tank)

b. PA2 port (With blind plug) h. Jet sensor outlet pressure NCA out port
c. Jet sensor outlet pressure NCB OUT port (To NC valve)
(To NC valve) i. B2 port (With blind plate)
d. P port (From swing pump) j. B1 port (To swing motor MA port)
e. A1 port (To swing motor MB port) k. PB1 port (From L.H. PPC valve)
f. A2 port (With blind plate) l. PB2 port (With blind plug)

10-84 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CONTROL VALVE

1. Main relief valve 6. Check valve

2. Spool return spring 7. Check valve spring
3. Spool (Swing) 8. Jet sensor relief valve
4. Spool (Swing shadow) 9. Jet sensor orifice
5. Body

PC1800-6 10-85
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CONTROL VALVE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Main relief valve Free length
1 x O.D. length load load
pilot poppet spring
289.1 N 231.3 N
30.7 x 9.6 27.3 — Replace
{29.5 kg} {23.6 kg}
spring if any
Main relief valve 86.2 N 68.6 N
2 52.3 x 16.5 38 — damages or
main valve spring {8.8 kg} {7.0 kg}
deforma-
Spool return spring tions are
3 75 x 37 75 0 — —
(inner) found
Spool return spring 431.2 N 345 N
4 69.9 x 57 63 —
(outer) {44 kg} {35.2 kg}
18.8 N 14.7 N
5 Check valve spring 78.2 x 26.6 52 —
{1.92 kg} {1.5 kg}

10-86 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR

SWING MOTOR
KMF160AB-2

1. Swing motor Specifications

2. Swing holding brake Model: KMF160AB-2
Theoretical discharge: 160.7 cc/rev
B : From swing holding brake solenoid valve Rated speed: 1830 rpm
S : From tank Brake release pressure:
T1 : To tank 1.8 ± 0.4 MPa {18.4 ± 4 kg/cm2}
T2 : From cooling piping port S
MA : From swing control valve port B1
MB : From swing control valve port A1

10-88 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR

1. SWING MOTOR

1. Housing
2. Brake spring (Belleville spring)
3. Brake piston
4. Plate
5. Disc
6. Brake case
7. Output shaft
8. Cylinder block
9. Piston
10. Valve plate
11. Center shaft

2. SAFETY VALVE

1. Safety valve Specifications

2. Housing
27 MPa {275 kg/cm2} (at 300 l/min)
Safety valve set pressure:
3. Check valve
4. Check valve spring
Min. 19.6 MPa {200 kg/cm2} (at 5 l/min)
Cracking pressure:

Check valve set pressure: 0.03 MPa {0.3 kg/cm2}

PC1800-6 10-89
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit Replace
Free length Installation Installation Installation spring if
Free length
1 Check valve spring x O.D. length load load damaged
7.0 N 5.6 N or
66.5 x 25.6 45 — deformed
{0.71 kg} {0.57 kg}

10-90 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

1. Cover
2. Body
3. Slipper seal
4. Oil seal
5. Shaft

Unit: mm
No. Check item Criteria Remedy
Standard
Clearance between rotor Standard size Clearance limit
1 clearance Replace
and shaft
110 0.056 – 0.105 0.111

PC1800-6 10-91
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

TRAVEL MOTOR

The travel motor assembly consists of the following Specifications

components. Type: KMF160ADT-2
Theoretical delivery: 160.7 cc/rev.
Parking brake releasing pressure:
1. Travel motor 1.32 MPa {13.5 kg/cm2}
2. Travel brake valve

10-92 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

TRAVEL MOTOR (WITH PARKING BRAKE)

1. Housing
2. Brake spring
3. Brake piston
4. Plate
5. Disc
6. Brake case
7. Center shaft
8. Valve plate
9. Piston
10. Cylinder block
11. Output shaft

PC1800-6 10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL BRAKE VALVE

TRAVEL BRAKE VALVE

1. Spool switching spring FUNCTION

2. Counterbalance valve spool This valve prevents the speed of the motor from
3. Housing being increased by the weight of the machine when
4. Check valve spring going downhill.
5. Check valve The brake valve consists of the counterbalance
valve, the check valve and the safety valve.

Rated flow: 420 l/min.

Safety valve set pressure:
32.4 0 MPa {330 0 kg/cm2} (at 5 l/min.)
+0.5 +5

Spool switching pressure:

1.27 ± 0.2 MPa {13 ± 2 kg/cm2}
(Cracking pressure)

10-94 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL BRAKE VALVE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Free length Replace
1 Spool return spring x O.D. length load load
spring if
641.9 N 497.8 N damaged or
51 49.5 50.7
{65.5 kg} {50.8 kg} deformed
7.0 N 5.6 N
2 Check valve spring 66.5 45 62.2
{0.71 kg} {0.57 kg}

PC1800-6 10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT RELIEF VALVE

PILOT RELIEF VALVE

1. Lock nut 7. Valve seat Set pressure:

kg/cm2} (at 135 l/min)
2. Adjustment screw 8. Main valve spring +0.3 +3
3. Holder 9. Main valve 2.94 0 MPa {30 0
4. Seat 10. Sleeve
5. Pilot poppet spring 11. Valve seat
6. Pilot poppet

10-96 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT RELIEF VALVE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Relief valve pilot Free length
1 x O.D. length load load
poppet spring
27.5 N 21.6 N Replace
41.1 x 11.8 40.1 32.9
{2.8 kg} {2.2 kg}
Relief valve main 19.6 N 15.7 N
2 44.5 x 11.2 31 35.6
valve spring {2.0 kg} {1.6 kg}

PC1800-6 10-97
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SAFETY LOCK VALVE

SAFETY LOCK VALVE

1. Spool P1. From control pump

2. Body P2. To PPC valve
3. Cover T. To tank

10-98 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SAFETY LOCK VALVE

FUNCTION
• Safety lock valve is in the circuit between the
control pump (Pilot relief valve) and the PPC
valve.
It acts to open and close the flow of pressurized
oil to the PPC valve.
• The operation of the control levers can be
locked by closing the circuit.

OPERATION
When safety lock lever is at FREE
When the safety lock lever is set to the FREE posi-
tion, the cable moves spool (1) to the right. Port P1
and port P2 are opened, and the pressurized oil
from the control pump flows to the PPC valve.
As a result, when the control levers are operated,
the PPC valves are actuated.

When safety lock lever is at LOCK

When the safety lock lever is set to the LOCK posi-
tion, the cable moves spool (1) to the left, port P1
and port P2 are closed, port P2 and port T are
opened, and the pressurized oil from the control
pump does not flow to the PPC valve. As a result,
when the control levers are operated, the PPC
valves are not actuated.

PC1800-6 10-99
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR

ACCUMULATOR

1. Cap SPECIFICATIONS
2. Nut Gas capacity: 300 cc
3. Cap Gas pressure: 1.18 MPa {12 kg/cm2}
4. Body
5. Bladder
6. Port
7. Nut

10-100 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC VALVE

PPC VALVE
FOR WORK EQUIPMENT AND SWING CONTROL

10-102 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC VALVE

1. Nut 7. Retainer
2. Disc 8. Centering spring
3. Joint 9. Valve
4. Piston 10. Body
5. Plate 11. Metering spring
6. Collar

PC1800-6 10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC VALVE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Free length
1 Centering spring x O.D. length load load Replace
9.0 N 7.3 N spring if any
36.5 x 12.6 34.5 29.2
{0.92 kg} {0.74 kg} damages or
33.3 N 26.5 N deformations
2 Metering spring 33.5 x 7.4 29.4 26.8 are found
{3.4 kg} {2.7 kg}
14.7 N 11.8 N
3 Return spring 28.3 x 11.5 17.5 22.6
{1.5 kg} {1.2 kg}

10-104 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC VALVE

FOR TRAVEL CONTROL

10-106 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC VALVE

1. Bolt 5. Retainer
2. Piston 6. Centering spring
3. Plate 7. Valve
4. Collar 8. Body

PC1800-6 10-107
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC VALVE

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation Replace
Free length
1 Metering spring x O.D. length load load spring if any
33.3 N 26.5 N damages or
33.5 x 7.5 29.4 26.8 deformations
{3.4 kg} {2.7 kg}
are found
14.7 N 11.8 N
2 Return spring 28.3 x 11.5 17.5 22.6
{1.5 kg} {1.2 kg}

10-108 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE

SOLENOID VALVE

FOR RESETTING CO, STRAIGHT TRAVEL, HEAVY LIFTING, PUSHING UP MACHINE, SWING HOLDING
BRAKE

1. Heavy lift solenoid valve T : To tank

2. Straight travel solenoid valve A1 : To No. 1 pump (CO valve)
3. Swing holding brake solenoid valve A2 : To straight travel valve
4. CO resetting solenoid valve A3 : To main valve (Relief valve)
5. Machine push-up solenoid valve A4 : To boom LOWER 2-stage safety valve
A5 : To left and right travel motor
P1 : From control pump
ACC : Blind
PPC : Blind

10-110 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE

1. Connector
2. Variable core
3. Coil
4. Cage
5. Spool
6. Block
7. Spring

OPERATION
When solenoid is deactivated
• The signal current does not flow from the con-
troller, so coil (3) is deactivated.
For this reason, spool (5) is pushed to the right
in the direction of the arrow by spring (6).
As a result, the circuit between ports P and A
closes and the pressurized oil from the control
pump does not flow to the actuator.
At the same time, the pressurized oil from the
actuator flows from port A to port T, and is then
drained to the tank.

When solenoid is excited

• When the signal current flows from the controller
to coil (3), coil (3) is excited.
For this reason, spool (5) is pushed to the left in
the direction of the arrow.
As a result, the pressurized oil from the control
pump flows from port P through the inside of
spool (5) to port A, and then flows to the actua-
tor.
At the same time, port T is closed, and this stops
the oil from flowing to the tank.

PC1800-6 10-111
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
BACK HOE

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-112 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Cylinder
size Shaft Hole clearance limit
Clearance –0.050 +0.257 0.089 –
Boom 190 —
between pis- –0.122 +0.039 0.379 Replace
1
ton rod and –0.043 +0.228 0.089 – bushing
bushing Arm 160 —
–0.106 +0.046 0.334
–0.043 +0.256 0.082 –
Bucket 140 —
–0.106 +0.039 0.362
–0.043 +0.263 0.243 –
Clearance Boom 160 1.0
–0.106 +0.200 0.369
between pis-
–0.043 +0.263 0.243 –
2 ton rod sup- Arm 140 1.0
–0.106 +0.200 0.369
port shaft and
bushing –0.043 +0.263 0.243 –
Bucket 140 1.0 Replace
–0.106 +0.200 0.369
pin or
–0.043 +0.263 0.243 – bushing
Clearance Boom 160 1.0
–0.106 +0.200 0.369
between cyl-
–0.043 +0.263 0.243 –
3 inder bottom Arm 140 1.0
–0.106 +0.200 0.369
support shaft
and bushing –0.043 +0.263 0.243 –
Bucket 140 1.0
–0.106 +0.200 0.369

PC1800-6 10-113
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

LOADING SHOVEL

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-114 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

BOTTOM DUMP CYLINDER

Unit: mm
No. Check item Criteria Remedy
Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
Clearance Boom 180 — — — —
between pis- Replace
1 Arm 150 — — — —
ton rod and bushing
bushing Bucket 160 — — — —
Bottom
100 — — — —
dump
Boom 150 — — — —
Clearance
between pis- Arm 120 — — — —
2 ton rod sup- Bucket 120.6 — — — —
port shaft and
Bottom
bushing 100 — — — — Replace
dump
pin,
Boom 180 — — — — bushing
Clearance
between cyl- Arm 120 — — — —
3 inder bottom Bucket 140.6 — — — —
support shaft
Bottom
and bushing 100.5 — — — —
dump

PC1800-6 10-115
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR SYSTEM

AIR SYSTEM

1. Air compressor OUTLINE

2. Air governor The PC1800 uses pressurized air to operate the air
3. Check valve horn and automatic greasing system.
4. Air tank The pressurized air is supplied by the compressor
5. Safety valve installed to the engine and is stored in the air tank.
6. Auto-drain valve When the pressure in the air tank reaches 0.7 MPa
7. Grease pump {7.3 kg/cm2}, the compressor is unloaded; when the
8. Solenoid valve (for lubrication)
9. Horn tank pressure drops below 0.6 MPa {6.2 kg/cm2}, the
10. Solenoid valve (for horn) compressor again starts to supply pressurized air.

10-116 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR GOVERNOR

AIR GOVERNOR

1. Valve seat
2. Diaphragm
3. Body
4. Sleeve
5. Adjustment screw
6. Spring
7. Cover

A. From air tank

B. To unloader valve

AIR TANK
Capacity: 15 l

AUTO-DRAIN VALVE

1. Filter
2. Body
3. Valve guide
4. Diaphragm
5. Cover

PC1800-6 10-117
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SAFETY VALVE

SAFETY VALVE

1. Cover
2. Sleeve
3. Spring
4. Pin
5. Cap
6. Valve
7. Nipple

FUNCTION
The safety valve is installed to the air tank, and is
actuated when the pressure inside the tank is abnor-
mal and exceeds the set pressure. The safety valve
then acts to release the pressure to the atmosphere.

0 0
Set pressure: 0.95 –0.05 MPa {9.7 –0.5 kg/cm2}

SOLENOID VALVE (FOR LUBRICATION, HORN)

1. Spring
2. Magnet
3. Wire
4. Wire
5. Coil
6. Cover
7. Piston
8. Body

A. From air tank

B. To horn or grease pump

10-118 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASE PUMP

GREASE PUMP

1. Silencer FUNCTION
2. Valve • The pump is divided into air chamber (4) and
3. Cover grease chamber (6). As the amount of grease in
4. Air chamber grease chamber (6) goes down, follow plate (5)
5. Follower plate is pulled down to push down the grease stuck to
6. Grease chamber the edge of grease chamber (6).
7. Grease tank

A. Air inlet port

B. Grease outlet port

PC1800-6 10-119
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASE PUMP

• HYDRAULICALLY ACTUATED TYPE

1. Vent valve A. Hydraulic oil inlet port FUNCTION

2. Pump B. Grease chamber • The grease pump is used for the automatic
3. Follower plate C. Refill port greasing system.
4. Tube T. Pump drain port • This pump is driven hydraulically to supply
5. Plate grease from chamber B with pressure. It is a
6. Grease tank double-action pump, which discharges grease in
both up-stroke and down-stroke.

Oil pressure flow rate : 28 l/min

Set pressure (Reducing valve):
2.4 ± 0.098 MPa {23.5 ± 1 kg/cm2}
Grease tank capacity: Approx. 32 kg

10-120 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASING SYSTEM

GREASING SYSTEM
• AIR ACTUATED TYPE

1. Bucket cylinder bottom pin A. Arm distributor

2. Arm cylinder rod pin B. Boom distributor
3. Boom point pin C. Main distributor (boom foot)
4. Arm cylinder bottom pin D. Chassis distributor (front face of revolving frame)
5. Boom cylinder rod pin
6. Boom foot pin
7. Swing circle
8. Boom cylinder bottom pin

10-122 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASING SYSTEM

FUNCTION OF EQUIPMENT
• Greasing switch
When greasing, turn the switch on to actuate the
grease pump.
• Solenoid valve
The electrical signal from the greasing switch
opens or closes the air circuit, thereby opening
or closing the supply of air to the grease pump.
• Grease pump
This is a reciprocal type pump which is driven by
air. It generates a grease pressure forty times
the air pressure.
★ During greasing, the grease pressure gauge
should read 4.9 – 19.6 MPa {50 – 200 kg/
cm2}.
★ If it is below 4.9 MPa {50 kg/cm2}, it means
that the grease can is empty.
★ If it reads more than 19.6 MPa {200 kg/cm2},
check the indicator of main distributor C at
the top of the boom foot.
If the plunger is out, the line is clogged.
• Stop valve
When the grease gun is being used to pump in
grease, tighten this valve to cut the automatic
greasing line.
★ When not using the grease gun, always set
to OPEN.
• Hose reel
This is used to store the grease can hose (auto-
matic wind-in).
• Grease gun
This is used for greasing (pins around bucket,
parts of radiator fan, track tension, etc.)
• Distributor
This is a valve to distribute the grease coming
from the pump to each line. The amount of
grease sent to each port is fixed by the internal
spool.
★ The spool is a sequential action type (the
grease does not flow simply to the low pres-
sure areas, but a fixed amount of grease is
supplied properly to each line). So if the line
to even one point becomes clogged, the
pressure in that line will rise and the system
will stop.

PC1800-6 10-123
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASING SYSTEM

• HYDRAULICALLY ACTUATED TYPE

10-124 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASING SYSTEM

PC1800-6 10-125
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASING SYSTEM

INJECTOR (DIVIDER VALVE) LINE FUNCTION OF EQUIPMENT

Backhoe specification • Auto grease switch
1. Bucket cylinder bottom pin When carrying out greasing, set to the AUTO
2. Arm cylinder rod pin position to actuate the grease pump. (The
3. Boom top pin switch is normally used at the AUTO position.)
4. Arm cylinder bottom pin • Grease pump

It can discharge a maximum of 28 l/min.

5. Boom cylinder rod pin This is a rotary type pump driven by oil pressure.
6. Boom foot pin
7. Swing circle Depending on the combination of controller and
8. Boom cylinder bottom pin oil pressure switch, it provides automatic opera-
tion equipped with various types of warning
A. Arm divider valve devices.
Discharge amount: 0.72 cc/rev x 4 ★ During greasing, the grease pressure gauge
B. Boom divider valve should read 4.9 – 19.6 MPa {50 – 200 kg/
Discharge amount: 0.72 cc/rev x 6 cm2}.
C. Main divider valve ★ If it is below 4.9 MPa {50 kg/cm2}, it means
Discharge amount: 0.72 cc/rev x 4 that the grease can is empty.
D. Chassis divider valve (revolving frame) ★ If any abnormality occurs in the automatic
Discharge amount: 0.13 cc/rev x 12 greasing system, the type of abnormality is
displayed on the controller.
Loading specification • Hose reel
1. Front, rear bucket connecting pin This is used to store the grease can hose (auto-
2. Bottom dump cylinder rod pin matic wind-in).
3. Bottom dump cylinder bottom pin • Grease gun
4. Arm top pin 1 This is used for greasing (pins around bucket,
5. Arm top pin 2 parts of radiator fan, track tension, etc.)
6. Arm cylinder rod pin • Injector
7. Arm cylinder bottom pin This is a valve that distributes the grease sent
8. Boom top pin from the pump to each line. The amount of
9. Bucket cylinder rod pin grease sent to each port is automatically set to a
10. Boom foot pin constant amount. (The amount of grease
11. Arm cylinder bottom pin divided can be adjusted.)
12. Boom cylinder rod pin
13. Swing circle
14. Boom cylinder bottom pin

A. Bucket divider valve

Discharge amount: 0.72 cc/rev x 6
B. Arm divider valve
Discharge amount: 0.72 cc/rev x 12
C. Boom divider valve
Discharge amount: 0.72 cc/rev x 6
D. Chassis divider valve (revolving frame)
Discharge amount: 0.13 cc/rev x 12

10-126 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASING SYSTEM

INJECTOR

1. Adjustment screw
2. Injector body
3. Injector piston
4. Piston spring
5. Slide valve
6. Manifold

Delivery: 0.13 – 1.31 cc/rev

PC1800-6 10-127
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASING SYSTEM

10-128 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

WORK EQUIPMENT
BACK HOE

10-130 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between boom- size clearance limit
Shaft Hole
1 revolving frame mounting
pin and bushing –0.043 +0.428 0.405 –
160 1.5
–0.106 +0.362 0.534
Clearance between boom-
–0.043 +0.117 0.095 –
2 revolving frame mounting 160 1.5
–0.106 +0.052 0.223
pin and bushing
Clearance between boom
–0.043 +0.117 0.095 –
3 cylinder-revolving frame 160 1.5
–0.106 +0.052 0.223
mounting pin and bushing
Clearance between boom-
–0.043 +0.402 0.380 –
4 boom cylinder rod mounting 160 1.5
–0.106 +0.337 0.508
pin and bushing
Clearance between boom-
–0.043
5 arm cylinder mounting pin 140 — — 1.5
–0.106
and bushing
Clearance between boom-
–0.050 +0.581 0.520 –
6 arm mounting pin and bush- 200 1.5
–0.122 +0.470 0.703
ing
Clearance between boom-
–0.050
7 arm mounting pin and bush- 200 — — 1.5
–0.122
ing
Clearance between arm-
–0.043
8 arm cylinder mounting pin 140 — — 1.5
–0.106
and bushing
Replace
Clearance between arm-
–0.043
9 bucket cylinder mounting pin 140 — — 1.5
–0.106
and bushing
Clearance between arm-link –0.043 +0.421 0.363 –
10 140 1.5
mounting pin and bushing –0.106 +0.320 0.527
Clearance between arm-
–0.043
11 bucket mounting pin and 140 — — 1.5
–0.106
bushing
Clearance between arm-link –0.043 +0.1 0.043 –
12 140 1.5
mounting pin and link –0.106 0 0.206
Clearance between arm-
–0.043 +0.2 0.043 –
13 bucket mounting pin and 140 1.5
–0.106 0 0.306
bushing
Clearance between bucket
–0.043 +0.398 0.378 –
14 cylinder-link mounting pin 140 1.5
–0.106 +0.335 0.514
and bushing
Clearance between bucket
–0.043 +0.1 0.043 –
15 cylinder-link mounting pin 140 1.5
–0.106 0 0.206
and link
Clearance between link-
–0.043 +0.417 0.360 –
16 bucket mounting pin and 140 1.5
–0.106 +0.317 0.523
bushing
Clearance between link-
–0.043 +0.2 0.043 –
17 bucket mounting pin and 140 1.5
–0.106 0 0.306
boss hole

PC1800-6 10-131
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

LOADING SHOVEL

10-132 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

Unit: mm
No. Check item Criteria Remedy
Clearance between Standard Tolerance Standard Clearance
boom-revolving frame size Shaft Hole clearance limit
1
mounting pin and
bushing 180 — — — —
Clearance between
2 boom-arm mounting 160 — — — —
pin and bushing
Replace
Clearance between
3 arm-bucket mounting 170 — — — —
pin and bushing
Clearance between
front bucket-rear
4 110 — — — —
bucket mounting pin
and bushing

PC1800-6 10-133
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT

DIMENSIONS OF WORK EQUIPMENT

1. ARM

10-134 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT

Unit: mm
Model PC1800-6
No. with 5.1 m arm
1 140
2 110
3 936
4 200
5 469
6 672.8
7 1,199
8 3,841.7
9 5,103
10 719
11 1,300
12 1,210
13 955
14 3,116
15 140
16 364
17 140
Arm as individual part 348
18
When press fitting bushing 364
Min. 3,250
19
Max. 5,420
20 124

PC1800-6 10-135
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT

2. BUCKET

10-136 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT

Unit: mm
Model PC1800-6
No. 12 m3 bucket
1 940
2 170
3 100°
4 955
5 3,076
6 494
7 1,322
8 410
9 330
10 165
11 71
12 86
13 20
14 365
15 370
16 98
17 88
18 208
19 215
20 R180
21 R130
22 φ160
23 φ185
24 φ140
25 φ325
26 φ220
27 25°
28 134
29 55
30 φ248
MxP M36 x 3

PC1800-6 10-137
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

ENGINE CONTROL

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

Engine speed control

• The fuel control dial sends signal voltages to the
engine controller according to its angle.
The engine controller sends drive signals to the
supply pump according to the signal voltages
received from the fuel control dial and controls
the fuel injection pump to control the engine
speed.

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

10-138 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

2. Components of system
Fuel control dial

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector

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

PC1800-6 10-139
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

Pump controller

10-140 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

Input and output signals

CN-1 CN-2 CN-3

Pin Input/ Pin Input/ Pin Input/
Name of signal Name of signal Name of signal
No. output No. output No. output
1 NC Input 1 NC Output 1 Controller power supply Input
2 NC Input 2 Swing prolix switch Input 2 Solenoid power supply Input
3 Hydraulic oil temperature Input 3 Lamp mode select Input 3 SOL_COM Input
4 Signal GND — 4 232C_RxD Input 4 Battery relay drive Output
5 Auto grease-up Input 5 O ver-load pressure sensor Input 5 NC Output
6 NC Input 6 Air cleaner clogging (FRON T) Input 6 TVC solenoid (FRONT) Output
7 NC Input 7 Machine select 4 Input 7 Travel valve solenoid Output
8 Fuel level Input 8 NC Output 8 Travel alarm Output
9 NC Input 9 Auto decel Output 9 Bucket curl switch Input
10 Signal GND — 10 NC Input 10 Boom raise switch Input
11 Key switch (C:REAR) Input 11 NC Output 11 Controller power supply Input
12 A ir cleaner clogging (R EAR ) Input 12 CAN_SH — 12 Solenoid power supply Input
13 NC Input 13 Travel-left switch Input 13 SOL_COM Input
14 NC Input 14 232C_TxD Output 14 VB Input
15 Charge voltage (FRONT) Input 15 Hydraulic oil filter Input 15 Step light relay Output
16 SENS_PWR Output 16 Hydraulic oil level Input 16 TVC solenoid (REAR) Output
17 Key switch (C:FRONT) Input 17 Machine select 3 Input 17 CO cancel solenoid Output
18 Engine oil level (REAR) Input 18 NC Output 18 NC Output
19 NC Input 19 Step light battery drive relay Output 19 Bucket dump switch Input
20 NC Input 20 NC Input 20 Boom lower switch Input
Input,
21 Analog GND — 21 S_NET output 21 GND Input
Input,
22 POT_PWR Output 22 CANO_L output 22 Solenoid power supply Input
Input,
23 Key switch (ACC) Input 23 NC output 23 SOL_COM Input
24 Engine coolant level (REAR) Input 24 FWE SW Input 24 VB Input
25 Horn switch Input 25 Flash light relay Output
26 Engine oil level (FRONT) Input 26 NC Output
27 Machine select 2 Input 27 NC —
28 Travel-right switch Input 28 2-stage relief solenoid Output
29 Puls GND — 29 Swing switch Input
30 Engine speed (REAR) Input 30 Arm curl switch Input
31 GND (S_NET GND) — 31 GND Input
Input,
32 CANO_H output 32 GND Input
Input,
33 NC output 33 GND Input
34 GND (232C_GND) — 34 NC —
35 Service switch Input 35 NC Output
36 Engine coolant level (FR O N T) Input 36 NC Output
37 Machine select 1 Input 37 Swing brake solenoid Output
38 Swing lock switch Input 38 NC Output
39 Puls GND — 39 Step light switch Input
40 Engine speed (FRONT) Input 40 Arm dump switch Input

PC1800-6 10-141
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

Engine controller

10-142 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

Input and output signals

CN-1 CN-2 CN-3

Pin Input/ Pin Input/ Pin Input/
Name of signal Name of signal Name of signal
No. output No. output No. output
1 Power supply (+24V) — 1 GND — 1 Power supply (Injector, Supply pump) —
2 Power supply (+24V) — 2 NC — 2 Power supply (Injector, Supply pump) —
3 Machine select 1 Input 3 NC Input 3 NC —
4 GND — 4 RS-232C RX1 Input 4 NC —
5 NC Input 5 NC — 5 Injector 3 (+) Output
6 NC Output 6 NC — 6 Injector 2 (+) Output
7 GND (Battery earth) — 7 NC Input 7 NC Input
8 GND (Battery earth) — 8 NC Input 8 Pow er mode select 1 (Test m ode) Input
9 NC Input 9 Sensor power supply 2 (+5V, 50m A{M AX}) Output 9 Lever neutral flag (Test m ode) Input
10 GND — 10 Fuel dial Input 10 Engine speed pulse Output
11 NC Input 11 GND — 11 GND (battery earth) Input
12 NC Output 12 CAN shield — 12 Supply pump 1 (+) Output
13 Key switch (Acc) Input 13 NC Output 13 Supply pump 2 (+) Output
14 NC Input 14 RS-232C TX1 Output 14 Injector 1 (+) Output
15 Oil press. switch (High) Input 15 G Shield — 15 Injector 3 (–) Output
16 Memory clear switch Input 16 Ne Shield — 16 Injector 2 (–) Output
17 Machine select 3 Input 17 Fuel temp. sensor Input 17 NC Input
18 NC Output 18 NC Input 18 Pow er mode select 2 (Test m ode) Input
19 Key switch (Acc) Input 19 Sensor power supply 2 (+5V, 50m A{M AX}) Output 19 NC Input
20 Starter switch (c) Input 20 Boost press. sensor (0 to +5V) Input 20 Q monitor Output
Input,
21 Oil press. switch (low) Input 21 Network (+) output 21 Pow er supply (Injector, Supply pum p) —
Input,
22 Auto decel signal Input 22 CAN (L) output 22 Supply pump 1 (–) Output
23 Machine select 2 Input 23 NC — 23 Supply pump 2 (–) Output
24 NC Output 24 ROM write switch Input 24 Injector 1 (–) Output
25 G sensor (–) Input 25 Injector 6 (+) Output
26 Ne sensor (–) Input 26 Injector 4 (+) Output
27 C oolant tem p. sensor (H igh tem p.) Input 27 NC Output
28 NC Input 28 Auto decel flag (Test m ode) Input
29 GND — 29 NC Input
30 Accel. sensor (Test mode) Input 30 GND —
Input,
31 Network (+) output 31 GND (Battery earth) —
Input,
32 CAN (H) output 32 GND (Battery earth) —
33 NC — 33 Injector 5 (–) Output
34 GND — 34 Injector 5 (+) Output
35 G sensor (+) Input 35 Injector 6 (–) Output
36 Ne sensor (+) Input 36 Injector 4 (–) Output
37 C oolant tem p. sensor (Low tem p.) Input 37 NC Output
38 NC Input 38 Auto decel control (Test m ode) Input
39 GND — 39 NC Input
40 Comm on rail press. sensor (0 to +5V) Input 40 GND —

PC1800-6 10-143
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

MACHINE CONTROL SYSTEM

CONTROL FUNCTIONS

1 OFF (Cancel)
Auto deceleration function

ON
2 3-mode selector type pump torque control

Electronic OLSS function Cut-off control

Flow control
3 OFF
Heavy-lift function
ON
4 OFF (Digging improvement mode)
2-stage boom pushing force
selector function
ON (Machine push-up mode)
Machine control (Machine push-up)
system
5
Swing control function

6
Engine automatic warming up, overheat
prevention function, turbocharger
protection function, split injection function

7 ON
Boom shockless control function
Cancel
8
Straight-travel function

PC1800-6 10-145
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

1. Auto deceleration system

Function
• If all the control levers are at neutral when wait-
ing for work or waiting for a dump truck, the
engine speed is automatically reduced to a
midrange speed to reduce fuel consumption and
noise.
• If any lever is operated, the engine speed
returns immediately to the set speed.

10-146 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

Operation
Control levers at neutral When control lever is operated
• If the engine is running at above the decelera- • If any control lever is operated when the engine
tion actuation speed (approx. 1400 rpm), and all speed is at No. 2 deceleration, the engine speed
the control levers are returned to neutral, the will immediately rise to the speed set by the fuel
engine speed drops immediately to approx. 100 control dial.
rpm below the set speed to the No. 1 decelera-
tion position.
• If another 4 seconds passes, the engine speed
is reduced to the No. 2 deceleration position
(approx. 1400 rpm), and is kept at that speed
until a lever is operated.

PC1800-6 10-147
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

2. Electronic OLSS function

Pump control system

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

PC1800-6 10-149
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

1) Control method in each mode

DH, H mode

• Matching point in DH, H mode: Rated output

point

Model
PC1800-6
Mode
DH 338 kW/1,750 rpm {454 HP/1,750 rpm}
H 316 kW/1,830 rpm {424 HP/1,830 rpm}
These values are for 1 engine.

• When the load on the pump rises and the pres-

sure rises, the engine speed goes down.
When this happens , the pump discharge
amount is reduced, and the engine speed is
controlled so that it becomes close to the rated
speed.
If the reverse happens and the pressure goes
down, the system is controlled so that the pump
discharge amount is increased until the engine
speed reaches close to the rated speed.
By repeating this control, the engine can always
be used at near the rated output point.
• The DH mode uses the CO cancel so it can gen-

mode at high pressure. (H mode: 520 l/min →

erate a greater discharge of oil than in the H

DH mode: 650 l/min)

10-150 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

G mode

• Matching point

Model
Mode G PC1800-6
Mode
286 kW/1,845 rpm
Partial output point 83% G
{378 HP/1,845 rpm}
These values are for 1 engine.

• When the load on the pump rises and the pres-

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

PC1800-6 10-151
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

2) Cut-off function
• If the load becomes larger during operation, and
the pump discharge pressure rises to close to
the relief pressure, the pump pressure sensor
detects this, and the controller sends a signal to
the TVC valve to reduce the discharge amount,
thereby reducing the relief loss.

3) Cut-off cancel function

• The cut-off cancel function acts to stop the oper-
ation of the cut-off function in order to ensure the
pump flow when close to the relief pressure,
thereby preventing any drop in speed.
• When the cut-off is operated the relief pressure
is 28.7 MPa {293 kg/cm2}, and when the cut-off
cancel function is operated (the relief pressure
is 1.5% higher than at cut-off), the relief pres-
sure becomes approx. 29.4 MPa {approx. 300
kg/cm2}.

• Cut-off function and actuation of each switch

Switch Working mode switch Swing lock switch Heavy lift

Function DH H G ON OFF ON OFF
Cut-off function Cancel Actuated Actuated Cancel Actuated Cancel Actuated

★ Quick warming up for hydraulic oil when swing

lock switch is ON
When the swing lock switch is turned ON, the
cut-off function is canceled.
If the work equipment is relieved in this condi-
tion, the temperature of the hydraulic oil can be
raised more quickly to reduce the warming up
time.

10-152 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

3. Heavy lift function

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

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

PC1800-6 10-155
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

Operation

Lever operation Heavy-lift Main relief

Heavy-lift CO valve Boom lifting
Arm IN or solenoid valve set
switch Boom RAISE switch force
bucket CURL valve pressure
29.4 MPa
OFF Operated — De-energized Actuated Normal
{300 kg/cm2}
31.4 MPa
Neutral Excited Canceled 10% up
{320 kg/cm2}
If the arm IN or bucket CURL are operated
ON Operated during boom RAISE operations, this function
Operated is automatically canceled, and the condition Normal
becomes the same as when the switch is
turned OFF.

★ Heavy-lift solenoid valve

For details of the structure and function, see SOLENOID VALVE ASSEMBLY.
★ CO valve
For details of the structure and function, see HYDRAULIC PUMP.
★ Main relief valve
For details of the structure and function, see V2 (L.H. 5-SPOOL) VALVE.

10-156 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

4. 2-stage boom pushing force selector

function

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

10-158 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

PC1800-6 10-159
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

Operation
• This function acts to change the set pressure of the safety valve at the boom cylinder end of the R.H. 4-
spool control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm2) and high pressure (33.3
MPa {340 kg/cm2}.

Machine Machine
Safety valve
Mode push-up push-up sole- Effect
set pressure
switch noid valve
By reducing the boom pushing force, it
is made easier for the boom to escape
Boom push- automatically in the RAISE direction
14.7 MPa
ing force Excited and to reduce the number of times that
{150 kg/cm2}
(low mode) the boom is operated. At the same
time it also makes the digging opera-
tion smoother.
By increasing the thrust force for boom
LOWER, the ease of operation is
Boom push- improved for excavation, digging
33.3 MPa
ing force De-energized square holes, carrying out twist turns,
{340 kg/cm2} or escaping from soft ground.
(high mode)
Set pressure when relieved:
29.4 MPa {300 kg/cm2}

★ Machine push-up solenoid valve

For details of the structure and function, see SOLENOID VALVE ASSEMBLY.
★ Boom safety valve
For details of the structure and function, see V3 (R.H. 4-SPOOL) VALVE.

10-160 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

5. Swing control system

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

10-162 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

1. Swing lock, swing holding brake function

• The swing lock (manual) can be locked at any ★ Swing brake solenoid valve
desired position, and the swing lock and swing For details of the structure and function, see
holding brake (automatic) are interconnected SOLENOID ASSEMBLY.
with the swing, so they prevent any hydraulic ★ Swing motor
drift after the swing is stopped. For details of the structure and function, see
SWING MOTOR.

Actuation
Swing
Swing lock Swing lock
Mode brake sole- Actuation
switch lamp
noid valve
When swing and work equipment levers are
placed at neutral, swing brake is applied after
approx. 9 sec; when any swing or work equipment
lever is operated, brake is canceled and swing can
be operated freely

See
Swing hold-
OFF OFF diagram on
ing brake
right

Swing lock is actuated and swing is held in posi-

Swing De-ener-
ON ON tion. Even when swing lever is operated, swing
brake gized
lock is not canceled and swing does not move.

Operation of swing lock prolix switch

• If any abnormality should occur in the controller, Swing
and the swing holding brake is not actuated nor- ON (when control- OFF (when control-
lock pro-
mally and the swing cannot be operated, the ler is abnormal) ler is normal)
lix switch
swing lock prolix switch can be operated to can-
Swing
cel the swing lock and allow the swing to be
lock ON OFF ON OFF
operated.
switch
★ Even when the swing lock prolix switch is turned
ON, the swing lock switch stays ON and the Swing
Swing Swing Swing
swing brake is not canceled. Swing holding
lock lock can- lock
★ When the swing brake is canceled, the swing has brake brake
applied celed applied
only a hydraulic brake operated by the safety applied
valve, so if the swing is stopped on a slope, there
may be hydraulic drift.

Hydraulic oil quick warm-up function when

swing lock switch is ON
• When the swing lock switch is turned ON, the
pump cut-off is canceled. If the work equipment
is relieved in this condition, the hydraulic oil tem-
perature will rise more quickly and the warming-
up time can be reduced.

PC1800-6 10-163
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

6. Automatic warming-up and engine over-

heat prevention function

Function
• If the water temperature is low, this automati-
cally raises the engine speed to warm up the
engine after it is started. In addition, if the water
temperature rises too high during operations, it
reduces the load of the pump to prevent over-
heating.

10-164 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

1) Engine automatic warming-up function

• After the engine is started, if the engine coolant
temperature is low, the engine speed is auto-
matically raised to warm up the engine.

Conditions for actuation (both are necessary) Actuation

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

Conditions for cancellation (any one) Cancellation

Coolant temperature: 30°C or above
Automatic Automatic warming-up time: 10 minutes or
more Engine speed: As desired
Fuel control dial: Held at more than 70% of
Manual
full throttle for more than 3 seconds

2) Engine overheat prevention function

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

Actuation condition Actuation, remedy

Water temperature: Working mode : In any mode
105°C and above Engine speed : Low idling
(Water temperature gauge: Monitor warning lamp : Lights up
Red range) Alarm buzzer : Sounds

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

PC1800-6 10-165
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

3) Turbo protection function

Function to protect turbocharger bearing during
cold weather by keeping engine speed below
fixed speed when engine is started.

Actuation condition
Engine water Turbo protect time
temperature (sec)
More than 10°C 0
Gradually changes
+10°C to –10°C
between 0 and 5
Less than –10°C 5

Engine speed: 1000 rpm

Even if the fuel control dial is operated during

the above time, the engine speed will not
change. After the set time passes, the operation
moves to the automatic warming up function in
Step 1).

4) Split injection function

To improve the ease of starting in cold weather,
a small amount of fuel is injected two or more
times within the set time after calculating in the
table below before starting the main injection.
As a result, the lower idling speed during this
time becomes slightly higher.

Actuation condition
Split injection time
Water temperature
(sec)
More than 20°C 0
20°C to –30°C 0 – 15
Less than –30°C 15

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

7. Boom shockless control function

This function improves safety by preventing spillage of the load from the bucket and by reducing the shock
when the boom is stopped, thereby reducing operator fatigue.

Actuation
Boom shockless Cancel solenoid Boom shockless
Remarks
switch valve control
ON
De-energized ON Suitable for normal operations
(Contacts open)
OFF
Excited Canceled Suitable for compacting or skeleton work
(Contacts closed)

• If the boom is raised, the pilot pressure from the PPC valve is generated in line A. When this happens, the
pressure in line A passes through check valve (2) and pushes the spool of the main valve in the direction of
the arrow. The pilot oil at the left end of the spool passes through line B and the PPC valve, and returns to
the tank. However, when this happens, check valve (4) is being pushed open by the pressure in line A, so it
also allows the oil to pass in the opposite direction. For this reason, the boom can be raised without any
delay in response.
• In this condition, if the boom RAISE operation is stopped, the spool of the main valve moves in the opposite
direction to the arrow and drains the oil from line A. However, the action of check valve (2) means that the
oil must pass through orifice (1). As a result, the spool returns slowly to the neutral position to prevent any
shock.

PC1800-6 10-167
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

8. Straight-travel function

LOWER
RAISE

DUMP
CURL
OUT
IN

R
F

Outline
• When the travel is operated at the same time as • To prevent this, the straight-travel valve is
the boom, arm, or bucket, the pressure oil flow- switched to interconnect the left and right travel
ing to the left and right travel circuits is divided circuits. This ensures that the amount of oil sup-
and sent to the boom, arm, or bucket circuit. plied to the left and right travel motors is equal,
If the oil in one travel circuit is divided off, the so the left and right travel motors both rotate at
amount of oil supplied to the travel motor will be the same speed, and this prevents any travel
less than in the travel circuit which is not divided, deviation.
so the drop in the supply of oil to the travel
motor will cause the machine to deviate.

10-168 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

PC1800-6 10-169
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

Operation

Work equipment
Left and right Straight-travel Straight-travel
control lever, Remarks
travel levers solenoid valve valve
swing lever
Left and right travel motor
Neutral De-energized Not actuated
circuits independent
Operation
Left and right travel motor
Operated Excited Actuated
circuits actuated

10-170 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM

9. Components of system

1) TVC prolix resistor

1 2

SBP00370

Function
1. Resistor • This resistor acts to allow a suitable current to
2. Connector flow to the TVC solenoid when the TVC prolix
switch is ON.
• No current flows when the TVC prolix switch is
OFF.
Specification
Resistance: 8.5 Ω

2) Fuel control dial, governor motor, engine throttle

and pump controller
★ See ENGINE CONTROL.

3) Monitor panel
★ See MONITOR SYSTEM.

4) TVC valve
★ See HYDRAULIC PUMP.

PC1800-6 10-171
STRUCTURE, FUNCTION AND ELECTRONIC COMPONENTS OF AUTOMATIC
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM

ELECTRONIC COMPONENTS OF AUTOMATIC WORK

EQUIPMENT CONTROL SYSTEM
1. OUTLINE

10-172 PC1800-6
STRUCTURE, FUNCTION AND ELECTRONIC COMPONENTS OF AUTOMATIC
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM

CIRCUIT DIAGRAM

PC1800-6 10-173
STRUCTURE, FUNCTION AND ELECTRONIC COMPONENTS OF AUTOMATIC
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM

2. COMPONENTS OF SYSTEM

1) CONTROLLER
The controller always calculates the height of
the arm top pin from the angles of the boom and
arm. It sends a signal current to the solenoid of
each EPC valve to control the control valves and
carry out the BOOM LOWER control during
ARM OUT operations, and BUCKET DUMP
control during BOOM RAISE operations.
The four red and green LEDs installed to the
wall of the controller light up, flash, or go out to
allow the operator to judge if the electronic sys-
tem is working normally and to allow high to
locate any malfunctions.
(See page 10-177)

2) POTENTIOMETERS
These are installed to the boom foot on the
revolving frame and to the arm mount on the
boom. They send electric signals to the control-
ler to show the angle of the work equipment.

1. Sensor
2. Connector

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STRUCTURE, FUNCTION AND ELECTRONIC COMPONENTS OF AUTOMATIC
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM

3) EPC VALVE (Electric Pressure Control valve)

1. Return spring
2. Retainer Function
3. Valve body • The EPC valve consists of a hydraulic valve and
4. Spool a proportional control solenoid.
5. Base • The signal current sent from the controller flows
6. Push rod to coil (7), and excites base (5) and iron core (8).
7. Coil As a result, variable core (8) is pushed to base
8. Iron core (5), and generates a thrust to the left.
9. Connector This thrust is proportional to the signal current.
Because of this, Pi port and Pc port open.

PC1800-6 10-175
STRUCTURE, FUNCTION AND ELECTRONIC COMPONENTS OF AUTOMATIC
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM

4) HYDRAULIC PRESSURES SWITCH

1. Plug
2. Switch
3. Connector

Specifications
Composition of points: N.O. points
Actuation (ON) pressure:
0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2}
Reset (OFF) pressure:
0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2}

Function
• There are 6 switches installed to
the PPC piping block. The operat-
ing condition of each actuator is
detected from the PPC pressure,
and this is sent to the automatic
control controller.

10-176 PC1800-6
STRUCTURE, FUNCTION AND ELECTRONIC COMPONENTS OF AUTOMATIC
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM

3. TABLE OF SELF-TESTING FUNCTION

OFF
1 2 3 4

ON

Green Red Red Red Flashing

LED display
Normal
1 2 3 4

ARC DIGGING mode

HORIZONTAL DIGGING mode

HORIZONTAL DIGGING + BUCKET ANGLE

COMPENSATION mode

ARM OUT hydraulic pressure switch actuation

BOOM RAISE and LOWER hydraulic pressure switch

or
actuation
ARM IN, BUCKET CURL and DUMP hydraulic pressure
switch actuation

LED display
Abnormal
1 2 3 4

Controller

Boom EPC valve solenoid

Bucket EPC valve solenoid

Boom potentiometer

Arm potentiometer

ARM OUT hydraulic pressure switch

BOOM RAISE and LOWER hydraulic pressure switch

ARM IN, BUCKET CURL and DUMP hydraulic pressure

switch

★ When lamp 1 (green LED) is ON or flashing, it shows that the system is NORMAL; lamps 2 to 4 show the
condition of each hydraulic pressure switch.
When lamp 1 (green LED) is OFF, it shows that the system is ABNORMAL; the combination of lamps 2 to 4
shows the location of the abnormality.

PC1800-6 10-177
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

MONITOR SYSTEM

10-178 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

Function
• The monitor system uses the sensors installed
to all parts of the machine to observe the condi-
tion of the machine. It processes this information
swiftly, and displays it on a panel to inform the
operator of the condition of the machine.
• The content of the information displayed on the
machine can broadly be divided as follows.

1. Monitor portion
This gives an alarm if any abnormality occurs in
the machine.
2. Gauge portion
This always displays the condition of the
machine (coolant temperature, fuel level).

• The monitor panel also has various built-in

mode selector switches, and functions as the
control panel for the machine control system.

• The VHMS extracts the machine information

from the network and processes the data neces-
sary for control of the machine.

PC1800-6 10-179
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

1. Monitor panel

Outline Input and output signals

• The monitor panel consists of the switches for CN-P01 CN-P02
the monitor display functions, mode selector, Pin No. Name of signal Pin No. Name of signal
and electrical components. 1 NC 1 GND
• It has a built-in CPU (Central Processing Unit),
2 NC 2 NC
and processes, displays, and outputs the infor-
3 NC 3 NC
mation.
• The monitor display panel uses a liquid crystal 4 N/W signal 4 NC
display (LCD). The mode switches are flat sheet 5 Swing lock 5 NC
switches. 6 Buzzer stop 6 NC
7 Buzzer output 7 NC
8 Lamp 8 +VB
9 Key ON signal 9 GND
10 Terminal BR 10 NC
11 N/W signal 11 NC
12 N/W GND 12 NC
13 NC 13 NC
14 N/W GND 14 +VB
15 NC 15 NC
16 NC 16 NC
17 NC
18 Preheating
19 Start signal
20 NC

10-180 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

DISPLAY MONITOR 1. Clock (displays error code when error occurs)

2. Service meter (displays telephone number when
error occurs)
3. Coolant temperature gauge
4. Fuel gauge
5. Engine oil level caution lamp
6. Hydraulic oil level caution lamp
7. Preheating pilot lamp
8. Swing holding brake pilot lamp
9. Battery charge caution lamp
10. Hydraulic oil temperature caution lamp
11. Air cleaner clogging caution lamp
12. Engine oil pressure caution lamp
13. Coolant level caution lamp
14. Fuel level caution
15. Coolant temperature caution
16. Hydraulic oil filter clogging caution lamp
Content of display
Symbol Display item Display range When engine is stopped When engine is running
Flashes and buzzer
Coolant level Below low level Flashes when abnormal
sounds when abnormal
SAP00519

Engine oil Below specified Lights up when normal (goes Flashes and buzzer
pressure level out when engine starts) sounds when abnormal
SAP00520

Air cleaner
When clogged OFF Flashes when abnormal
clogging
SAP00521

When charging is Lights up when normal (goes

Charge level Flashes when abnormal
SAP00522
defective out when engine starts)

Engine oil level Below low level Flashes when abnormal OFF
SAP00523

Hydraulic oil
Below low level Flashes when abnormal OFF
level
SAP00524

When swing is Lights up when swing is locked, flashes when swing lock
Swing lock
locked prolix switch is ON
SAT00098

Lights up for 30 seconds when starting switch is at HEAT,

Preheating During preheating then flashes for 10 seconds to indicate that preheating is
SAP00526 completed

Coolant tem- Flashes when above 102°C, flashes and buzzer

perature sounds when above 105°C
SAP00527

Fuel level Flashes when below low level

SAP00528
All lamps below relevant level light up

Hydraulic oil Flashes when Flashes and buzzer sounds

temperature above 97°C when above 100°C
SAD01484

Hydraulic oil fil-

When clogged OFF Flashes when abnormal
ter clogging

PC1800-6 10-181
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

SWITCHES

1. Working mode switch

2. Auto deceleration switch
3. Hydraulic oil•water temperature switch
4. Engine selector switch
5. Heavy lift switch

• There are five mode selector switches on the Switch actuation table
switch panel. Each time any of these switches is
pressed, the condition of the machine will Item Actuation
change. The LEDs on the switch panel light up Working mode DH ↔ H ↔ G
to indicate the condition of the machine. Heavy lift ON ↔ OFF

• When the LED for the front engine is lighted up, Auto decel ON ↔ OFF
the coolant temperature gauge shows the cool- Engine select Front engine ↔ Rear engine
ant temperature of the front engine and when Hydraulic oil-water
the LED for the rear engine is lighted up, it OFF ↔ ON
temperature select
shows one of the rear engine.
★ The bold letters indicate the default position
• When the hydraulic temperature switch is being
of the switch when the starting switch is
pressed and LED over the switch is lighted up,
turned ON.
the temperature gauge shows the hydraulic tem-
perature.

• When there is overheat in front engine or rear

engine or hydraulic oil, LED over the relevant
switch lights up and the gauge shows the tem-
perature automatically.

10-182 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

VHMS controller

10-184 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

Input and Output signals

CN-1 CN-2 CN-3 CN-4

Pin Input/ Pin Input/out- Pin Input/ Pin Input/
Name of signal Name of signal Name of signal Name of signal
No. output No. put No. output No. output
Main valve press.
1 Gear pump press Input A1 Input A1 . Input A1 . —
1, 2F

2 Sensor power supply Output A2 F PTO oil temp. Input A2 . Input A2 . —

Input,
3 Sensor power supply Output A3 F Engine oil temp. Input A3 Function select Input A3 RS232C GND output
CAN (1) H Input,
4 Sensor power supply Output A4 R Charge volt Input A4 . Output A4 output
(KOM-NET/c)

5 Sensor power supply Output A5 R Exhaust temp. 2 Input A5 Function select Input A5 CAN (0) SH (CGC) Input

Input,
6 Power supply Input A6 F Exhaust temp. 2 Input A6 . Input A6 CAN (0) H (CGC) output

7 Power supply Input A7 F Exhaust temp. 1 Input A7 . Input A7 . —

Input,
8 Power supply (BR) Input A8 F Engine oil press. Input A8 S-NET (+) A8 . —
output
CONNECTOR SEL0 CONNECTOR SEL2
9 Power supply (BR) Input A9 Input A9 Input A9 GND Input
(GND) (OPEN)
RS232C RX0 for PC
10 Main valve SW press Input A10 R PTO oil temp. Input A10 Dump count SW 2 Input A10 Input
Tool
RS232C TX0 for PC
11 GND Input A11 R Engine oil temp. Input A11 Dump count SW 1 Input A11 Output
Tool
CAN (1) L (KOM- Input,
12 GND Input A12 Sensor GND Input A12 . Input A12 output
NET/c)
CAN (1) SH (KOM-
13 . — A13 Sensor GND Input A13 GND Input A13 Input
NET/c)
Input,
14 Dump count lamp Input A14 F Blow-by press. Input A14 Function select Input A14 CAN (0) L (CGC)
output

15 . — A15 R Engine oil press. Input A15 Function select Input B1 . —

16 . — A16 R Exhaust temp. 1 Input A16 Function select Input B2 . —

17 Start signal Input A17 . — A17 GND Input B3 RS232C SH Input

Input, RS232C TX1 for

18 . — A18 R Blow-by press. Input A18 S-NET (+) output B4 Output
Orbcomm

19 GND Input B1 . — B1 PC select Input B5 . —

20 GND Input B2 R NC Valve press. Input B2 . — B6 . —

B3 . — B3 . — B7 . —

Main valve press.

B4 Input B4 . — B8 . —
1, 2R
Main valve press.
B5 Input B5 . — B9 GND Input
3, 4F
RS232C RX1 for
B6 . — B6 . — B10 Input
Orbcomm

B7 Air temp. Input B7 . —

B8 . — B8 . —

B9 GND Input B9 . —

B10 F NC Valve press. Input B10 . —

Main valve press.

B11 Input B11 . —
3, 4R
CONNECTOR SEL1 CONNECTOR SEL3
B12 Input B12 Input
(GND) (OPEN)

PC1800-6 10-185
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

2. Sensors
• The signals from the sensors are input directly to the monitor panel.
The contact type sensors are always connected at one end to the chassis GND.
Name of sensor Type of sensor When normal When abnormal
Coolant level switch Contact type ON (closed) OFF (open)
Engine oil level switch Contact type ON (closed) OFF (open)
Hydraulic oil level switch Contact type ON (closed) OFF (open)
Engine oil pressure switch Contact type OFF (open) ON (closed)
Coolant temperature sensor Resistance type — —
Fuel level sensor Resistance type — —
Air cleaner clogging switch Contact type OFF (closed) ON (open)
Hydraulic oil temperature sensor Resistance type — —
Hydraulic oil filter clogging switch Contact type ON (open) OFF (closed)
Engine oil pressure sensor Analog type — —
Engine oil temperature sensor Resistance type — —
PTO oil temperature sensor Resistance type — —
Main pump oil pressure sensor Analog type — —
Control pump oil pressure sensor Analog type — —
Engine blow-by pressure sensor Analog type — —

Coolant level switch

1. Sub-tank
2. Float
3. Sensor
4. Connector

10-186 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

Engine oil level switch

1. Connector
2. Bracket
3. Float
4. Switch

Hydraulic oil level switch

1. Float
2. Sensor
3. Tube
4. Wire
5. Connector

Engine oil pressure switch

1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal

PC1800-6 10-187
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

Coolant temperature sensor

Hydraulic oil temperature sensor

1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector

Engine oil temperature sensor

PTO oil temperature sensor

1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector

Fuel level sensor

1. Float
2. Switch
3. Connector
4. Variable resistor

10-188 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

Air cleaner clogging switch

Hydraulic oil filter clogging switch

1. Block
2. Sensor
3. Wire
4. Connector

Engine oil pressure sensor (0 – 1.0 MPa {0 – 10 kg/cm2})

1. Sensor
2. Connector

PC1800-6 10-189
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

Main pump oil pressure sensor (0 – 49.0 MPa {0 – 500 kg/cm2})

1. Sensor
2. Connector

Control pump oil pressure sensor (0 – 4.9 MPa {0 – 50 kg/cm2})

1. Sensor
2. Connector

10-190 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

Engine blow-by pressure sensor

1. Sensor Specifications and function

2. Connector
3. Atmospheric pressure intake tube • Pressure range: 0 – 20 kPa {0 – 2,040 mmH2O}
• Allowable pressure:
A. GND (Black) –20 – 100 kPa {–2,040 – 10,200 mmH2O}
B. Power source (Red) • Source voltage: 5 ± 0.25 V
C. Output (White) • Main characteristics: See graph.
• The blow-by pressure sensor is a fine relative
pressure sensor which measures the difference
between the pressure in the crankcase and
atmospheric pressure.
• The pressure in the crankcase is introduced
from the sensor tip side and atmospheric pres-
sure is introduced from the wiring harness side.

PC1800-6 10-191
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

3. CGC Monitor

Outline
• On the CGC monitor, the monitor screen to dis-
play gauges, maintenance screen, setting
screen, etc. can be selected with the buttons on
the screens (touch switches).
• If any trouble occurs in the machine, the warning
screen appears automatically.
• In addition to the screen for operator which is
normally displayed, the screen for serviceman is
available to check and set the machine data and
clear the saved data. (A special ID is required to
open the screen for serviceman).

10-192 PC1800-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

CN-1 CN-2
Pin Pin
Signal Name Signal Name
No. No.
A GND A GND
B GND B TXD TST
C GND C RXD TST
D +Vin D GND
E +Vin E TXB 485
F +Vin F TXA 485
G CAN H G RXB 485
H CAN L H RXA 485
J CAN SHLD J GND
L n/c K TXD 232
L RIS 232
M RXD 232
N CTS 232
P n/c
R BEE PER
S GND
T NTSC IN
U n/c
V GND

PC1800-6 10-193
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

System flow chart

10-194 PC1800-6
 20 TESTING AND ADJUSTING

STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE ........................................................................................20-2
STANDARD VALUE TABLE FOR CHASSIS ......................................................................................20-3

TESTING AND ADJUSTING .................................................................................................................20-101

TROUBLESHOOTING ..........................................................................................................................20-301

★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.

1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.

k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
the safety pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed
when the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.

PC1800-6 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE

Machine model PC1800-6

Engine SAA6D140E-3

Standard Permissible
Item Measurement condition Unit
value value

High idling 1,980±50 1,980±50

Engine speed Low idling rpm 825±50 825±50

Rated speed 1,800 1,800

Intake air pressure kPa Min. 117 93.3

At rated output
(boosted pressure) {mmHg} {Min. 880} {700}

All speed range

Exhaust gas temperature °C Max. 650 700
(intake air temp: 20°C)

At sudden acceleration Bosch Max. 4.0 6.0

Exhaust gas color
At high idling index Max. 1.0 2.0

Valve clearance Intake valve 0.35 —

mm
(normal temperature) Exhaust valve 0.57 —

Oil temperature:40–60°C MPa Min. 3.8 2.7

Compression pressure {kg/cm2} {Min. 39} {27}
(Engine speed) (rpm) (200–250) (200–250)

(Coolant temperature: within operating

kPa Max. 1.96 3.92
Blow-by pressure range) (SAE30 oil)
{mmH2O} {Max. 200} {400}
At rated output

(Coolant temperature: within operating

range)

0.34–0.54 0.21
At high idling (SAE30 or SAE15W-40)
{3.5–5.0} {2.1}

MPa 0.29–0.49 0.18

Oil pressure At high idling (SAE10W)
{kg/cm2} {3.0–5.0} {1.8}

Min. 0.12 0.08

At low idling (SAE30 or SAE15W-40)
{Min. 1.2} {0.8}

Min. 0.10 0.07

At low idling (SAE10W)
{Min. 1.0} {0.7}

Oil temperature All speed range (inside oil pan) °C 90–110 120

Deflection when pressed with finger

Alternator belt tension mm 13–16 13–16
force of approx. 98 N {10 kg}

Deflection when pressed with finger

Air compressor belt tension mm 6 6
force of approx. 58.8 N {6 kg}

20-2 PC1800-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS

★ The Standard value for new machine and Service limit value in the table below are all values when measured
in the DH mode.

Applicable model PC1800-6

Cate- Standard value for new

Item Measurement conditions Unit Service limit value
gory machine
• Engine water temperature:
Within operating range
• Hydraulic oil temperature:
All pumps at relief operating range 1,750±100 1,800±100
• Engine at high idling
• In DH mode
• Arm IN relief
Engine speed

• Engine water temperature:

Within operating range
• Hydraulic oil temperature: rpm
All pumps at relief
Within operating range
+ 1,750±100 1,800±100
• Engine at high idling
heavy lift
• In DH mode
• Heavy lift switch ON
• Boom RAISE relief
• Auto-deceleration switch
Engine speed when
ON
auto-deceleration is 1,400±100 1,400±100
• Fuel control dial at MAX.
actuated
• Control levers at neutral.

Boom Lo control valve l a b l a b

Boom Hi control valve

Arm Lo control valve

Spool stroke

Arm Hi control valve

Bucket Lo control valve 111.5 16±0.5 16±0.5 111.5 16±0.5 16±0.5

Bucket Hi control valve

Travel control valve mm

Swing control valve

• Engine stopped
Boom control lever • Center of lever knob 85±10 85±10
• Read max. value to end of
Arm control lever travel 85±10 85±10
control levers

• Exclude play at neutral.

Travel of

Bucket control lever 85±10 85±10

Travel control lever 132±13 132±13

Swing control lever 85±10 85±10

PC1800-6 20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC1800-6

Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
• Engine at high idling
Operating effort of control levers

Boom control 16.67±4.9 16.67±4.9

lever • Hydraulic oil temperature: Within operating {1.7±0.5} {1.7±0.5}
range
16.67±4.9 16.67±4.9
Arm control lever • Fit push-pull scale to center of control lever knob
or tip of pedal to measure {1.7±0.4} {1.7±0.4}
Bucket control • Measure max. value to end of travel 13.7±4.5 13.7±4.5
N {kg}
lever {1.4±0.5} {1.4±0.5}
Swing control 13.7±4.5 13.7±4.5
lever {1.4±0.5} {1.4±0.5}
Travel control 25.5±4.5 25.5±4.5
lever {2.6±0.5} {2.6±0.5}
+1.0
29.4±1.0 29.4 –2.0
Normal
{300±10} {300 +10
}
–20
RAISE
+0.5 +0.5
At heavy lift 31.4 –1.0 31.4 –2.0
ON {320
+ 5
} {320
+ 5
}
Boom –10 –20

14.7±1.47 14.7±1.47
Normal
{150±15} {150±15}
LOWER +1.0
At machine 29.4±1.0 29.4 –2.0
push-up ON {300±10} {300 +10
}
–20

• Engine at high idling 29.4±1.0 29.4

+1.0
–2.0
Arm • Hydraulic oil temperature: Within operating tem- {300±10} {300 +10
}
perature –20

• Relieve only circuit being measured +1.0

29.4±1.0 29.4 –2.0
Bucket • In DH mode
{300±10} {300 +10
}
–20

+1.0
31.4±1.0 31.4 –2.0
Travel
Hydraulic pressure

{320±10} {320 +10

}
–20

+2.45 +2.45
MPa 28.4 0 28.4 0
Swing +25 +25
{kg/cm2} {290 0 } {290 0 }
+0.34 +0.34
3.13 0 3.13 0
Control pump +3.5 +3.5
{32 0 } {32 0 }
• Engine at high idling 2.25±0.2 Min. 1.76
Levers at neutral
• Hydraulic oil tempera- {23±2} {Min. 18}
TVC valve output ture: Within operating Boom RAISE relief 1.52±0.2 1.48±0.2
pressure temperature (normal) {15.4±2} {15±2}
• In DH mode
Boom RAISE relief 1.46±0.2 1.41±0.2
(at heavy lift ON) {14.8±2} {14.3±2}
• Engine at high idling Max. 0.4 Max. 0.55
NC valve output Levers at neutral
• Hydraulic oil tempera- {Max. 4} {Max. 5.5}
pressure ture: Within operating
(No. 1, 2, 3, 4 Travel lever at full,
temperature Min. 1.8 Min. 1.8
pump) (tracks rotating under no
• In DH mode {Min. 18} {Min. 18}
load)
• Hydraulic oil tempera- Max. 0.4 Max. 0.55
Levers at neutral
NC valve output ture: Within operating {Max. 4} {Max. 5.5}
pressure range
(swing pump) • Engine at high idling Swing lever at end of Min. 1.37 Min. 1.8
• In DH mode travel (swing relief) {Min. 14} {Min. 18}

20-4 PC1800-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable Model PC1800-6

Cate- Standard value Service limit

Item Measuring Conditions Unit
gory for new machine value
• Engine high idling 1.76±0.2 1.5 max.
Control lever at neutral
Jet sensor differential • Hydraulic oil tem- {18±2} {15 max.}
pressure (V1, V2, V3 perature : Within Travel lever in full
and V4 control valves) operating temper- stroke (Track turns with- 0.2 max. 0.2 max.
ature {2 max.} {2 max.}
out load.)
• Engine high idling 1.76±0.2 1.5 max.
Oil Pressure

Control lever at neutral

Jet sensor differential • Hydraulic oil tem- MPa {18±2} {15 max.}
pressure (Swing con- perature : Within 2
{kg/cm }
trol valve) operating temper- Swing lever in full stroke 0.2 max. 0.2 max.
ature range (swing relief)) {2 max.} {2 max.}

• Hydraulic oil temperature : Within operating

temperature range
2.0 max. 2.9
Oil pressure drop • Difference of relief pressures at engine high
{20 max.} {30}
idling time and at engine low idling time
(Relief pressures for relieving all pumps)
Work equipment posture
Max. reach

No load
Overrun when stop- Degree 55 max. 70 max.
ping swing • Engine high idling <mm> <1,413 max.> <1,800 max.>
• Hydraulic oil temperature : Within operating
temperature range
• Swing circle misalignment when stopping
after a swing
• Values in < > are misalignments on swing
circle outer perimeter.
Work equipment posture
Max. reach
90° 6±0.6 5.6 max.
No load
Swing

Time taken to start

swing • Engine high idling
• DH mode
• Hydraulic oil temperature : Within
180° 9.3±0.7 9.0 max.
operating temperature range
• Time taken to pass a 90° or 180°
swing from start position
sec
Work equipment posture
Max. reach

No load
Time taken to swing 62–72 74 max.

• Engine high idling

• DH mode
• Hydraulic oil temperature : Within operating
temperature range
• Time taken to make 5 swings after a swing.

PC1800-6 20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable Model PC1800-6

Standard
Cate Service limit
Item Measuring Conditions Unit value for new
gory value
machine

15˚

BKP00103

Hydraulic drift of swing • Engine stopped mm 0 0

• Hydraulic oil temperature: Within operating
Swing

range
• Set machine on 15° slope, and set upper
structure at 90° to the side.
• Make match marks on swing circle outer race
and track frame.
• Measure distance that match marks move
apart after 5 minutes.
• Engine at high idling
l/min
• Hydraulic oil temperature: Within operating
Leakage from swing motor Max. 5 Max. 10
range
• Relieve swing circuit.

BKP00104
Travel speed (1) 93.5–113.5 115
• Engine at high idling
• Hydraulic oil temperature: Within operating
range
• In DH mode
• Raise track on one side at a time, rotate one
turn, then measure time taken for next 5 turns
Travel

with no load.
sec

45˚

BKP00105
Travel speed (2) 24.6–28.6 29
• Engine at high idling
• Hydraulic oil temperature: Within operating
range
• In DH mode
• Run up for at least 10 m, and measure time
taken to travel next 20 m on flat ground.

20-6 PC1800-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable Model PC1800-6

Standard
Cate Service limit
Item Measuring Conditions Unit value for
gory value
new machine
Work equipment posture

45˚

BKP00106

• Engine at high idling

• Hydraulic oil temperature: Within operating
range
• In DH mode
Travel deviation Max. 200 Max. 220
• Run up for at least 10 m, and measure devia-
tion when traveling next 20 m on hard flat
ground.

20m

mm

10m BKP00107

• Measure dimension χ.
Travel

12˚

BKP00108

Hydraulic drift of travel 0 0

• Engine stopped
• Hydraulic oil temperature: Within operating
range
• Stop machine on 12° slope with sprocket at
uphill end of machine.
• Measure the distance the machine moves in
5 minutes.

Leakage of travel motor l/min Max. 25 Max. 30

• Engine at high idling

• Hydraulic oil temperature: Within operating
range
• Lock shoes and relieve travel circuit.

PC1800-6 20-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC1800-6

Cate- Standard value for Service limit

Item Measurement conditions Unit
gory new machine value
Work equipment posture Load-
Total work Back Loading Back
Back hoe ing
equipment hoe shovel hoe
shovel
(hydraulic
drift at tip of Max. Max.
bucket 1,200 Max. 1,800 Max.
teeth) (Max. 1,500 (Max. 1,800
650) 1,000)
BKP00110

Boom cylin- Loading shovel

der (amount Max. 90
60 Max. Max.
Hydraulic drift of work equipment

of retrac- (Max.
(35) 150 240
tion of cylin- 50)
der)

mm
• Place in above posture and measure extension
Arm cylin- or retraction of each cylinder and downward Max.
der (amount movement at tip of bucket teeth. 165 250 Max.
Max. 40
of extension Rated load of work equipment (70) (Max. 60
of cylinder) Backhoe specification: 21,600 kg 105)
Loading shovel specification:19,800 kg
• Horizontal, flat ground
• Levers at neutral
• Engine stopped
Work equipment

Bucket cyl- • Hydraulic oil temperature: Within operating

inder range Max. 80
50 Max.
(amount of • Start measuring immediately after setting. Max.10 (Max.
(15) 20
retraction of • Measure hydraulic drift every 5 minutes, and 30)
cylinder) judge from results for 15 minutes.
• Figures in ( ) are value when bucket is not
loaded.

Boom
RAISE

Bucket 7.5± 0.7 8.5±0.9 — —

teeth in
contact with
ground
LOWER

Cylinder • Engine at high idling

Work equipment speed

fully • Hydraulic oil temperature: Within operating 5.2±0.5 6.0±0.6 — —

extended range
• In DH mode
sec

Arm 7.7±0.8 4.3±0.5 — —

IN

Cylinder
fully
retracted

Fully • Engine at high idling

OUT

extended 5.4±0.5 2.3±0.4 — —

• Hydraulic oil temperature: Within operating
range
• In DH mode

20-8 PC1800-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC1800-6

Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value

Back Loading Back Loading

hoe shovel hoe shovel

CURL
Bucket
Cylinder
fully 5.3±0.5 4.8±0.5 5.3±0.5 —
retracted
Work equipment speed

Fully

DUMP
• Engine at high idling
extendedd • Hydraulic oil temperature: Within operating 4.0±0.4 3.5±0.4 4.0±0.4 —
range
• In DH mode

Bottom

OPEN
dump — 2.2±0.3 — —
Cylinder
fully
retracted
• Engine at high idling
Fully • In DH mode CLOSE — 1.8±0.3 — —
extended • Hydraulic oil temperature: Within operating
Work equipment

range

sec

Boom BKP00114 Max. 6 Max. 6 Max. 6 Max. 6

• Lower boom and measure time taken from point

where bucket contacts ground to point where front
size of chassis rises from ground
• Engine at low idling
Time lag

• Hydraulic oil temperature: Within operating range

Arm Max. 5 Max. 5 Max. 5 Max. 5

BKP00115

• Stop arm suddenly and measure time taken for

arm to stop
• Engine at low idling
• Hydraulic oil temperature: Within operating range

PC1800-6 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Applicable model PC1800-6

Cate- Standard value

Item Measurement conditions Unit Service limit value
gory for new machine
Load-
Back Loading
ing Back hoe
hoe shovel
shovel

Bucket BKP00116

• Stop bucket suddenly and measure time Max. 4 Max. 4 Max. 4 Max. 4
taken for bucket to stop
• Engine at low idling
• Hydraulic oil temperature: Within operating
Time lag

range sec
Work equipment

Bottom
— Max. 3 — Max. 3
dump • Time taken for bottom dump to move again
when operated from max. bottom open posi-
tion to close position and stopped temporarily.
• Engine at low idling
• Hydraulic oil temperature: Within operating
range
• Engine at high idling
Internal oil leakage

Cylinders • Hydraulic oil temperature: Within operating Max. 5 Max. 5 Max. 20 Max. 20
range
• Hydraulic oil pressure: cc/min
31.4±1.0 MPa {320±10 kg/cm2}
Center Max. Max.
Max. 10 Max. 100
swivel joint 10 100

20-10 PC1800-6
 TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING........................................................ 20- 101-1
MEASUREMENT OF ENGINE SPEED.......................................................................................................20-102
MEASUREMENT OF AIR BOOST PRESSURE (BOOST PRESSURE) ....................................................20-103
MEASUREMENT OF EXHAUST GAS TEMPERATURE ............................................................................20-104
MEASUREMENT OF EXHAUST GAS COLOR ..........................................................................................20-104
ADJUSTMENT OF VALVE CLEARANCE ...................................................................................................20-106
MEASUREMENT OF COMPRESSION PRESSURE..................................................................................20-107
MEASUREMENT OF BLOW-BY PRESSURE ............................................................................................20-107
MEASUREMENT OF ENGINE OIL PRESSURE ........................................................................................20-108
HANDLING OF FUEL SYSTEM EQUIPMENT............................................................................................20-109
REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT..................................................20-109
MEASUREMENT OF FUEL PRESSURE....................................................................................................20- 110
AIR BLEEDING FROM FUEL CIRCUIT ......................................................................................................20- 111
INSPECTION OF LEAKAGE FROM FUEL SYSTEM .................................................................................20- 113
ADJUSTMENT OF ENGINE SPEED SENSOR ..........................................................................................20- 114
INSPECTION AND ADJUSTMENT OF FAN BELT TENSION ....................................................................20- 115
TESTING AND ADJUSTING ALTERNATOR BELT TENSION....................................................................20- 116
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION ................................20- 117
INSPECTION OF SWING CIRCLE BEARING CLEARANCE .....................................................................20- 118
REMAINING PRESSURE RELIEF FROM HIC CIRCUIT ...........................................................................20- 119
GAS FILLING IN HIC CIRCUIT ACCUMULATOR.......................................................................................20- 119
BLEEDING AIR FROM AND FILLING PRESSURIZED OIL IN HIC CIRCUIT............................................20-121
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION .............................................................20-122
INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT, SWING
AND TRAVEL CIRCUIT OIL PRESSURES ..........................................................................................20-123
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE .........................................20-128
INSPECTION AND ADJUSTMENT OF PISTON PUMP CONTROL OIL PRESSURE ...............................20-129
INSPECTION OF SERVO PISTON STROKE .............................................................................................20-136
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE..........................................................................20-137
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE ..............................................................20-139
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE..........................................................20-141
INSPECTION AND ADJUSTMENT OF TRAVEL DEVIATION ....................................................................20-142
INSPECTION OF WORK EQUIPMENT HYDRAULIC DRIFT CAUSE PORTION ......................................20-144
INSPECTION OF OIL LEAKAGE ................................................................................................................20-145
REMAINING PRESSURE RELIEF FROM HYDRAULIC CIRCUIT .............................................................20-148
AIR BLEEDING FROM EACH COMPONENT ............................................................................................20-149
TESTING AND ADJUSTING HYDRAULIC AUTO GREASE SYSTEM................................................... 20- 153-1
SPECIAL FUNCTIONS OF MACHINE MONITOR ......................................................................................20-154
FUNCTION AMD OPERATION OF CGC MONITOR ..................................................................................20-174
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT...............................................................20-209
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER...................................................................20-210
SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER .......................................................20-224
TESTING AND ADJUSTING DEVICES RELATED TO VHMS................................................................ 20- 240-1
ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL) .......................................20-241

PC1800-6 20-101
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Symbol
Test, measurement

Q’ty
Part No. Part name Remarks
item

Handy smoke
1 799-201-9001 1 Bosch index: 0 – 9
checker
Exhaust gas color A
Commercialy
2 Smoke meter 1
available
Commercialy
Engine valve clearance B Thickness gauge 1
available
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 1
kit (analog type) {25, 60, 400, 600 kg/cm2}
1
Fuel pressure C Oil pressure gauge
799-261-1204 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
kit (digital type)
2 799-401-2320 Oil pressure gauge 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
Swing circle bearing Commercialy Dial gauge
D 1
clearance available (with magnet)
Remaining pressure
relief from HIC circuit,
E 209-98-11140 Handle 1
air bleeding, and filling
pressurized oil
Gas filling in HIC circuit Charge valve
F 792-610-1700 1
accumulator assembly
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 1
kit (analog type) {25, 60, 400, 600 kg/cm2}
1
Piston pump control oil Oil pressure gauge
G 790-261-1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
presssure kit (digital type)
21T-06-64590 Coupling assembly 1 Attached tool
2
21T-06-64392 Wiring Harness 1 Attached tool
708-25-14140 Cap 1 No.1, 2, 3, 4 pump
1
07000-B2065 O-ring 1 No.1, 2, 3, 4 pump
Servo piston stroke H 708-27-14150 Cap 1 Swing pump
2
07000-B2075 O-ring 1 Swing pump
3 566-98-41120 Disc gauge 1
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 1
PPC valve output pres- kit (analog type) {25, 60, 400, 600 kg/cm2}
1
sure Oil pressure gauge
J 790-261-1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Solenoid valve output kit (digital type)
pressure 799-401-3200 Adapter assembly 1
2
02896-11009 O-ring 1
Releasing remaining
pressure in hydraulic K 790-445-1350 Hose assembly 1
circuit

20-101-1 PC1800-6
(6)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Symbol
Test, measurement

Q’ty
Part No. Part name Remarks
item

799-608-3101 Service tool kit 1

1 799-608-3211 Diskette 1
Initialization procedure 799-608-3220 Wiring harness 1
and setting procedure L Commercialy Laptop personal
for VHMS controller 2 1 OS: Windows98/2000
available computer
21T-06-64590 Coupling assembly 1 Attached tool
3
21T-06-64392 Wiring harness 1 Attached tool
Water temperature,
M 799-101-1502 Digital thermometer 1 –99.9 – 1,299ºC
oil temperature
79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
Operating force N
79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Stroke and hydraulic Commercialy
P Scale 1
drift available
Commercialy
Work equipment speed Q Stopwatch 1
available
Commercialy
Voltage and resistance R Tester 1
available
799-601-7400 T-adapter assembly 1
799-601-3460 Adapter 1 For BENDIX (MS)-10
799-601-7310 Adapter 1 For SWP-12
799-601-7320 Adapter 1 For SWP-16
799-601-7360 Adapter 1 For relay (5-pin)
799-601-7510 Adapter 1 For AMP070-10
Troubleshooting of sen- 1
799-601-7520 Adapter 1 For AMP070-12
sors and wiring har- S
nesses 799-601-7530 Adapter 1 For AMP070-14
799-601-7540 Adapter 1 For AMP070-18
799-601-7550 Adapter 1 For AMP070-20
799-601-9410 Adapter 1 For NE, G sensor
799-601-9420 Adapter 1 For fuel, boost pressure sensor
2 799-601-9000 T-adapter assembly 1 For DT connector
3 799-601-9300 T-adapter assembly 1 For DT connector (For 24, 40-pin)

PC1800-6 20-101-2
TESTING AND ADJUSTING MEASUREMENT OF ENGINE SPEED

MEASUREMENT OF ENGINE SPEED

★ Measure engine speed under the following con- 2. Measurement of Low Idling Engine Speed
ditions: 1) Start the engine and set the fuel dial to the
• Engine water temperature : Within operating low idling position.
temperature range 2) Measure engine speeds at the time of set-
• Hydraulic oil temperature : Within operating ting the work equipment and swing lever,
temperature range and the travel lever to the neutral position.

1. Preparatory Work 3. Measurement of High Idling Engine Speed

Turn on the starting switch and display the 1) Start the engine and set the fuel dial to the
screen for measuring engine speed on the high idling position.
machine monitor or CGC monitor. 2) Set the working mode switch to the DH
★ For the control method, refer to the para- Mode.
graph of SPECIAL FUNCTION OF MA- 3) Turn the auto-deceleration switch to OFF.
CHINE MONITOR or FUNCTION AND 4) Measure engine speeds at the time of set-
OPERATION OF CGC MONITOR. ting the work equipment and swing lever,
★ The figure shows the F (front) engine. and the travel lever to the neutral position.
★ Screen Display on Machine Monitor (Unit :
10rpm) 4. Measurement of Engine Speed at the time of
• F (front) engine : Monitoring [10], [70] relieving all pumps
• R (rear) engine : Monitoring [11], [90] 1) Start the engine and set the fuel dial to the
high idling position.
2) Set the working mode switch to the DH
Mode.
3) Measure engine speed at the time of reliev-
ing the arm IN.

5. Measurement of Engine Speed at the time of

relieving all pumps and of heavy lift
1) Start the engine and set the fuel dial to the
high idling position.
2) Set the working mode switch to the DH
Mode.
3) Turn on the heavy lift switch.
4) Measure engine speeds at the time of lifting
★ Screen Display on CGC Monitor (Unit : and relieving the boom.
1rpm) ★ The heavy lift function is available only
• F (front) engine : Real time monitor (1/6) when boom RAISE is operated inde-
• R (rear) engine : Real time monitor (2/6) pendently.

6. Measurement of Engine Speed when auto-

deceleration is activated
1) Start the engine and set the fuel dial to the
high idling position.
2) Set the working mode switch to the DH
Mode.
3) Turn on the auto-deceleration switch.
4) Set the work equipment lever and the travel
lever to the neutral positions and measure
engine speed when auto deceleration is
activated.
★ Auto-deceleration activated speed is in-
dicated at the position where the speed
lowers automatically about 5 seconds
later after all the levers are set to the
neutral positions.

20-102 PC1800-6
TESTING AND ADJUSTING MEASUREMENT OF AIR BOOST PRESSURE (BOOST PRESSURE)

MEASUREMENT OF AIR BOOST PRESSURE

(BOOST PRESSURE)
a Measure air boost pressure (boost pressure) un- 2. Start the engine and set the working mode
der the following conditions: switch to DH Mode.
• Engine water temperature : Within operating
temperature range 3. Measure air boost pressure (boost pressure) at
• Hydraulic oil temperature : Within operating the time of relieving the arm IN at engine high
temperature range idling.

1. Turn on the starting switch and display the

screen for measuring air boost pressure (boost
pressure) on the machine monitor or CGC moni-
tor.
a For the control method, refer to the para-
graph of SPECIAL FUNCTION OF MA-
CHINE MONITOR or FUNCTION AND
OPERATION OF CGC MONITOR.
a The figure shows the F (front) engine.
a Screen Display on Machine Monitor (Unit :
kPa)
• F (front) engine : Monitoring [76]
• R (rear) engine : Monitoring [96]

a Screen Display on CGC Monitor

(Unit : kPa, mmHg)
• F (front) engine : PM clinic(2/6)
• R (rear) engine : PM clinic (3/6)

PC1800-6 20-103
 MEASUREMENT OF EXHAUST GAS TEMPERATURE
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOR

MEASUREMENT OF MEASUREMENT OF
EXHAUST GAS EXHAUST GAS COLOR
TEMPERATURE
a Measuring instrument of exhaust gas tempera-
a Measure exhaust gas temperatures under the ture
following conditions:
Symbol Part Number Part Name
• Engine water temperature : Within operating
temperature range Handy smoke
1 799-201-9001
• Hydraulic oil temperature : Within operating A checker
temperature range 2 Commercial item Smoke meter

1. Turn on the starting switch and display the k Be careful not to touch hot areas when mounting
screen for measuring exhaust gas temperature and removing an measuring instrument.
on the CGC monitor. a When air source or electric power supply is not
a For the control method, refer to the para- available in field, use A1 Handy Smoke Checker,
graph of FUNCTION AND OPERATION OF but use A2 Smoke Meter, when recording official
CGC MONITOR. data.
a The figure shows the F (front) engine. a Measure exhaust gas color under the following
a Exhaust gas temperatures on the front side conditions:
of the engine (No. 1, 2 and 3 cylinders) are • Engine water temperature : Within the oper-
displayed separately from those on the rear ating temperature range.
side of the engine (No. 4, 5 and 6 cylinders).
a Screen Display on CGC Monitor (Display 1. Measurement with A1, Handy Smoke
unit : degC, °C) Checker
• F (front) engine : PM clinic (2/6) 1) Set a filter paper in the handy smoke
• R (rear) engine : PM clinic (3/6) checker A1.
2) Insert the exhaust gas suction port in the
exhaust pipe.
3) Start the engine.
4) Operate the handle of the smoke checker
A1, and adhere exhaust gas to the filter
paper when accelerating the engine quickly
or at a high idling.

2. Maximum Value Measuring Method in Trouble-

shooting
Measure the maximum value of exhaust gas
temperature at the time of actual operation.

3. Periodic Measuring Method in Preventive Main-

tenance Service (PM Clinic)
1) Start the engine and set the working mode 5) Remove the filter paper and compare the
switch to DH Mode. color on the filter paper with the accessory
2) Measure exhaust gas temperature at the scale.
time of relieving the arm IN at engine high 6) After the measurement, remove the meas-
idling. uring instrument and return the engine to
a Measure and record the value when ex- the original state.
haust gas temperature becomes stable.

20-104 PC1800-6
(6)
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOR

2. Measurement with Smoke Meter A2 6) Start the engine.

1) Insert the probe (1) of the smoke meter A2, 7) When accelerating the engine quickly or at a
in the outlet of the exhaust pipe and fix it to high idling, step down the accelerator pedal
the exhaust pipe with clip. of the smoke meter A2, and collect exhaust
gas in the filter paper.
8) Place the filter paper contaminated with
exhaust gas on new filter papers (more than
10 sheets) in the filter paper holder and read
the indicated value.
9) After the measurement, remove the meas-
uring instrument and return the engine to
the original state.

2) Connect the probe hose, the receptacle of

the accelerator switch and the air hose to
the smoke meter A2.
★ The supply air pressure shall be less
than 1.5MPa (15kg/cm2).
3) Connect the power cord to an AC100V
receptacle.
★ Before connect the power cord, make
sure that the power switch of the smoke
meter is turned off.
4) Loosen the cap nut of the suction pump and
set a filter paper there.
★ Set the filter paper accurately so that ex-
haust gas does not leak out.
5) Turn on the power switch of the smoke
meter A2.

PC1800-6 20-105
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE

ADJUSTMENT OF VALVE CLEARANCE

★ Adjustment Device of Valve Clearance 4. Fix the adjustment screw (5) and tighten the
locknut (6).
Symbol Part Number Part Name 3 Locknut :
B Commercial item Filler gauge 53.0 – 64.7Nm {5.4 – 6.6kgm}
★ After tightening the locknut, check the valve
1. Remove the cylinder head cover (1) completely. clearance again.

2. Rotate the crankshaft forward, bring the 5. Rotate the crankshaft 120° each forward and
"1.6TOP" stamp line a of the damper to the repeat Steps 3 to 5 for each cylinder according
pointer (2) and bring No. 1 cylinder to the com- to the firing order.
pression top dead center. • Firing order : 1-5-3-6-2-4
★ The crankshaft cranks at the hexagon por-
tion at the tip of the water pump drive shaft. 6. After the adjustment, return the engine to the
original state.
3 Cylinder head cover mounting bolt :
★ The rocker arm of No. 1 cylinder can be
moved as much as the valve clearance by
hand at the compression top dead center. 29.4 – 34.3Nm {3.0 – 3.5kgm}
When the rocker arm does not move, it is not
at the compression top dead center, rotate
one turn.

3. Insert the filler gauge B in the clearance b

between the rocker arm (3) and the crosshead
(4) and adjust the valve clearance with the
adjustment screw (5).
★ After inserting the filler gauge, turn the ad-
justment screw to adjust the valve clearance
so that the filler gauge comes to move lightly.

20-106 PC1800-6
 MEASUREMENT OF COMPRESSION PRESSURE
TESTING AND ADJUSTING MEASUREMENT OF BLOW-BY PRESSURE

MEASUREMENT OF MEASUREMENT OF
COMPRESSION PRESSURE BLOW-BY PRESSURE
★ For the measuring method of compression pres- ★ Measure blow-by pressures under the following
sure, refer to the Shop Manual for 140-3 Series conditions:
engine shop manual. • Engine water temperature : Within operating
temperature range
• Hydraulic oil temperature : Within operating
temperature range

1. Turn on the starting switch and display the

screen for measuring blow-by pressure on the
CGC monitor.
★ For the control method, refer to the para-
graph of FUNCTION AND OPERATION OF
CGC MONITOR.
★ The figure shows the F (front) engine.
★ Screen Display on CGC Monitor (Display
unit : kPa, mmAq)
• F (front) engine : PM clinic (2/6)
• R (rear) engine : PM clinic (3/6)

2. Start the engine and set the working mode

switch to the DH mode.

3. Measure blow-by pressures at the time relieving

the arm IN at engine high idling.

PC1800-6 20-107
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE

MEASUREMENT OF ENGINE OIL PRESSURE

★ Measure engine oil pressures under the follow-
ing conditions:
• Engine water temperature : Within operating
temperature range

1. Turn on the starting switch and display the

screen for measuring engine oil pressure on the
CGC monitor.
★ For the control method, refer to the para-
graph of FUNCTION AND OPERATION OF
CGC MONITOR.
★ Screen Display on CGC Monitor (Display
unit : MPa, kg/cm2)
• PM clinic (1/6)

2. Start the engine and measure engine oil pres-

sure at the times of low idling and high idling.

20-108 PC1800-6
 HANDLING OF FUEL SYSTEM EQUIPMENT
TESTING AND ADJUSTING REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT

HANDLING OF FUEL SYSTEM REMAINING PRESSURE

EQUIPMENT RELIEF FROM FUEL SYSTEM
EQUIPMENT
a While the engine is rotating, pressures occur in
a Precautions in Inspection and Maintenance of the low pressure circuit and the high pressure cir-
Fuel System Equipment cuit of the fuel system.
The common rail type fuel injection system Low pressure circuit : Among Feed pump – Fuel
(CRI) is composed of more precise components filter – Fuel supply pump
than the usual fuel injection pump and nozzle High pressure circuit : Among Fuel supply pump
and will probably get out of order when foreign – Common rail – Fuel injector
matters enters the system. a When 30 seconds elapse after the engine
During inspection and maintenance of the fuel stopped, pressures in both the low pressure cir-
system, pay more attention to foreign matters cuit and the high pressure circuit drop to the safe
than in case of usual fuel injection pumps and level automatically.
wash the system carefully with clean fuel if dusts a Since pressure remaining in the fuel system
enter the system. should be relieved certainly before inspection of
the fuel system and mounting and removing of
a Precautions in Replacement of Fuel Filter Car- equipment, be sure to observe the following pre-
tridge cautions:
k Inspect the fuel system or mount or remove
Be sure to use genuine fuel filter cartridge of
Komatsu. equipment more than 30 seconds later after the
The common rail type fuel injection system engine stopped and after pressure remaining in
(CRI) is composed of more precise components the fuel system is relieved. (Pressure remains in
than the usual fuel injection pump and nozzle the fuel system right after the engine stopped, so
and is equipped with special filter with highly do not start any work until 30 seconds elapse.)
efficient filtration performance to prevent foreign
matters from entering the system.
Therefore, be sure to use genuine filters only.
Otherwise, the fuel system will possibly get out
of order.

PC1800-6 20-109
(4)
TESTING AND ADJUSTING MEASUREMENT OF FUEL PRESSURE

MEASUREMENT OF FUEL PRESSURE

a Measuring Instrument of Fuel Pressure 3. Start the engine and measure fuel pressure at
the time of high idling.
Symbol Part Number Part Name a Standard value of fuel pressure:
799-101-5002 Hydraulic tester 0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
1 Digital type hydraulic
790-261-1204
C tester
Hydraulic tester
2 799-401-2320
(1.0MPa {10kg/cm2})

a Measure fuel pressure in the low pressure circuit

among the feed pump – the fuel filter – the fuel
supply pump.
k Since very high pressure are generated in the
high pressure circuit among the fuel supply
pump – the common rail – the fuel injector, they
cannot be measured in the circuit.

1. Remove the fuel pressure measurement plug 4. After the measurement, return the circuit to the
(1). original state.

2. Attach the nipple [1] of the hydraulic tester, C1,

and connect the hydraulic gauge, C2.

20-110 PC1800-6
(6)
TESTING AND ADJUSTING AIR BLEEDING FROM FUEL CIRCUIT

AIR BLEEDING FROM FUEL CIRCUIT

★ When the fuel has run out, or after mounting or

removing any device to or from the fuel circuit,
bleed air from the circuit as follows:

1. Remove the fuel filter (1), fill the circuit with the
fuel and mount the filter again.
★ Fill the circuit with clean fuel and be careful
to prevent dusts from entering the circuit.
★ Pour the fuel in the inlet ports "a" (at 8 plac-
es) of the filter. The portion "b" is the outlet
port (clean side) after filtration, and do not
pour the filter in this port.
★ When clean fuel is not readily available, do
not remove the fuel filter and fill the filter with
the fuel by operating the priming pump.

PC1800-6 20-111
TESTING AND ADJUSTING AIR BLEEDING FROM FUEL CIRCUIT

2. Remove the air bleeding plug (2a) from the fuel

filter and operate the priming pump (3).
★ Keep operating the priming pump until the
fuel comes out of the plug hole, and attach
the plug to the fuel filter when checking the
fuel.
3 Air bleeding plug :
7.8 – 9.8Nm {0.8 – 1.0kgm}

3. Remove the plug (2b) from the fuel filter and

operate the priming pump (3).
★ Keep operating the priming pump until the
fuel comes out of the plug hole, and attach
the plug to the fuel filter when checking the
fuel.
3 Air bleeding plug :
3.8 – 6.9Nm {0.4 – 0.7kgm}

4. Loosen the air bleeder (4) on the fuel supply

pump and operate the priming pump (3) 90 to
100 times.
★ Keep operating the priming pump until the
fuel comes out of the bleeder, and tighten the
bleeder when you could check the fuel.
Then, operate the priming pump several
times until it become tight.
3 Air bleeder :
4.9 – 6.9Nm {0.5 – 0.7kgm}

5. Crank the engine with the starting motor and

start the engine.
★ When the engine is cranked, air is bled auto-
matically from the high pressure circuit.
★ When the engine does not start, air would
not have been bled sufficiently from the low
pressure circuit. Execute the procedures
again from Step 2.

20-112 PC1800-6
TESTING AND ADJUSTING INSPECTION OF LEAKAGE FROM FUEL SYSTEM

INSPECTION OF LEAKAGE FROM FUEL SYSTEM

k Since very high pressures are generated in the 7. Check if fuel is leaking from the fuel pipe and
high pressure fuel circuit, there is an danger of equipment.
getting fire if fuel leaks while the engine is run- ★ Check if fuel is leaking from the high pres-
ning. sure circuit, mainly from the area where color
After inspecting the fuel circuit or mounting or checker was sprayed.
removing equipment to or from the fuel circuit, ★ When finding fuel leakage, repair the rele-
execute the following procedures to check if fuel vant portions. Then, repeat the procedures
is leaking. from Step 2 to check that there is no leakage
★ Clean and degrease the engine body and the from the relevant portions.
area around before inspection so that fuel leak-
age can be checked easily. 8. Start the engine and keep low idling. Apply any
load to the engine.
1. Spay color checker (developer) to the connec- ★ Relieve the arm IN.
tions of the fuel supply pump, the common rail,
the fuel injector and the high pressure pipe. 9. Check if fuel is leaking from the fuel pipe and
equipment.
2. Start the engine, keep the speed below ★ Check if fuel is leaking from the high pres-
1,000rpm and stop the engine when the rotation sure circuit, mainly from the area where color
became stable. checker was sprayed.
★ When finding fuel leakage, repair the rele-
3. Check if fuel is leaking from the fuel pipe and vant portions. Then, repeat the procedures
equipment. from Step 2 to check that there is no leakage
★ Check if fuel is leaking from the high pres- from the relevant portions.
sure circuit, mainly from the area where color ★ When no leakage is found, end the inspec-
checker was sprayed. tion.
★ When finding fuel leakage, repair the rele-
vant portions. Then, repeat the procedures
from Step 2 to check that there is no leakage
from the relevant portions.

4. Start the engine and keep low idling.

5. Check if fuel is leaking from the fuel pipe and

equipment.
★ Check if fuel is leaking from the high pres-
sure circuit, mainly from the area where color
checker was sprayed.
★ When finding fuel leakage, repair the rele-
vant portions. Then, repeat the procedures
from Step 2 to check that there is no leakage
from the relevant portions.

6. Start the engine and keep high idling.

PC1800-6 20-113
TESTING AND ADJUSTING ADJUSTMENT OF ENGINE SPEED SENSOR

ADJUSTMENT OF ENGINE SPEED SENSOR

★ Adjust the engine speed sensor for pump con-
troller according to the following procedures:
★ Adjusting the engine G speed sensor and the en-
gine Ne speed sensor for engine controller is not
possible.

1. Screw in the sensor (1) until its tip comes to the

tip of the flywheel ring gear (2).
★ Before the connection, carefully check that
the sensor tip is not adhered with iron pow-
ders and is not flawed.
2 Threaded portion : Hydraulic sealant

2. Bring back the sensor (1) 1/2 or 2/3 turns from

the present position.
★ Clearance a of 0.75 – 1.00mm is formed be-
tween the sensor tip and the gear tip.

3. Fix the sensor (1) with the nut (3).

3 Nut : 69 – 74Nm {7.0 – 7.5kgm}

20-114 PC1800-6
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FAN BELT TENSION

INSPECTION AND ADJUSTMENT OF FAN BELT TENSION

Inspection
You need not inspect this fan belt tension until the
belt is replaced.

Adjustment
1. Set 2 pieces of the belt (1).
★ Loosen the stopper bolt before setting the
belt.

2. Screw in the stopper bolt (2) until it comes in

contact with the bracket (3).

3. Screw in the stopper bolt (2) 2 turns more from

the present position and fix it with the lock nut
(4).
3 Lock nut :
245.0 – 308.7Nm {25.0 – 31.5kgm}

PC1800-6 20-115
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

TESTING AND ADJUSTING ALTERNATOR BELT TENSION

Testing procedure
• Measure the belt deflection a when pushing a
point midway between the alternator pulley and
the drive pulley with the finger.

★ Deflection a when press force is approx. 98N

{10kg}: 13 - 16 mm

Adjustment procedure
★ Adjust the belt according to the following proce-
dure when the belt deflection is not normal.

1. Loosen nuts and bolts (1), (2), (3) and (4) in this
order.

2. Turn nut (5) to move alternator (6), and adjust

the belt tension.
★ Nut (5):
• It is moved to the side that belt is loos-
ened when fastening it clockwise.
• It is moved to the side that belt is ten-
sioned when loosening it counterclock-
wise.
★ Test for breakage of each pulley, friction of
V-ditch, friction of belt, and contact between
belt and V-ditch.
★ Replace it with new belt if it was too
stretched so that adjustability was lost, or cut
and crack occurred.

3. Tighten nuts and bolts (4), (3), (2) and (1) in this
order.
★ When the belt was replaced, readjust it after
one-hour operation.

20-116 PC1800-6
(4)
 TESTING AND ADJUSTING AIR CONDITIONER
TESTING AND ADJUSTING COMPRESSOR BELT TENSION

TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR

BELT TENSION

Testing procedure
1. Dismount the belt cover.

2. Measure the belt deflection a when pushing a

point midway between the air conditioner com-
pressor pulley and the drive pulley with the fin-
ger.

★ Press force at approx. 58.8N {Approx. 6kg},

a: 6 mm

Adjustment procedure 4. Mount the belt cover.

★ Adjust the belt according to the following proce-
dure when the amount of belt deflection is not
normal.

1. Loosen nuts and bolts (1), (2), (3) and (4) in this
order.

2. Turn nut (5) to move air conditioner compressor

(6), and adjust the belt tension.
★ Nut (5):
• It is moved to the side that belt is loosen
when fastening it clockwise.
• It is moved to the side that belt is ten-
sioned when loosening it counterclock-
wise.
★ Test for breakage of each pulley, friction of
V-ditch, friction of belt, and contact between
belt and V-ditch.
★ Replace it with new belt if it was too
stretched so that adjustability was lost, or cut
and crack occurred.

3. Tighten nuts and bolts (4), (3), (2) and (1) in this
order.

PC1800-6 20-117
TESTING AND ADJUSTING INSPECTION OF SWING CIRCLE BEARING CLEARANCE

INSPECTION OF SWING CIRCLE BEARING CLEARANCE

★ Inspection Device of Swing Circle Bearing Clear- 3. Set the dial gauge D to the zero point.
ance
4. Arrange the arm almost at right angles to the
Symbol Part Number Part Name ground and lower the boom until the front leg of
Dial gauge the machine body rises.
D Commercial item ★ At the time, the front of the upper structure
(with magnet)
rises and its rear lowers.
★ When measuring swing circle bearing clearance
on a machine, follow the procedures below:
1. Fix the dial gauge D to the track frame (center
frame) and bring the stylus to the outer race end
face.
★ Set the dial gauge to the front or to the rear.

5. At the time, read the value on the dial gauge D.

This value on the dial gauge indicates the swing
circle bearing clearance.
k During the measurement, never place
hands and legs below the undercarriage.

2. Set the work equipment to the maximum reach 6. Return the work equipment to the state in Para-
and set the bucket tip to the height of the revolv- graph 2 and make sure that the dial gauge D
ing frame lower face. has returned to the zero point. If not, repeat
★ At the time, the front of the upper structure Steps 3 to 5.
lowers and its rear rises.

20-118 PC1800-6
 REMAINING PRESSURE RELIEF FROM HIC CIRCUIT
TESTING AND ADJUSTING GAS FILLING IN HIC CIRCUIT ACCUMULATOR

REMAINING PRESSURE GAS FILLING IN HIC CIRCUIT

RELIEF FROM HIC CIRCUIT ACCUMULATOR
★ Device for relieving pressure remaining in HIC ★ Device for filling gas in HIC circuit Accumulator
circuit
Symbol Part Number Part Name
Symbol Part Number Part Name
Charge valve
F 792-610-1700
E 209-98-11140 Handle assembly

★ If the HIC edquipment is to be removed or the ★ If the gas was discharged from the HIC circuit ac-
piping are to be disconnected, release the re- cumulator or the accumulator was replaced,
lease the remaining pressure from the HIC circuit charge the accumulator with gas according to the
as follows. following procedure.
k Lower the work equipment completely to the
ground, stop the engine and use the control le- 1. Relieve pressure remaining in the HIC circuit.
ver several times to relieve pressure remaining ★ Refer to the Paragraph of REMAINING
in the pipe. Then, loosen the oil filler cap of the PRESSURE RELIEF FROM HIC CIRCUIT
hydraulic tank gradually to relieve pressure in and leave 2 pieces of the stop valve loos-
the tank. ened.

1. Use the handle E to loosen the stop valves (1) 2. Attach the plug (1) to the accumulator.
and (2) and relieve pressure remaining in the
circuit.
k Quick loosening will cause a high pressure
in the tank circuit, so be sure to loosen the
stop valves slowly.
★ After a minute elapsed, the remaining gas
will have been relieved completely.

3. Attach the valve kit [1] of the charge valve

assembly F to the accumulator (2) and attach
the nipple [2] to the nitrogen bomb (3). Then,
connect the valve kit [1] and the nipple [2] with
the hose [3].
★ Before attaching the valve kit [1], turn the
valve [4] fully to the left and turn the valve [5]
2. When the remaining pressure is relieved com- to the left and keep it opened.
pletely, retighten stop valves (1) and (2).

PC1800-6 20-119
TESTING AND ADJUSTING GAS FILLING IN HIC CIRCUIT ACCUMULATOR

4. Open the valve [7] of the nitrogen bomb (3)

slowly, keep the pressure to the pressure gauge
[6] at 0.2 – 0.3MPa {2 – 3kg/cm2} and tighten the
valve [5].
k Quick filling high pressure gas will expand
the plug suddenly and may break it, so be
sure to fill nitrogen gas slowly.

5. Screw in the valve [4] until it touches something

lightly.

6. Open the valve [7] further slowly and fill the

accumulator (4) with nitrogen gas.
★ Close the valve [7] gradually until the pres-
sure gauge becomes stable, and then read
the value shown on the pressure gauge.

7. After filling nitrogen gas to the specified pres-

sure, tighten the valve [7] firmly.
★ Specified pressure :
13.2 ± 0.3MPa {135 ± 3kg/cm2}
(Atmospheric temperature: 20 ± 3°C)
★ If more pressure than the specified one was
filled in, tighten the valve [7] and turn the
valve [4] slowly to the left to relieve the gas
gradually to the specified pressure.

8. Turn the valve [4] to the left until it stops, turn the
valve [5] to open it and discharge gas remaining
in the valve kit [1] and the hose [3].

9. Remove the valve kit [1] from the accumulator

(2) and attach the plug (3) to the valve kit.

10. After filling gas, bleed air from the HIC circuit
and fill pressurized oil in the circuit.
★ Refer to the paragraph of BLEEDING AIR
FROM AND FILLING PRESSURIZED OIL
IN HIC CIRCUIT.

20-120 PC1800-6
TESTING AND ADJUSTING BLEEDING AIR FROM AND FILLING PRESSURIZED OIL IN HIC CIRCUIT

BLEEDING AIR FROM AND FILLING PRESSURIZED OIL IN HIC

CIRCUIT
4. Loosen the air bleeding plug (3) of the relief
★ Device for bleeding air from and filling pressu- valve about one turn.
rized oil in HIC circuit
5. Start the engine and idle it at low speed for 2 to
Symbol Part Number Part Name 3 minutes.
E 209-98-11140 Handle
6. When bubble-free oil flows out of the air bleed-
★ After relieving pressure remaining in the HIC cir- ing plug (2), use the handle E to tighten the stop
cuit or mounting or removing the HIC circuit, valve (4).
bleed air from and fill pressurized oil in the HIC
circuit. 7. Keep idling the engine at a low speed and oper-
ate the R.H. travel lever to FORWARD 2 to 3
1. Relieve pressure remaining in the HIC circuit. times.
★ Refer to the paragraph of REMAINING
PRESSURE RELIEF FROM HIC CIRCUIT 8. When bubble-free oil flows out of the air bleed-
and leave 2 pieces of the stop valve loos- ing plugs (2) and (3), use the handle E to tighten
ened. the air bleeding plugs (2) and (3) and the stop
valve (4).
2. Loosen the grease valve (1) of the left-to-right
grease cylinder one turn.
k Since the valve may be jumped out due to
the internal high pressure grease, never
loosen the valve more than one turn.

9. Tighten the grease plug (1) of the left and right

grease cylinders and make sure that the plunger
(6) protrusion a is normal.
• Plunger protrusion "a" : 135±5mm

3. Loosen the air bleeding plug (2) of the left-to-

right cushion cylinder about one turn.

PC1800-6 20-121
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION

INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION

Inspection Adjustment
1. Start the engine, move the machine forward the ★ When the track shoe tension is abnormal, adjust
length of the track shoe only and stop it slowly. it according to the following procedures:

2. Place a square bar [1] on the track shoe 1. In case of too tight tension
between the center and the rear carrier rollers. Loosen the valve (1) and discharge grease.
★ Use L-shaped steel hardly deflected as the k Since the valve may jump out due to the in-
square bar. ternal high pressure grease, never loosen
the valve more than one turn.
3. Measure the maximum clearance "a" between ★ Move the machine forward and backward
the square bar [1] and the track shoe. and check the tension again according to the
• Standard clearance "a" : 10 – 30mm above-mentioned inspection procedures.

2. In case of weak tension

Fill grease from the grease fitting (1).
★ When the shoe tension is not appropriate,
move the machine slowly forward and back-
ward.
★ After moving the machine forward and back-
ward, check the tension again according to
the above-mentioned inspection proce-
dures.

20-122 PC1800-6
 INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT,
TESTING AND ADJUSTING SWING AND TRAVEL CIRCUIT OIL PRESSURES

INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT,

SWING AND TRAVEL CIRCUIT OIL PRESSURES
Measurement ★ When the boom cylinder is lowered and
★ Measure the work equipment, swing and travel relieved at the stroke end, the safety
circuit oil pressures under the following condi- valve with suction on the boom lower
tions: side of the control valves V1 and V3 is
• Hydraulic oil temperature : Within operating relieved (because the set pressure is
temperature range lower than that of the main relief valve).
2) Measurement of Relief Oil Pressure at the
1. Preparatory Work time of heavy lift operation
Turn on the starting switch and display the i) Start the engine and turn on the heavy
screen for measuring the work equipment, lift switch.
swing and travel circuit oil pressures on the ii) Measure the oil pressure when the
CGC monitor. boom cylinder is raised and is relieved
★ For the control method, refer to the para- individually at the stroke end at high
graph of FUNCTION AND OPERATION OF idling.
CGC MONITOR. ★ The heavy lift function works only when
★ The figure shows the F (front) pump. the boom is individually raised.
★ Screen Display on CGC Monitor (Display ★ The main relief valve of each control
unit : MPa, kg/cm2) valve is relieved on the high pressure set
• F (front) pump + swing pump : Real time side.
monitor (3/6) 3) Measurement of Relief Oil Pressure at the
• R (rear) pump + swing pump : Real time time of machine push operation
monitor (4/6) i) Start the engine and turn on the
machine push-up switch.
ii) Measure the oil pressure when the
boom cylinder is lowered and is relieved
individually at the stroke end at high
idling.
★ Since the set pressure of the safety
valve with suction on the boom head
side of the control valves V1 and V3 ris-
es more than the set pressure of the
main relief valve, the main relief valve is
relieved on the low pressure set side.

4. Measurement of Swing Oil Pressure

1) Start the engine and turn on the swing lock
2. Combination of Hydraulic Pump and Actua- switch.
tor 2) Measure the oil pressure when the swing
★ See the oil pressure measuring circuit dia- motor is relived at engine high idling.
gram (Measuring Positions of Hydraulic ★ The safety valve of the swing motor is re-
Pump, Control Valve and Oil Pressure). lieved.
3. Measurement of Work Equipment Oil Pres- 5. Measurement of Travel Oil Pressure
sure 1) Start the engine and place a pin or a block
1) Measurement of Normal Relief Oil Pressure between the sprocket and the track frame or
Start the engine and measure the oil pres- the track link to lock traveling.
k Make sure that travel is certainly locked.
sure when each cylinder is relieved individu-
ally at the stroke end at high idling.
★ The main relief valve of each control 2) Measure the oil pressure when the travel
valve is relieved on the low pressure set motor is relieved at engine high idling.
side. ★ The main relief valve of each control
valve is relieved on the high pressure set
side.

PC1800-6 20-123
 INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT,
TESTING AND ADJUSTING SWING AND TRAVEL CIRCUIT OIL PRESSURES

Adjustment 3) Fix the elbow (6) and tighten the lock nut
1. Adjustment of Main Relief Valve (High Pres- (5).
sure Set) of Control Valves V1, V2, V3 and V4
★ When the work equipment oil pressure
(when the machine push-up is working) is
abnormal or when the travel oil pressure is
abnormal, adjust the high pressure set side
of the main relief valves (1), (2), (3) and (4)
of each control valve according to the follow-
ing procedures:
• (1) : V1 control valve (No. 1 and 2F pumps)
• (2) : V2 control valve (No.1 and 2R pumps)
• (3) : V3 control valve (No. 3 and 4F pumps)
• (4) : V4 control valve (No. 3 and 4R pumps)

4) After the adjustment, check the oil pressure

again according to the above measurement
procedures.

★ High Pressure Set is the state that the 2-

stage relief solenoid valve is ON and that a
pilot pressure is applied to the changeover
port.
1) Loosen the lock nut (5) and make the elbow
(6) free.
2) Loosen the lock nut (7) and turn the holder
(8) for adjustment.
• Turn the holder to the right, and the pres-
sure will rise.
• Turn the holder to the left, and the pres-
sure will lower.
★ Pressure adjusted by a turn of the
holder: about 21.8MPa {222kg/cm2}
3 Lock nut :
93 – 123Nm {9.5 – 12.5kgm}
★ Since the low pressure set changes
when the high pressure set is adjusted,
the low pressure set should be adjusted.

20-124 PC1800-6
 INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT,
TESTING AND ADJUSTING SWING AND TRAVEL CIRCUIT OIL PRESSURES

2. Adjustment of Main Relief Valve (Low Pres-

sure Set) of Control Valves V1, V2, V3 and V4
★ When the work equipment relief oil pressure
(normal relief) is abnormal, adjust the low
pressure set side of the main relief valves
(1), (2), (3) and (4) of each control valve ac-
cording to the following procedures:
★ Low Pressure Set is the state that the 2-
stage relief solenoid valve is OFF and that a
pilot pressure is not applied to the changeo-
ver port.
1) Loosen the lock nut (5) and make the elbow
(6) free.
2) Loosen the lock nut (9) and turn the holder
(10) for adjustment.
• Turn the holder to the right, and the pres-
sure will rise.
• Turn the holder to the left, and the pres-
sure will lower.
★ Pressure adjusted by a turn of the
holder: about 21.8MPa {222kg/cm2}
3 Lock nut :
78 – 93Nm {8.0 – 9.5kgm}

3) Fix the elbow (6) and tighten the lock nut

(5).

1) Loosen the lock nut (13) and turn the adjust-

ment screw (14) for adjustment.
• Turn the adjustment screw to the right,
and the pressure will rise.
• Turn the adjustment screw to the left,
and the pressure will lower.
★ Pressure adjusted by a turn of the ad-
justment screw :
about 4.70MPa {47.9kg/cm2}
3 Lock nut :
147 – 196Nm {15 – 20kgm}
4) After the adjustment, check the oil pressure
again according to the above measurement
procedures.

3. Adjustment of Swing Motor Safety Valve

★ When the swing oil pressure is abnormal,
adjust the swing motor safety valves (11)
and (12) according to the following proce-
dures:
• (11) : For the front swing motor
• (12) : For the rear swing motor

2) After the adjustment, check the oil pressure

again according to the above measurement
procedures.

PC1800-6 20-125
 INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT,
TESTING AND ADJUSTING SWING AND TRAVEL CIRCUIT OIL PRESSURES

Oil pressure measuring circuit diagram

(measuring positions of hydraulic pump, control valve and oil pressure)

★ The hydraulic pump shows the state of the pump portion viewed from the left side of the machine, and the
control valve shows the state of the valve portion viewed from the front side of the machine.

20-126 PC1800-6
 INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT,
TESTING AND ADJUSTING SWING AND TRAVEL CIRCUIT OIL PRESSURES

No. 1/2F pump V1 control valve related measuring positions

[11] : Main relief pressure (CGC monitor)
[12] : TVC valve output pressure (Oil pressure gauge)
[13] : CO/NC valve output pressure (CGC monitor)
[14] : Jet sensor output pressure/high pressure (Oil pressure gauge)
[15] : Jet sensor output pressure/low pressure (Oil pressure gauge)

No. 1/2R pump V2 control valve related measuring positions

[21] : Main relief pressure (CGC monitor)
[23] : CO/NC valve output pressure (CGC monitor)
[24] : Jet sensor output pressure/high pressure (Oil pressure gauge)
[25] : Jet sensor output pressure/low pressure (Oil pressure gauge)

No. 3/4F pump V3 control valve related measuring positions

[31] : Main relief pressure (CGC monitor)
[32] : TVC valve output pressure (Oil pressure gauge)
[33] : CO/NC valve output pressure (CGC monitor)
[34] : Jet sensor output pressure/high pressure (Oil pressure gauge)
[35] : Jet sensor output pressure/low pressure (Oil pressure gauge)

No. 3/4R pump V4 control valve related measuring positions

[41] : Main relief pressure (CGC monitor)
[43] : CO/NC valve output pressure (CGC monitor)
[44] : Jet sensor output pressure/high pressure (Oil pressure gauge)
[45] : Jet sensor output pressure/low pressure (Oil pressure gauge)

Swing F/R pump swing control valve related measuring positions

[51] : Main relief pressure (CGC monitor)
[53] : CO/NC valve output pressure (CGC monitor)
[54] : Jet sensor output pressure/high pressure (Oil pressure gauge)
[55] : Jet sensor output pressure/low pressure (Oil pressure gauge)

Control pump related measuring position

[61] : Control relief pressure (CGC monitor)

PC1800-6 20-127
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE

INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL

PRESSURE
Measurement Adjustment
★ Measure the control circuit oil pressure under the ★ When the control circuit oil pressure is abnormal,
following conditions: adjust the control relief valve (1) according to the
• Hydraulic oil temperature : Within operating following procedures:
temperature range

1. Turn on the starting switch and display the

screen for measuring the control circuit oil pres-
sure on the CGC monitor.
★ For the control method, refer to the para-
graph of FUNCTION AND OPERATION OF
CGC MONITOR.
★ Screen Display on CGC Monitor (Display
unit : MPa, kg/cm2)
• PM clinic (5/6)

1. Loosen the cap nut (2) and the lock nut (3) and
turn the adjustment screw (4) for adjustment.
• Turn the adjustment screw to the right, and
the pressure will rise.
• Turn the adjustment screw to the left, and the
pressure will lower.
★ Pressure adjusted by a turn of the adjust-
ment screw : 3.5MPa {35.7kg/cm2}
3 Lock nut, cap nut :
27.4 – 34.3Nm {2.8 – 3.5kgm}

2. Start the engine and measure the oil pressure

after setting the work equipment swing lever and
the travel lever to the neutral position.

2. After the adjustment, check the oil pressure

again according to the above measurement pro-
cedures.

20-128 PC1800-6
 INSPECTION AND ADJUSTMENT OF
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

INSPECTION AND ADJUSTMENT OF PISTON PUMP CONTROL

OIL PRESSURE
2) Attach a nipple to the hydraulic tester G1
★ Devices for inspecting and measuring piston and connect it to the oil pressure gauge [1].
pump control oil pressure ★ Use the oil pressure gauge of 5.9MPa
{60kg/cm2}.
Symbol Part Number Part Name 3) Start the engine and measure the TVC
799-101-5002 Hydraulic tester valve output pressure when the following
1 conditions are satisfied at high idling:
Digital type hydraulic
799-261-1203 i) When all control levers are set at the
tester
neutral positions,
G Coupling assembly
21T-06-64590 ii) At boom RAISE relief
(accessory tool) iii) At boom RAISE relief + heavy lift ON
2
Harness
21T-06-64392
(accessory tool)

Measurement
★ Measure the piston pump control oil pressure un-
der the following conditions:
• Hydraulic oil temperature : Within the operat-
ing temperature range

1. Measurement of TVC Valve Output Pressure

★ Before measuring the TVC valve output
pressure, make sure that the control circuit
oil pressure is normal.
1) Remove the oil pressure measurement plug
4) After the measurement, remove the meas-
(1) from the swing pump.
uring instrument and return the engine to
the original state.

PC1800-6 20-129
 INSPECTION AND ADJUSTMENT OF
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

2. Measurement of NC Valve Output Pressure

★ Before measuring NC valve output pressure,
make sure that the TVC valve output pres-
sure is normal.
1) Turn on the starting switch and display the
screen for measuring the NC valve output
pressure on the CGC monitor.
★ For the control method, refer to the par-
agraph of FUNCTION AND OPERA-
TION OF CGC MONITOR.
★ The figure shows the display of the F
(front) engine.
★ Screen Display on CGC Monitor (Dis-
play unit : MPa, kg/cm2)
• F (front) engine : Real time monitor
(3/6) ★ Measuring positions on the front engine
• R (rear) engine : Real time monitor side
(4/6) a : for No. 1 and 2F pumps
b : for No. 1 and 2R pumps
c : for F swing pump

2) Connect the coupling assembly G2 for

measuring oil pressure to a coupler to be
measured. ★ Measuring positions on the rear engine
★ The coupling assembly G2 is readily side
available in the tool box. d : for No. 3 and 4F pumps
★ The NC valve output pressure is meas- e : for No. 3 and 4R pumps
ured at 6 places at all of the front engine f : for R swing pump
and the rear engine. But only one cou-
pling assembly G2 is available, so con-
nect it to measuring positions one after
another.
k The coupling assembly pressure sen-
sor is for low pressure circuit only. So,
be sure to use it for measuring NC valve
output pressure only.

20-130 PC1800-6
 INSPECTION AND ADJUSTMENT OF
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

3) Start the engine and measure the NC valve 3. Measurement of Jet Sensor Differential Pres-
output pressure under the following condi- sure
tions at high idling: ★ When the NC valve output pressure is ab-
i) When all control levers are set to the normal, measure the differential pressure of
neutral positions, the jet sensor to make sure that it is normal.
ii) When the one-side travel lever is at the 1) Remove the oil pressure measuring plug (2)
full stroke and the track shoe rotates from the high pressure (Pt) side and the oil
without load (work equipment, travel pressure measuring plug (3) from the low
pump), or when the swing lever is at the pressure (Pd) side.
full stroke and swing relief (swing pump) ★ V1 control valve (control valve side)
k When rotating the track shoe without
load, push up the one-side track shoe
from the ground with the work equip-
ment.

★ V2 control valve (No. 2 pump side)

★ V3 control valve (control valve side)

PC1800-6 20-131
 INSPECTION AND ADJUSTMENT OF
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

★ V4 control valve (No. 4 pump side)

★ Swing control valve (swing pump side) 4) After the measurement, remove the meas-
uring instrument and return the engine to
the original state.

2) Attach the nipple to the hydraulic tester G1

and connect it to the oil pressure gauge [1].
★ Use the oil pressure gauge of 58.8MPa
{600kg/cm2}.
3) Start the engine and measure the jet sensor
differential pressure under the following
conditions at high idling:
i) When all control levers are set to the
neutral positions,
ii) When the one-side travel lever is at the
full stroke and the track shoe rotates
without load (work equipment, travel
pump), or when the swing lever is at the
full stroke and swing relief (swing pump)
k When rotating the track shoe without
load, push up the one-side track shoe
from the ground with the work equip-
ment.
★ Jet sensor differential pressure = High
pressure (Pt) – Low pressure (Pd)

20-132 PC1800-6
 INSPECTION AND ADJUSTMENT OF
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

Adjustment 2. Adjustment of CO/NC Valve

1. Adjustment of TVC Valve ★ When the NC valve output pressure is ab-
★ When the TVC valve output pressure is ab- normal, adjust the CO/NC valve according to
normal, adjust the TVC valve (4) of No. 2 the following procedures:
pump or No. 4 pump according to the follow- • (7) : For No. 1 and 2F pumps or No. 1 and 2R
ing procedures: pumps
• (8) : For No. 3 and 4F pumps or No. 3 and 4R
pumps

1) Loosen the lock nut (5) and turn the adjust-

ment screw (6) for adjustment.
• Turn the adjustment screw to the right, • (9) : For F and R swing pumps
and the pressure will rise.
• Turn the adjustment screw to the left,
and the pressure will lower.
★ Pressure adjusted by one turn of adjust-
ment screw :
14.4 MPa {146.4kg/cm2} (in pump pres-
sure)
3 Lock nut :
5.9 – 9.8Nm {0.6 – 1.0kgm}

1) Adjustment of CO Valve Side

Loosen the lock nut (10) and turn the adjust-
ment screw (11) for adjustment.
• Turn the adjustment screw to the right,
and the pressure will rise.
• Turn the adjustment screw to the left,
and the pressure will lower.
★ Pressure adjusted per a turn of the ad-
justment screw :
2) After the measurement, check the oil pres- 4.05MPa {41.25kg/cm2} (in pump pres-
sure again according to the above measure- sure)
ment procedures. 3 Lock nut :
5.9 – 9.8Nm {0.6 – 1.0kgm}

PC1800-6 20-133
 INSPECTION AND ADJUSTMENT OF
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

★ The figure shows the CO valve for No. 1, 3. Adjustment of Jet Sensor
2, 3 and 4 pumps. ★ When the jet sensor differential pressure is
abnormal, adjust the jet sensor relief valve
according to the following procedures:
• (14) : For V1 control valve
• (15) : For V2 control valve
• (16) : For V3 control valve
• (17) : For V4 control valve

2) Adjustment of NC Valve Side

Loosen the lock nut (12) and turn the adjust-
ment screw (13) for adjustment.
• Turn the adjustment screw to the right,
and the pressure will rise.
• Turn the adjustment screw to the left,
and the pressure will lower. • (18) : For swing control valve
★ Pressure adjusted per a turn of the ad-
justment screw :
0.39MPa {4.0kg/cm2} (in J/S differential
pressure)
3 Lock nut :
5.9 – 9.8Nm {0.6 – 1.0kgm}
★ The figure shows the NC valve for No. 1,
2, 3 and 4 pumps.

3) After the adjustment, check the oil pressure

again according to the above measurement
procedures.

20-134 PC1800-6
 INSPECTION AND ADJUSTMENT OF
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

1) Loosen the lock nut (19) and turn the adjust-

ment screw (20) for adjustment.
• Turn the adjustment screw to the right,
and the pressure will rise.
• Turn the adjustment screw to the left,
and the pressure will lower.
★ Pressure adjusted per a turn of the hold-
er : 0.29MPa {2.96kg/cm2}
3 Lock nut : 59 – 78Nm {6 – 8kgm}
★ The figure shows the jet sensor for V1,
V2, V3 and V4 control valves.

2) After the adjustment, check the oil pressure

again according to the above measurement
procedures.

PC1800-6 20-135
TESTING AND ADJUSTING INSPECTION OF SERVO PISTON STROKE

INSPECTION OF SERVO PISTON STROKE

★ Devices for inspecting and measuring piston 2. Measuring Procedures
pump control oil pressure 1) Remove the cap and the shim of the servo
valve on the measuring side.
Symbol Part Number Part Name ★ Since the cap is pressed with the spring,
Cap (No. 1, 2, 3 remove the cap carefully with the long
708-25-14140 bolt (01016-31070, etc.) and the nut so
and 4 pumps)
1 that the cap does not jump out.
O-ring (No. 1, 2, 3
07000-B2065 2) Mount the measuring tools H, on the servo
and 4 pumps)
H piston together with the removed shim.
708-27-14150 Cap (Swing pump) ★ Be careful so that the shim is not caught
2 O-ring in the bolt threads.
07000-B2075
(Swing pump) 3) Push in the rods of the measuring tools, H,
3 566-98-41120 Disc gauge fully and measure the size of the protrusion
a1.
★ When the NC valve output pressure is normal but 4) Start the engine, keep it at full throttle and
the pump performance is considered inappropri- move the track shoe without load or swing it
ate, inspect the acceptability of the servo valve without load.
according to the following procedures: ★ Operate the lever to the full stroke.
★ During the measurement, press the rod
1. Preparation of Tool with hand and check at the same time
Drill a through hole PT1/4 in the center of the that the rod moves smoothly as the con-
cap H1 or H2 and screw the disc gauge H3 in trol lever changes the stroke.
the hole. ★ After checking that the rod moves
★ Prepare the cap for the side where the spring smoothly, keep it at the position where it
of the hydraulic pump servo piston is fitted. is most protruded.
5) Stop the engine and measure the size of the
rod protrusion a2.
6) Calculate the servo piston stroke b from the
measured size.
★ Servo piston stroke b = a2 – a1
★ Standard stroke b
• No. 1, 2, 3 and 4 pumps : about 8.9mm
• Swing pump : about 12.6mm

20-136 PC1800-6
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

★ Devices for measuring PPC valve output pres- 4. Start the engine, operate the control lever of the
sure measuring PPC circuit at high idling and mea-
sure the oil pressure.
Symbol Part Number Part Name ★ When the oil pressure is 0 while the control
799-101-5002 Hydraulic tester lever is set at the neutral position, operate
1 Digital type the lever to the full stroke. If the oil pressure
790-261-1203 comes almost to the one of the control cir-
J hydraulic tester
cuit, the valve is normal.
799-401-3200 Adapter assembly
2
02896-11009 O-ring

★ Measure the PPC valve output pressure under

the following conditions:
• Hydraulic oil temperature : Within operating
temperature range

1. Disconnect the hoses (1) – (12) from the mea-

suring PPC circuit.
★ Disconnect these hoses at the PPC junction
block pant.

2. Attach the adapter J2 and connect the discon-

5. After the measurement, remove the measuring
nected hoses again.
devices and return the valve to the original state.
3. Attach the nipple [1] of the hydraulic tester J1
and connect it to the oil pressure gauge [2].

PC1800-6 20-137
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

No. PPC Circuit Colored band No. PPC Circuit Colored band
1 Boom RAISE Red, white 7 Swing left Blue, white
2 Boom LOWER Brown 8 Swing right None
3 Arm IN Yellow 9 L.H. travel FORWARD Red, black
4 Arm OUT Red 10 L.H. travel REVERSE Green, black
5 Bucket CURL White 11 R.H. travel FORWARD Green
6 Bucket DUMP Black 12 R.H. travel REVERSE Black

20-138 PC1800-6
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

★ Devices for measuring solenoid valve outlet 4. Start the engine, idle it at a high speed under the
pressure measuring conditions and measure the oil pres-
sure.
Symbol Part Number Part Name
799-101-5002 Hydraulic tester
1 Digital type
790-261-1203
J hydraulic tester
799-401-3200 Adapter assembly
2
02896-11009 O-ring

★ Measure the solenoid valve outlet pressure un-

der the following conditions:
• Hydraulic oil temperature : Within operating
temperature range

1. Disconnect the hoses (1) – (5) from the measur-

5. After the measurement, remove the measuring
ing solenoid valve circuit.
devices and return the valve to the original state.

2. Attach the adapter J2 and connect the discon-

nected hoses again.

3. Attach the nipple [1] of the hydraulic tester J2

and connect it to the oil pressure gauge [2].

PC1800-6 20-139
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

Solenoid Oil pressure

No. Solenoid valve Measuring conditions Machine operation
operation (MPa {kg/cm2})
When the heavy lift switch is turned The main relief valve is
OFF 0 {0}
off set to low pressure.
1 2-stage relief When the heavy lift switch is turned
The main relief valve is Min. 3.13
on and boom RAISE is operated ON
set to high pressure. {Min. 32}
independently
The CO function
Working mode : In the H or G mode OFF 0 {0}
operates.
2 CO cancel
The CO function is Min. 3.13
Working mode : In the DH mode ON
released. {Min. 32}
When the swing lock switch is The swing lock
OFF 0 {0}
turned on operates.
Swing holding
3 When the swing lock switch is
brake The swing lock is Min. 3.13
turned off and the work equipment is ON
released. {Min. 32}
operated or a swing operation starts
When the all control levers are set at The left and right travel
OFF 0 {0}
the neutral position circuits are separated.
4 Straight-travel When the left/right travel lever and
The left and right travel Min. 3.13
the work/swing lever are operated at ON
circuits are merged, {Min. 32}
the same time
The boom LOWER
When the machine push-up switch
safety valve is set to OFF 0 {0}
is turned on
Machine push- high pressure.
5
up The boom LOWER
When the machine push-up switch Min. 3.13
safety valve is set to ON
is turned off {Min. 32}
low pressure.

★ Since two solenoids are merged for the swing holding brake solenoid valve circuit, disconnect one-side wiring
connector and measure when checking their respective operations.

20-140 PC1800-6
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE

ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE

★ When the work equipment and swing lever tip
plays much, adjust according to the following
procedures.
k Lower the work equipment completely to the
ground, stop the engine and operate the work
equipment control lever several times to relieve
pressure remaining in the pipe. Then, loosen the
hydraulic tank oil filler cap slowly and bring the
safety lock lever to the lock position.
★ Lever play : 0.5 to 3mm at the position of
200mm from the center of the lever mounting
pin.

1. Loosen the lock nut (1), turn the disc (2) to

adjust the lever play.
★ At the time, do not move the piston.

2. Fix the disc (2) and tighten the lock nut (1) by
applying the specified torque.
3 Lock nut : 29.4 – 39.2Nm {3 – 4kgm}

PC1800-6 20-141
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF TRAVEL DEVIATION

INSPECTION AND ADJUSTMENT OF TRAVEL DEVIATION

Measurement
★ Measure travel deviations under the following
conditions:
• Hydraulic oil temperature : Within operating
temperature range
• Measuring position : Horizontal hard flat
ground

1. Start the engine and bring the work equipment

to the travel posture.

2. Set the working mode to the DH Mode.

3. Run the machine 10m with the engine at full

throttle and run it further 20m as it is, then mea-
sure the deviation A.

20-142 PC1800-6
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF TRAVEL DEVIATION

Adjustment ★ No. 1 and 3 pumps

★ When the travel deviation is abnormal, adjust the
thickness of the shim at the servo piston accord-
ing to the following procedures:

1. Check the shim adjustment position from the

side of travel deviation.
★ Adjusting method

Left deviation Right deviation

Add shims to the rear Add shims to the con-
pump side b. trol pump side c.

★ No. 1 and 3 pumps

★ No. 2 and 4 pumps

★ No. 2 and 4 pumps

3. Add shims (2) suitable for the deviation and
tighten the bolt (1).
★ Additional shims shall be up to 3mm a pump.
3 Bolt : 59 – 74Nm {6.0 – 7.5kgm}
★ Travel deviation and additional shims

2. Loosen 4 pieces of the bolt (1) on the shim

adjusting side.
★ Since the shim is a split type, the cap needs
not be removed.
★ Since the cap is pressed with the spring,
loosen the bolt until the shim can be inserted. 4. After the adjustment, check the travel deviation
again according to the above measurement pro-
cedures.

PC1800-6 20-143
TESTING AND ADJUSTING INSPECTION OF WORK EQUIPMENT HYDRAULIC DRIFT CAUSE PORTION

INSPECTION OF WORK EQUIPMENT HYDRAULIC DRIFT CAUSE

PORTION
2. Inspection of Arm Cylinder
★ When a hydraulic drift occurred to the work 1) Stop the arm cylinder about 100mm before
equipment, follow the procedures below to check the IN stroke end and stop the engine.
if the cause has come from the cylinder piston
ring side or from the control valve side.

1. Inspection of Boom Cylinder and Bucket Cyl-

inder
1) Take the same posture as that for measur-
ing hydraulic drift and srop the engine.
★ Place the rated load or sand in the buck-
et.

2) Operate the arm control lever to the "IN

side".
• If the drift speed becomes faster, the cyl-
inder piston ring is defective.
• If the speed does not change, the control
valve is defective.
★ Operate the control lever when the start-
ing switch is ON.
★ When the accumulator pressure is 0, run
2) In case of boom, bring the boom control the engine for about 10 seconds to accu-
lever to the "RAISE side", or in case of mulate pressure.
bucket, bring the bucket control lever to the
"CURL side". [Reference] The reason why the above operation
• If the drift speed becomes faster, the cyl- makes the drift speed faster when the
inder piston ring is defective. cause of hydraulic drift is the cylinder
• If the speed does not change, the control piston ring:
valve is defective. 1) In case of the above work equipment posture
★ Operate the control lever when the start- (the holding pressure rises on the bottom side),
ing switch is ON. oil leaks from the bottom side to the head side
★ When the accumulator pressure is 0, run but the head side volume is smaller than the
the engine for about 10 seconds to accu- bottom side one by the rod. So, oil flowing in
mulate pressure. from the bottom side increases the internal pres-
sure on the head side.
2) As the internal pressure on the head side
increases, both pressures come to balance at a
certain pressure (depending on leakage), and
the drift speed becomes slow.
3) If the head side circuit opens to the drain circuit
at the time (the bottom side is closed with the
check valve) by the above lever operation, oil
will flow from the head side to the drain circuit.
Pressure will come not to balance, and the drift
speed will become faster.

20-144 PC1800-6
TESTING AND ADJUSTING INSPECTION OF OIL LEAKAGE

INSPECTION OF OIL LEAKAGE

★ Measure oil leakage under the following condi- 2. Measurement of Leakage from Arm Cylinder
tions: 1) Extend the cylinder fully and stop the
• Hydraulic oil temperature : within operating tem- engine.
perature range

1. Measurement of Leakage from Boom Cylin-

der
1) Extend the cylinder fully and stop the
engine.

2) Disconnect the pipes (2) from the head side

and block the pipe on the control valve side
with flange.
k Be careful not to disconnect the pipe on
the bottom side.

2) Disconnect the pipes (1) from the head side

and block the pipe on the control valve side
with flange.
k Be careful not to disconnect the pipe on
the bottom side.

3) Start the engine, operate the right control

lever to the "Arm IN" side at high idling and
apply the relief oil pressure to the cylinder
bottom side.
k Be careful not to operate the control le-
ver to the "Arm OUT" side.
3) Start the engine, operate the left control 4) After 30 seconds elapsed, measure oil leak-
lever to the "Boom RAISE" side at high age for 1 minute.
idling and apply the relief oil pressure to the
cylinder bottom side.
k Be careful not to operate the control le-
ver to the "Boom LOWER" side.
4) After 30 seconds elapsed, measure oil leak-
age for 1 minute.

PC1800-6 20-145
TESTING AND ADJUSTING INSPECTION OF OIL LEAKAGE

3. Measurement of Leakage from Bucket Cylin- 4. Measurement of Leakage from Swing Motor
der k After the engine stopped, loosen the oil filler
1) Extend the cylinder fully and stop the cap of the hydraulic tank slowly to relieve
engine. pressure from the tank.
1) Disconnect the drain hose (4) from the
swing motor and block the hose side with
plug.

2) Disconnect the pipe (3) from the head side

and block the pipe on the control valve side
with flange.
k Be careful not to disconnect the pipe on 2) Start the engine and turn the swing lock
the bottom side. switch to the lock position.
3) Run the engine at high idling speed and
relieve the swing motor.
4) After 30 seconds elapsed, measure oil leak-
age for 1 minute.
★ Measure oil leakages several times while
moving the swing motor little by little (by slid-
ing the valve plate and the cylinder block).

3) Start the engine, operate the left control

lever to the "Bucket CURL" side at high
idling and apply the relief oil pressure to the
cylinder bottom side.
k Be careful not to operate the control le-
ver to the "Bucket DUMP" side.
4) After 30 seconds elapsed, measure oil leak-
age for 1 minute.

20-146 PC1800-6
TESTING AND ADJUSTING INSPECTION OF OIL LEAKAGE

5. Measurement of Leakage from Travel Motor 6. Measurement of Leakage from Center Swivel
1) Start the engine and place a pin or a block Joint
between the sprocket and the track frame or 1) Start the engine and place a pin or a block
the track link to lock the travel. between the sprocket and the track frame or
k Make sure that the travel is locked cer- the track link to lock the travel.
tainly. k Make sure that the travel is locked cer-
k After the engine stopped, loose the oil tainly.
filler cap of the hydraulic tank slowly to k After the engine stopped, loosen the oil
relieve pressure from the tank. filler cap of the hydraulic tank slowly to
2) Disconnect the drain hoses (5) and (6) from relieve pressure from the tank.
the travel motor and block the hose side 2) Disconnect the upper and lower measuring
with plug. port hoses of the inspection port with the
upper and lower swivels and block the hose
side with plug or flange.

Inspection Measuring
Circuit
port port
A Left travel FORWARD T, A
B Left travel REVERSE A, C
C Right travel FORWARD P, D
D Right travel REVERSE D, T

3) Start the engine and operate the travel on

the measuring side at high idling to relieve
the travel motor.
4) After 30 seconds elapsed, measure oil leak-
age for 1 minute.
★ Measure oil leakages several times while
moving the travel motor little by little (by slid-
ing the valve plate and the cylinder block).

3) Start the engine and operate the travel of

the measuring port at high idling to relieve
the travel motor.
k Check the inspection port and conduct
the travel operation carefully.
4) After 30 seconds elapsed, measure oil leak-
age for 1 minute.
★ Measure oil leakages from the two
measuring ports of the lower swivel.

PC1800-6 20-147
TESTING AND ADJUSTING REMAINING PRESSURE RELIEF FROM HYDRAULIC CIRCUIT

REMAINING PRESSURE RELIEF FROM HYDRAULIC CIRCUIT

★ Device for relieving pressure remaining in hy-
draulic circuit

Symbol Part Number Part Name

K 790-445-1350 Hose assembly

k When disconnecting the pipe between the con-

trol valve and the cylinder or the motor, relieve
pressure remaining in the circuit according to the
following procedures.
★ No pressure remains in the swing motor circuit
and the travel motor circuit, but the internal pres-
sure of the hydraulic tank influences the relief.
So, open the cap of the hydraulic tank.

1. Stop the engine and loosen the oil filler cap of

the hydraulic tank slowly to relieve pressure in
the tank.

2. Free the safety lock lever and operate the con-

trol lever several times.
★ When the control lever is operated 2 or 3
times, the pressure accumulated in the accu-
mulator is relieved completely.

3. Start the engine, idle it at low speed for about 10

seconds to accumulate pressure in the accumu-
lator, then stop the engine.

4. Repeat Steps 2 and 3 several times.

5. Connect the hose assembly K to the quick cou-

pler for relieving remaining pressure on the
block between the control valve and the cylinder
and relieve remaining pressure.
k Be sure to connect the hose assembly K
only after executing Steps 1 to 4. Note that,
if connected in advance, high pressure oil
will probably spurt out.

20-148 PC1800-6
TESTING AND ADJUSTING AIR BLEEDING FROM EACH COMPONENT

AIR BLEEDING FROM EACH COMPONENT

1. Air Bleeding from Hydraulic Pump

★ After removing and installing the hydraulic 4) After bleeding air from the bleeders (5) and
pump or changing hydraulic oil, bleed air (6) of the swing pumps (PS1 and PS2),
from the hydraulic pump according to the fol- tighten the bleeder (6) only on the rear
lowing procedures. engine side temporarily.
k If air was not bled or air was bled insuffi- ★ Keep the bleeder (5) on the front engine
ciently, the pump may be broken. So, be side loose.
sure to bleed air strictly according to the 5) Loosen 2 pieces of the plug (9) for suction
procedures. tube and check that oil flows out. Then,
tighten the plug temporarily.
1) Loosen the bleeders (1) – (8) of all hydraulic
pump 1 or 2 turns at the same time.
★ Connect a tube (1) to each bleeder to
prevent oil from being scattered and to
receive oil in oil pan.
2) Feed hydraulic oil up to the specified level.
★ Even after feeding oil to the hydraulic
tank, keep the oil filler cap removed.
3) After oil flew out of the bleeders (7) and (8)
of the gear pumps PG1 and PG2 and from
the bleeders (1), (2), (3) and (4) of the work
equipment and travel pumps P1, P2, P3 and
P4, tighten each bleeder temporarily.

PC1800-6 20-149
TESTING AND ADJUSTING AIR BLEEDING FROM EACH COMPONENT

6) Crank the front engine and make sure that 2. Air Bleeding from Work Equipment Cylinder
oil flows out of the bleeder (5) of the swing Circuit
pump PS1 on the front engine side. Then,
tighten the bleeder temporarily.
★ For cranking, idle the engine at low
speed for 15 seconds twice.
7) Loosen the bleeder (6) of the swing pump
PS2 on the rear engine side.
8) Crank the rear engine and make sure that
oil flows out of the bleeder (6) of the swing
pump PS2 on the rear engine side. Then,
tighten the bleeder temporarily.
★ For cranking, idle the engine at low
speed for 15 seconds twice.
9) Start the front engine and the rear engine in
this order and keep them idling at low
speed. ★ When removing and installing the work
10) Loosen the bleeders (1) – (8) of all hydraulic equipment cylinder or when disconnecting
pumps and make sure that bubble-free oil and connecting the cylinder circuit piping,
flows out of them. Then, tighten these bleed air from the work equipment cylinder
according to the following procedures.
k If air was not bled or air was bled insuffi-
bleeders temporarily.
11) Close the oil filler caps of the hydraulic tank.
12) Keep the engine idling at low speed, raise ciently, the cylinder piston ring may be bro-
the work equipment from the ground and ken. So, be sure to bleed air strictly
swing the upper structure 180°. according to the procedures.
★ After the swing, lower the work equip- 1) Start the engine and idle it at low speed for
ment completely to the ground. about 5 minutes.
13) Loosen 2 pieces of the plug (9) for the suc- 2) Repeat raising and lowering the boom 4 or 5
tion tube and make sure that bubble-free oil times at the low idling.
flows out of it. Then, tighten the plug. ★ Stop the piston rod about 100mm before
3 Plug : 58.8 – 78.4Nm {6 – 8kgm}
the stroke end and be careful not to re-
14) Loosen the bleeders (1) – (8) of all hydraulic lieve it.
pumps and make sure that bubble-free oil 3) Execute Step 2) at high idling.
flows out of them. Then, tighten these 4) Bring the piston rod to the stroke end at low
bleeders temporarily. idling and relieve it.
★ This work is the same as in the above 5) Execute Steps 2) – 4) for the arm and the
Step 10. bucket.
15) Keep the engine idling at low speed, raise ★ When the cylinder was replaced, execute the
the work equipment from the ground and procedures before connecting the work
swing the upper structure 180°. equipment. Especially, when the boom cylin-
★ Swing the upper structure in the reverse der was installed to the work equipment, the
direction from the one in the above Step lowering side does not move to the stroke
12. After the swing, lower the work end.
equipment completely to the ground.
16) Loosen the bleeders (1) – (8) of all hydraulic
pumps and make sure that bubble-free oil
flows out of them. Then, tighten these
bleeders.
3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}
17) Stop the rear engine and the front engine in
this order.
18) Loosen the oil filler cap of the hydraulic tank
slowly and remove it. Relieve pressure from
the hydraulic tank and feed hydraulic oil up
to the specified level.

20-150 PC1800-6
TESTING AND ADJUSTING AIR BLEEDING FROM EACH COMPONENT

3. Air Bleeding from Swing Motor Circuit 4. Air Bleeding from Swing Motor Circuit (Park-
(Swing Motor) ing Brake Circuit)

★ When removing and installing the swing mo- ★ When removing and installing the swing mo-
tor or when disconnecting and connecting tor or when disconnecting and connecting
the swing motor main circuit pipes, bleed air the swing holding brake circuit piping, bleed
from the swing motor according to the follow- air from the brake circuit according to the fol-
ing procedures. lowing procedures.
k If air was not bled or air was bled insuffi- k If air was not bled or air was bled insuffi-
ciently, the swing motor may be damaged. ciently, the swing holding brake may be
So, be sure to bleed air strictly according to dragged. So, be sure to bleed air strictly ac-
the procedures. cording to the procedures.
1) Start the engine and operate it while the 1) Start the engine and loosen the bleeder
engine is idling at low speed. (11).
2) Loosen hose (10) for the swing motor S ★ The bleeder is mounted on the front and
port. rear swing motors.
★ Do not disconnect the hose, but loosen it 2) Turn off the swing lock switch.
to the extent that oil flows because oil 3) Swing the motor while the engine is idling at
pressure (back pressure) is provided to low speed and make sure that bubble-free
the S port. oil flows out of the bleeder (11). Then,
3) When non-bubble oil flows out of hose con- tighten the bleeders.
nection (10), retighten the hose. 3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}
★ The swing operation may be as faintly as
the swing oil pressure switch turns on.

PC1800-6 20-151
TESTING AND ADJUSTING AIR BLEEDING FROM EACH COMPONENT

5. Air Bleeding from Travel Motor Circuit 6. Air Bleeding from Travel Motor Circuit (Con-
(Travel Motor) trol Valve PPC Circuit)

★ When removing and installing the travel mo- ★ When removing and installing the control
tor or when disconnecting and connecting valve or when disconnecting and connecting
the travel motor main circuit pipes, bleed air the travel PPC circuit piping, bleed air from
from the travel motor according to the follow- the control valve PPC circuit according to the
ing procedures. following procedures.
k If air was not bled or air was bled insuffi- k If air was not bled or air was bled insuffi-
ciently, the travel motor may be damaged. ciently, any travel deviation may occur. So,
So, be sure to bleed air strictly according to be sure to bleed air strictly according to the
the procedures. procedures.
1) Start the engine and loosen the bleeder
(12). 1) Start the engine and loosen the bleeder
★ The bleeder is mounted on 4 units of the (13).
right and left travel motors. ★ Two bleeders are mounted on both the
2) Make sure that bubble-free oil flows out of right and left sides of the control valves
the bleeders (12). Then, tighten the bleeder. V1, V2, V3 and V4.
3 Bleeder : 2) Control travel while the engine is idling at
8.8 – 9.8Nm {0.9 – 1.0kgm} low speed, and make sure that bubble-free
oil flows out of the bleeder (13). Then,
tighten the bleeders.
3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}
k Air can be bled fast when the travel con-
trol is made to a large stroke, but fine
control is acceptable when air bleeding
is difficult during travel.
k One side of the track frame may be lifted
and the shoe may be rotated without
load for bleeding air. But note that, in
this case, air can be bled on the one
side rotating without load at a time.

20-152 PC1800-6
TESTING AND ADJUSTING AIR BLEEDING FROM EACH COMPONENT

7. Air Bleeding from Travel Motor (Parking

Brake Circuit)

★ When removing and installing the travel mo-

tor or when disconnecting and connecting
the travel parking brake circuit pipes, bleed
air from the parking brake circuit according
to the following procedures.
k Unless air was bled or bled sufficiently, the
swing parking brake may be dragged. So,
be sure to bleed air strictly according to the
procedures.

1) Start the engine and loosen the bleeders

(14).
★ The bleeders are mounted on four units
of the right and left travel motors.
2) Make sure that bubble-free oil flows out of
the bleeder (14). Then, tighten the bleeders.
3 Bleeder :
8.8 – 9.8Nm {0.9 – 1.0kgm}

PC1800-6 20-153
TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC AUTO GREASE SYSTEM

TESTING AND ADJUSTING HYDRAULIC AUTO GREASE

SYSTEM
1. Indication of abnormality by auto grease
controller
If the auto grease system has abnormality, the
auto grease caution lamp lights up and the
abnormality is indicated in the controller display
(1).

Lamp Indication by controller Abnormality Cause

• Pump trouble
CONTROLLER REST Pump is running but pressure in • No grease
FAILURE grease piping does not rise. • Breakage of grease piping or
Lighting leakage
up
Vent valve does not return and • Vent valve trouble
VENT PRESSURE SW • Leakage or clogging at grease
injector is not filled with grease
ALARM piping on upper side of injector
again.

2. Adjusting discharge from injector

★ The discharge from the injector is set to the
maximum when shipped. If necessary, re-
duce the discharge according to the follow-
ing procedure.
• Discharge set when shipped:
1.3 cc/st (Dimension "a": 10 mm)
1) Remove the cap from the adjustment screw
and loosen locknut (2).
2) Turn the adjustment screw (3) to adjust the
discharge.
★ If the adjustment screw
• is turned clockwise, the discharge is
reduced.
• is turned counterclockwise, the dis-
charge is increased.
★ Change of discharge by 1 turn of adjust-
ment screw: 0.13 cc/st
★ Limit dimension "a" of the adjustment
screw to 10 mm.
★ If the adjustment screw is tightened fully
to reduce dimension "a" to 0 mm, the
discharge is 0.13 cc/st.
3) Tighten locknut (2) and install the cap of the
adjustment screw.

20-153-1 PC1800-6
TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC AUTO GREASE SYSTEM

3. Bleeding air from grease pump line 4. Bleeding air from distributor line
★ When a new machine is delivered or trans- ★ When a new machine is delivered or trans-
ported disassembled or when the grease ported disassembled or when the grease
can becomes empty or when the hose, can becomes empty or when the hose,
pump, or injector is replaced, bleed air from pump, or injector is replaced, bleed air from
the grease pump line according to the follow- the grease pump line according to the follow-
ing procedure. ing procedure.
1) Set the auto grease selector switch (4) to ★ Perform this work after "Bleeding air from
the MANUAL position and set grease circuit grease pump line" is finished.
selector switch (5) to the GREASE GUN ★ Perform this work on the all distributor lines
position. in order from the one nearest to the grease
pump (Swing circle → Boom cylinder bottom
→ Boom → Arm).
1) Set the auto grease selector switch (4) to
the MANUAL position and set grease circuit
selector switch (5) to the AUTO GREASE
position.

2) Operate the grease gun to bleed air from the

grease pump line.
★ Check that the grease discharged from
the grease gun does not contain air.

2) Remove plug (6) of the distributor.

PC1800-6 20-153-2
TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC AUTO GREASE SYSTEM

3) Operate the grease switch in the operator's 5. Bleeding air from injector line
cab to bleed air from the distributor line. ★ When a new machine is delivered or trans-
k Once the grease switch is set to the ported disassembled or when the grease
START position, grease is supplied con- can becomes empty or when the hose,
tinuously for 15 minutes, unless the pump, or injector is replaced, bleed air from
grease switch is set to the OFF position. the grease pump line according to the follow-
Take care. ing procedure.
★ Check that the grease discharged from ★ Perform this work after "Bleeding air from
the plug hole does not contain air. distributor line" is finished.
★ Perform this work on the all distributor lines.
4) Install plug (6). 1) Set the auto grease selector switch (4) to
3 Plug: the MANUAL position and set grease circuit
19.6 – 29.4 Nm {2.0 – 3.0 kgm} selector switch (5) to the GREASE GUN
position.

2) Remove plug (7) of the injector.

3) Using the grease gun, supply grease
through service nipple (8) to the injector line.

4) Install plug (7).

3 Plug:
3.92 – 5.88 Nm {0.4 – 0.6 kgm}

20-153-3 PC1800-6
TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC AUTO GREASE SYSTEM

6. Check of completion of air bleeding 7. Method of supplying grease manually

★ After finishing procedures 3 – 5, check that ★ If the auto grease system has a trouble and
air has been bled according to the following cannot supply grease automatically. In this
procedure. case, supply grease manually according to
1) Set the auto grease selector switch (4) to the following procedure.
the MANUAL position and set grease circuit 1) Set the auto grease selector switch (4) to
selector switch (5) to the AUTO GREASE the MANUAL position and set grease circuit
position. selector switch (5) to the GREASE GUN
position.
★ The manual grease supply section of the
injector does not have a check valve.
Accordingly, set grease circuit selector
switch (5) to the GREASE GUN position
to prevent sudden operation of the injec-
tor, even if the grease gun is not used.

2) Set the grease switch in the operator's cab

to the START position and check that the
operation lamp lights up.
3) Check that indicator (9) of the injector is
operating normally.
★ If the indicator reciprocates vertically, it
is normal.
2) Remove plug (7) of the injector.
3) Using the grease gun, supply grease
through service nipple (8) to the injector line.

4) Set the grease switch in the operator's cab

to the OFF position to stop greasing.
★ If the indicator does not operate normal-
ly, air has not been bled completely. In 4) Install plug (7).
this case, perform procedures 3 – 5 3 Plug:
again. 3.92 – 5.88 Nm {0.4 – 0.6 kgm}

PC1800-6 20-153-4
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

SPECIAL FUNCTIONS OF MACHINE MONITOR

Ordinary and special functions of machine monitor

The machine monitor is provided with ordinary and special functions by which it is possible to check and set var-
ious kinds of information by the time/service meter display.
Some items and contents on the display are automatically displayed based on internal setting, and others are
displayed by switch operation.

1. Ordinary functions: Operator menu

Ordinarily displayed contents or automatically displayed contents at abnormality occurrence.
2. Special functions: Service menu
Contents which are not for ordinary display or setting, but displayed by special switch operation of service-
man. (The operations are used for special settings, testing and adjusting, and troubleshooting.)

No. Operator menu ⇒ No. Service menu

1 Time/service meter display function 3 Error code display function
⇓ 4 Monitoring function
2 User code display function 5 Operating on reduced cylinders function
6 Working mode default setting function

★ The No. above indicates order of explanation, but not order of on-screen display or priority.

20-154 PC1800-6
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

OPERATION AND DISPLAY OF OPERATOR MENU (OUTLINE)

★ This section outlines only the operator menu. For

more information about the contents and opera-
tion of each menu, refer to the Operation and
Maintenance Manual.

1. Time/service meter display function

Displays the current time on the left of the time/
service meter display (1) and service meter on
the right at starting switch ON.

★ The right figure is an example indicating the

current time [12:34] and service meter
[12345.6h].

2. User code display function

Abnormality information of the engine controller,
pump controller, and VHMS controller is sent to
the machine monitor across the network.
It automatically displays the abnormality infor-
mation with high urgency on the time/service
meter display (1) of machine monitor using a
user code, prompting the operator to take an
appropriate action.

★ The right figure is an example indicating the

user code [E02].

PC1800-6 20-155
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

User Code and Action Promoted to Operator

User
Failure mode Action promoted to operator
code
Immediately receive testing, though turning on the
E02 TVC system error
emergency pump drive switch enables ordinary work.
Turn on the swing holding brake release switch to
release swing brake. To turn it on, manually operate
E03 Swing brake system error swing lock switch. It may not be released according to
cause of problem. In any case, immediately receive
testing.
If engine works, operate machine to safety attitude and
receive testing immediately. If engine stops at engine
running, turn emergency pump drive switch on, operate
E0E Network system error
machine to safety attitude, and receive testing
immediately. When engine cannot start, receive testing
immediately.
If engine stops during operation, check for 1) out of gas,
2) activation of fuel cut system, and 3) operation of
E10 Engine emergency stop system error engine stop switch (emergency stop). If engine does not
start even after carrying out checks above, receive test-
ing immediately.
If output extremely lowers due to abnormality in sensor
E11 Engine control system error for engine control, park machine at safe place and
receive testing immediately.
If engine does not rotate normally even by operating fuel
E14 Fuel dial system error dial, check for disconnection of fuel dial. If same problem
still occurs, receive testing immediately.
Though ordinary work is possible, it is suspected that
E15 Light failure of engine controller engine sensor have malfunction. Receive testing
immediately.
Engine oil temperature or PTO oil
E22 Stop engine to test PTO oil level and engine oil level.
temperature error
Defective VHMS controller connector
Though ordinary work is possible, receive testing
E23 connection or abnormality of F or R
immediately.
engine water temperature sensor

20-156 PC1800-6
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

OPERATION AND DISPLAY OF SERVICE MENU

3. Error code display function

Checks the error code of abnormality appearing
on the machine and elapsed time from error
occurrence.
★ The same function is provided on the CGC
monitor.

1) Changing method to error code display

Simultaneously and continuously press time
switch (2) and F engine water temperature
display switch (3) at least 2.5 seconds.
Then, first error code and elapsed time are
displayed on time/service meter display (1).

2) Information displayed
The error code is displayed on the left of
time/service meter display (1) and elapsed
time from abnormality occurrence is dis-
played on the right.
When some error codes are recorded, one
with shortest elapsed time is always dis-
played.
A: Display example 1 in which error code
[E213] appeared six hours ago (When
error code has no leading character [E],
abnormality has already reset.)

B: Display example 2 in which error code

[E213] appeared six hours ago (When
error code has leading character [E],
abnormality is appearing even now.)

C: Display example in which no error code

is recorded

3) Advancing and returning display

i) While pressing time switch (2), press
working mode right switch (4) to display
error code with second longest elapsed
time (Display advances).
ii) While pressing time switch (2), press
the working mode left switch (5) to dis-
play second shortest elapsed time (Dis-
play returns.)

PC1800-6 20-157
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

4) Erasing error code

While pressing time switch (2), turn off start-
ing switch once and turn it on, and continu-
ously press time switch (2) for 2.5 seconds,
error code is erased.
★ The erase is completed when the time/
service meter display is as shown in the
figure to the right.

5) Ending error code display

Simultaneously press time switch (2) and F
engine water temperature display switch (3)
at least 2.5 seconds to go back to ordinary
display.
★ This is the same operation as that for
changing over to error code display.

20-158 PC1800-6
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

Error Code Table (Order of Service Code)

User code Error code Failure code

No. Description
(Machine monitor) (Machine monitor) (CGC monitor)
1 101 DA20KT Abnormality in error history data
2 102 DV00KY Short circuit in buzzer output
3 104 AA10NX F. air cleaner clogging
4 105 aA10NX R. air cleaner clogging
5 108 B@BCNS Abnormal F. coolant temp.
6 111 b@BCNS Abnormal R. coolant temp.
7 115 B@HANS Abnormal Hydraulic temp.
8 E0E 116 DBB0KR VHMS network overtime error
9 118 DAB0KR Pump controller network overtime error
10 E91b DLE3LC F. engine Ne sensor problem
11 E91C DLH1LC F. engine G sensor problem"
12 E920 DB29KQ F. engine type selection error
13 E922 A000N1 F. engine overrun
14 E924 B@BAZG F. engine oil press. down
15 E05 E931 DK10KX F. fuel dial sys. error
16 E935 DB2RMC F. KOM-NET/c error
17 E936 DDE2L6 F. engine oil press. sw. error
18 E93C DH30KX F. engine boost press. sensor error
19 E93d DGE4KX F. engine fuel temp. sensor error
20 E954 DD11KB Short F. engine starter sw.
21 E0E E955 DB2SMC F. S-NET error
22 E0E E956 DB22KK F. engine power failure (1)
23 E957 D1D0KB F. engine power failure (2)
24 E95A DB2AMA F. engine Q-adjust sw. signal error
25 E970 AD11KB F. PCV1 over current
26 E971 AD51KB F. PCV2 over current
27 E974 AD11KA F. PCV1 line cut
28 E975 AD51KA F. PCV2 line cut
29 E977 DH40KX F. engine common rail press. sensor error
30 E979 AD00L2 F. common rail press. high
31 E97A AD00MA F. common rail press. abnormal
32 E97b AD10L3 F. common rail press. low
33 E97C AD10MB F. common rail press. too low
34 E97d AD10MA F. common rail press. out of control

PC1800-6 20-159
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

User code Error code Failure code

No. Description
(Machine monitor) (Machine monitor) (CGC monitor)
35 E980 DB20KT F. engine controller failure
36 E981 ADA1KA F. TWV#1 line cut
37 E982 ADB1KA F. TWV#2 line cut
38 E983 ADC1KA F. TWV#3 line cut
39 E984 ADD1KA F. TWV#4 line cut
40 E985 ADE1KA F. TWV#5 line cut
41 E986 ADF1KA F. TWV#6 line cut
42 E98A ADAZKB F. TWV#1,2,3 line short
43 E98b ADDZKB F. TWV#4,5,6 line short
44 EA1b dLE3LC R. engine Ne sensor problem
45 EA1C dLH1LC R. engine G sensor problem
46 EA20 dB29KQ R. engine type selection error
47 EA22 a000N1 R. engine overrun
48 EA24 b@BAZG R. engine oil press. down
49 E05 EA31 dK10KX R. fuel dial sys. error
50 EA35 dB2RMC R. KOM-NET/c error
51 EA36 dDE2L6 R. engine oil press. sw. error
52 EA3C dH30KX F. engine boost press. sensor error
53 EA3d dGE4KX R. engine fuel temp. sensor error
54 EA54 dD11KB Short R. engine starter sw.
55 E0E EA55 dB2SMC R. S-NET error
56 E0E EA56 dB22KK R. engine power failure (1)
57 EA57 d1D0KB R. engine power failure (2)
58 EA5A dB2AMA R. engine Q-adjust sw. signal error
59 EA70 aD11KB R. PCV1 over current
60 EA71 aD51KB R. PCV2 over current
61 EA74 aD11KA R. PCV1 line cut
62 EA75 aD51KA R. PCV2 line cut
63 EA77 dH40KX F. engine common rail press. sensor error
64 EA79 aD00L2 R. common rail press. high
65 EA7A aD00MA R. common rail press. abnormal
66 EA7b aD10L3 R. common rail press. low
67 EA7C aD10MB R. common rail press. too low
68 EA7d aD10MA R. common rail press. out of control
69 EA80 dB20KT R. engine controller failure

20-160 PC1800-6
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

User code Error code Failure code

No. Description
(Machine monitor) (Machine monitor) (CGC monitor)
70 EA81 aDA1KA R. TWV#1 line cut
71 EA82 aDB1KA R. TWV#2 line cut
72 EA83 aDC1KA R. TWV#3 line cut
73 EA84 aDD1KA R. TWV#4 line cut
74 EA85 aDE1KA R. TWV#5 line cut
75 EA86 aDF1KA R. TWV#6 line cut
76 EA8A aDAZKB R. TWV#1,2,3 line short
77 EA8b aDDZKB R. TWV#4,5,6 line short
78 6014NX Hydraulic oil filter clogging
79 7@HAKA Break F. pump 1,2 press. sensor failure
80 7@HAKB Short F. pump 1,2 press. sensor failure
81 7@HAZL High relief press. F. pump 1,2
82 7@HBKA Break R. pump 1,2 press. sensor failure
83 7@HBKB Short R. pump 1,2 press. sensor failure
84 7@HBZL High relief press. R. pump 1,2
85 7@HCKA Break F. pump 3,4 press. sensor failure
86 7@HCKB Short F .pump 3,4 press. sensor failure
87 7@HCZL High relief press. F. pump 3,4
88 7@HDKA Break R. pump 3,4 press. sensor failure
89 7@HDKB Short R .pump 3,4 press. sensor failure
90 7@HDZL High relief press. R. pump 3,4
91 aB00KE Low R. charge voltage
92 AB00KE Low F. charge voltage
93 b@BAZK Low R. engine oil level
94 B@BAZK Low F. engine oil level
95 b@BCZK Low R. coolant level
96 B@BCZK Low F. coolant level
97 b@CBNS High R. PTO temp.
98 B@CBNS High F. PTO temp.
99 B@HAZK Low Hydraulic oil level
100 E05 D110KB Short in F. battery relay drive sys.
101 D163KB Short in flash light relay sys.
102 D194KZ Break in step light power keep
103 D195KB Short in step light relay sys.
104 E0E DA2SKA Network overtime error

PC1800-6 20-161
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

User code Error code Failure code

No. Description
(Machine monitor) (Machine monitor) (CGC monitor)
105 DA2SKQ Machine model selection error
106 E0E DA80MA Auto grease controller error
107 DBB0KK VHMS controller power source voltage error
108 DBB0KM Connector mismatch
109 E0E DBB0KP Voltage source sys. error
110 DBB0KQ VHMS machine model selection error
111 DBB0KT VHMS sys. error
112 DBBQKR VHMS KOM-NET/c error
113 dGT4KA Exhaust temp. sensor R-F failure
114 DGT4KA Exhaust temp. sensor F-F failure
115 dGT4KB Exhaust temp. sensor R-F failure
116 DGT4KB Exhaust temp. sensor F-F failure
117 dGT5KA Exhaust temp. sensor R-R failure
118 DGT5KA Exhaust temp. sensor F-R failure
119 dGT5KB Exhaust temp. sensor R-R failure
120 DGT5KB Exhaust temp. sensor F-R failure
121 dHE4KB R. engine oil Press. sensor failure
122 DHE4KB F. engine oil Press. sensor failure
123 dHE4KY R. engine oil Press. sensor failure
124 DHE4KY F. engine oil Press. sensor failure
125 dHE5KB R. engine blowby Press. sensor failure
126 DHE5KB F. engine blowby Press. sensor failure
127 dHE5KY R. engine blowby Press. sensor failure
128 DHE5KY F. engine blowby Press. sensor failure
129 dLE2MA R. engine speed sensor sys. error
130 DLE2MA F. engine speed sensor sys. error
131 E0E DPA0KR Monitor network overtime error
132 DV20KB Short in taravel alarm sys.
133 DW42KZ Auto decel output sys. error
134 E03 DW45KA Break in swing brake sys.
135 E03 DW45KB Short in swing brake sys.
136 DW48KA Break in CO cancel sol. sys.
137 DW48KB Short in CO cancel sol. sys.
138 DW91KA Break in straight travel sol. sys.
139 DW91KB Short in straight travel sol. sys.

20-162 PC1800-6
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

User code Error code Failure code

No. Description
(Machine monitor) (Machine monitor) (CGC monitor)
140 DWK0KA Break in 2-stage relief sol. sys.
141 DWK0KB Short in 2-stage relief sol. sys.
142 E02 dXA0KA Break in R. TVC sol. sys.
143 E02 DXA0KA Break in F. TVC sol. sys.
144 E02 dXA0KB Short in R. TVC sol. sys.
145 E02 DXA0KB Short in F. TVC sol. sys.
146 f@BBZL High blowby Press. R. engine
147 F@BBZL High blowby Press. F. engine
148 f@BVL6 R. engine stop
149 F@BVL6 F. engine stop
150 f@BYNR High R-F cyl. exhaust temp. 2
151 F@BYNR High F-F cyl. exhaust temp. 2
152 f@BYNS High R-F cyl. exhaust temp. 1
153 F@BYNS High F-F cyl. exhaust temp. 1
154 f@BZNR High R-R cyl. exhaust temp. 2
155 F@BZNR High F-R cyl. exhaust temp. 2
156 f@BZNS High R-R cyl. exhaust temp. 1
157 F@BZNS High F-R cyl. exhaust temp. 1
158 F@HCKA Break swing press. sensor failure
159 F@HCKB Short swing press. sensor failure
160 F@HCZL High relief press. swing pump
161 J100KA Break gear pump Press. sensor failure
162 J100KB Short gear pump Press. sensor failure
163 J100L6 Abnomality gear pump press.
164 MFA0 Manual trigger

★ This error code table is the same as one given in FUNCTION AND OPERATION OF CGC MONITOR. Items
are arranged, however, in order of error code in consideration of use on the machine monitor.
★ Regarding items with their error codes blank, their error codes are not displayed on the machine monitor, but
their service codes are displayed only on the CGC monitor.

PC1800-6 20-163
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

4. Monitoring function
Monitors signals from various switches and sen-
sors and actuators provided on each unit of
machine in real time.
★ The same function is provided on the CGC
monitor.
1) Changing method to monitoring function
Simultaneously press time switch (2) and
heavy lift switch (6) at least 2.5 seconds to
display first monitoring code on time/service
meter display (1).

2) Information displayed
Monitoring code is displayed on the left of
time/service meter display (1) and monitor-
ing information is displayed on the right.
A: Value display
Monitoring code [10] displaying engine
rpm (Display unit: 10 rpm)
B: Bit display
Monitoring code [08] displaying connec-
tion to S-NET

3) Advancing and returning display

i) While pressing time switch (2), press
working mode right switch (4) to display
monitoring code (Display advances).
ii) While pressing time switch (2), press
the working mode left switch (5) to dis-
play second shortest elapsed time (Dis-
play returns.)

4) Ending monitoring function

Simultaneously press time switch (2) and
heavy lift switch (3) at least 2.5 seconds to
go back to ordinary display.
★ This is the same operation as that for
changing over to monitoring function.

20-164 PC1800-6
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

Monitoring Code Table (All Codes)

No. Monitoring code Monitoring information Unit Device

1 01 Machine monitor model code — Machine monitor
2 02 Pump controller model code — Pump controller
3 03 Engine controller model code (F engine) — F engine controller
4 04 Engine controller model code (R engine) — R engine controller
5 05 VHMS controller model code — VHMS controller
6 08 S-NET connection condition (6bit) Machine monitor
7 10 Engine rpm (F engine) 10rpm Pump controller
8 11 Engine rpm (R engine) 10rpm Pump controller
9 13 TVC current (F engine) 10mA Pump controller
10 14 TVC current (R engine) 10mA Pump controller
11 15 2nd throttle command value (F engine) 10rpm Pump controller
12 16 2nd throttle command value (R engine) 10rpm Pump controller
13 20 Pump controller switch input 1 (6bit) Pump controller
14 21 Pump controller switch input 2 (6bit) Pump controller
15 22 Pump controller switch input 3 (6bit) Pump controller
16 23 Pump controller solenoid output 1 (6bit) Pump controller
17 24 Machine monitor alarm sensor input 1 (F engine) (6bit) Pump controller
18 25 Machine monitor alarm sensor input 2 (F engine) (6bit) Pump controller
19 26 Pump controller solenoid output 1 (6bit) Pump controller
20 32 VBB voltage (Battery voltage) 100mV Pump controller
21 36 Pump controller switch input 4 (6bit) Pump controller
22 42 Fuel level sensor input voltage 10mV Pump controller
23 43 Charge input voltage 100mV Pump controller
24 44 Hydraulic oil temperature sensor input voltage 10mV Pump controller
25 47 Machine monitor output 1 (6bit) Machine monitor
26 48 Machine monitor input 1 (6bit) Machine monitor
27 49 Machine monitor input 2 (6bit) Machine monitor
28 4A Machine monitor input 3 (6bit) Machine monitor
29 4C Machine monitor output 2 (6bit) Machine monitor
30 54 Machine monitor alarm sensor input 1 (R engine) (6bit) Pump controller
31 55 Machine monitor alarm sensor input 2 (R engine) (6bit) Pump controller
32 70 Engine rpm (F engine) 10rpm F engine controller
33 71 Accelerator opening (F engine) % F engine controller
34 72 Fuel injection quantity command (F engine) mm3/st F engine controller
35 73 Common rail pressure command (F engine) MPa F engine controller

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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

No. Monitoring code Monitoring information Unit Device

36 74 Fuel injection timing command (F engine) 0.1CA F engine controller
37 75 Common rail pressure (f engine) MPa F engine controller
38 76 Boost pressure (F engine) kPa F engine controller
39 77 Engine high water temperature (F engine) °C F engine controller
40 78 Engine low water temperature (F engine) °C F engine controller
41 79 Fuel temperature (F engine) °C F engine controller
42 80 Engine control mode (F engine) — F engine controller
43 81 Conversion torque/load output (F engine) % F engine controller
44 82 Accelerator voltage (F engine) 10mV F engine controller
45 83 Right Q adjustment switch (F engine) — F engine controller
46 84 Left Q adjustment switch (F engine) — F engine controller
47 85 Engine controller input condition (F engine) (6bit) F engine controller
48 86 PCV valve closing time (F engine) CA F engine controller
49 90 Engine rpm (R engine) 10rpm R engine controller
50 91 Accelerator opening (R engine) % R engine controller
51 92 Fuel injection quantity command (R engine) mm3/st R engine controller
52 93 Common rail pressure command (R engine) MPa R engine controller
53 94 Fuel injection timing command (R engine) 0.1CA R engine controller
54 95 Common rail pressure (R engine) MPa R engine controller
55 96 Boost pressure (R engine) kPa R engine controller
56 97 Engine high water temperature (R engine) °C R engine controller
57 98 Engine low water temperature (R engine) °C R engine controller
58 99 Fuel temperature (R engine) °C R engine controller
59 A0 Engine control mode (R engine) — R engine controller
60 A1 Conversion torque/load output (R engine) % R engine controller
61 A2 Accelerator voltage (R engine) 10mV R engine controller
62 A3 Right Q adjustment switch (R engine) — R engine controller
63 A4 Left Q adjustment switch (R engine) — R engine controller
64 A5 Engine controller input condition (R engine) (6bit) R engine controller
65 A6 PCV valve closing time (R engine) CA R engine controller
66 C0 Machine monitor program version — Machine monitor
67 C1 Pump controller program version — Pump controller
68 C2 Engine controller program version (F engine) — F engine controller
69 C3 Engine controller program version (R engine) — R engine controller
70 C4 VHMS controller program version — VHMS controller
★ For more information of the monitoring codes with (6bit) in Unit column, refer to the DETAILS OF BIT PAT-
TERN CODE.

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Details of Bit Pattern Code

★ Light-ON or -OFF of the bit from [1] to [6] in the
right figure indicate monitoring condition.
★ The right figure displays the condition with all bits
[1] to [6] ON.

Monitoring
Monitoring information Bit Information displayed (Condition at bit-on)
code
[1] Pump controller: Connected
[2] Pump controller: Connected
[3] F engine controller: Connected
08 S-NET connection condition
[4] R engine controller: Connected
[5] VHMS controller: Connected
[6] (Not allocated: Always OFF)
[1] Swing oil pressure switch: ON
[2] Right travel oil pressure switch: ON
[3] Boom lowering oil pressure switch: ON
20 Pump controller switch input 1
[4] Boom raising oil pressure switch: ON
[5] Arm excavating oil pressure switch: ON
[6] Arm dump oil pressure switch: ON
[1] Bucket excavating oil pressure switch: ON
[2] Bucket dump oil pressure switch: ON
[3] Swing lock switch: ON
21 Pump controller switch input 2
[4] Service oil pressure switch: ON
[5] Left travel oil pressure switch: ON
[6] Swing parking brake release switch: Abnormal position
[1] Model selection 1 signal: GND input
[2] Model selection 2 signal: GND input
[3] Model selection 3 signal: GND input
22 Pump controller switch input 3
[4] Model selection 4 signal: GND input
[5] Step light switch: ON
[6] Horn switch: ON

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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

[1] CO cancel solenoid: ON

[2] Straight-travel solenoid: ON
[3] Swing parking brake solenoid: ON
23 Pump controller solenoid output 1
[4] 2-stage relief solenoid valve: ON
[5] Battery relay holding signal: ON
[6] Travel alarm: ON
[1] (Not allocated: Always OFF)
[2] (Not allocated: Always OFF)

Machine monitor alarm sensor [3] Radiator water level switch: Abnormality detected
24
input 1 (F engine) [4] Engine oil level switch: Abnormality detected
[5] Hydraulic oil level switch: Abnormality detected
[6] Air cleaner clogging switch: Abnormality detected
[1] (Not allocated: Always OFF)
[2] Overload sensor: OPEN

Machine monitor alarm sensor [3] (Not allocated: Always OFF)

25
input 2 (F engine) [4] Hydraulic oil filter switch: OPEN
[5] Automatic lubrication controller: Abnormality detected
[6] (Not allocated: Always OFF)
[1] (Not allocated: Always OFF)
[2] (Not allocated: Always OFF)
[3] Deceleration signal: Output
26 Pump controller solenoid output 1
[4] Step light power holding signal: ON
[5] Step light relay: ON
[6] Flash light relay: ON
[1] Starting switch/F engine C signal: ON once
[2] Starting switch/R engine C signal: ON once
[3] (Not allocated: Always OFF)
36 Pump controller switch input 4
[4] (Not allocated: Always OFF)
[5] Starting switch ACC signal: ON
[6] (Not allocated: Always OFF)
[1] (Not allocated: Always OFF)
[2] Alarm buzzer : ON
[3] (Not allocated: Always ON)
47 Machine monitor output 1
[4] (Not allocated: Always ON)
[5] (Not allocated: Always ON)
[6] (Not allocated: Always OFF)

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[1] (Not allocated: Always ON)

[2] (Not allocated: Always ON)
[3] (Not allocated: Always ON)
48 Machine monitor input 1
[4] (Not allocated: Always ON)
[5] (Not allocated: Always ON)
[6] (Not allocated: Always ON)
[1] Starting switch: OFF
[2] Battery relay terminal voltage: Hi
[3] Light switch: ON
49 Machine monitor input 2
[4] Preheater switch: ON
[5] Starting switch C signal: Once ON
[6] (Not allocated: Always OFF)
[1] Time switch: OFF
[2] PPC oil pressure selector switch: OFF
[3] Overload selector switch: OFF
4A Machine monitor input 3
[4] (Not allocated: Always OFF)
[5] Swing lock switch: OFF
[6] Buzzer cancel switch: OFF
[1] (Not allocated: Always OFF)
[2] (Not allocated: Always OFF)
[3] (Not allocated: Always OFF)
4C Machine monitor switch output 2
[4] (Not allocated: Always OFF)
[5] (Not allocated: Always OFF)
[6] (Not allocated: Always OFF)
[1] (Not allocated: Always OFF)
[2] (Not allocated: Always OFF)

Machine monitor alarm sensor [3] Radiator water level switch: Abnormality detected
54
input 1 (R engine) [4] Engine oil level switch: Abnormality detected
[5] (Not allocated: Always OFF)
[6] (Air cleaner clogging switch: Abnormality detected)
[1] (Not allocated: Always OFF)
[2] (Not allocated: Always OFF)

Machine monitor alarm sensor [3] (Not allocated: Always OFF)

55
input 2 (R engine) [4] (Not allocated: Always OFF)
[5] (Not allocated: Always OFF)
[6] (Not allocated: Always OFF)

PC1800-6 20-169
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

[1] Starting switch C signal: ON

[2] Auto deceleration signal: GND connected

Engine controller input condition [3] Model selection input 1: ON

85
(F engine) [4] Model selection input 2: ON
[5] Model selection input 3: ON
[6] (Not allocated: Always OFF)
[1] Starting switch C signal: ON
[2] Auto deceleration signal: GND connected

Engine controller input condition [3] Model selection input 1: ON

A5
(R engine) [4] Model selection input 2: ON
[5] Model selection input 3: ON
[6] (Not allocated: Always OFF)

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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

5. Operating on reduced cylinders

Operates the engine on reduced cylinders by
putting a specific cylinder in non-injection condi-
tion and measuring engine rpm at that time to
specify the cylinder with abnormality.

1) Changing over to operating on reduced cyl-

inders
Simultaneously press time switch (2), work-
ing mode right switch (4), and R engine
water temperature display switch (7) at least
2.5 seconds to display condition of front
engine on time/service meter display (1).
★ Carry out this operation with engine run-
ning since this function specifies the cyl-
inder with abnormality based on change
in engine rpm at operating it on reduced
cylinders.
2) Changing over engine to operate on
reduced cylinders
Press F engine water temperature display
switch (8) or R engine water temperature
display switch (7) to turn on lamp.
• F engine water temperature display
lamp: Front engine
• R engine water temperature display
lamp: Rear engine
3) Information displayed
Engine rpm is displayed on the left side of
time/service meter display (1) and cylinder
No. is displayed on the right.
★ The display unit of the engine rpm is 10
rpm.
4) Setting cylinder to reduce
i) While pressing time switch (2), press
working mode right switch (4) or work-
ing mode left switch (5) to flash cylinder
number to reduce.
ii) While pressing time switch (2), press
heavy lift switch (6) to put cylinder to
reduce on non-injection condition.

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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR

★ When the flashing condition of cylinder

No. to reduce changes from flashing of
value to flashing of upper and lower 2
bits, the cylinder is in non-injection con-
dition.
★ As a cylinder to reduce, either single of
several cylinders can be set.
5) Setting cylinder to reset
i) While pressing time switch (2), press
working mode right switch (4) or work-
ing mode left switch (5) to flash 2 bits of
cylinder No. to reset. (When several cyl-
inders are reduced)
ii) While pressing time switch (2), press
heavy lift switch (6) to put cylinder to
reset in injection condition.
★ When the flashing condition of the cylin-
der No. to reset changes from flashing
of upper and lower 2 bits to flashing of
value, the cylinder is in non-injection
condition.
4) Ending operating on reduced cylinders
Simultaneously press time switch (2), work-
ing mode right switch (4), and R engine
water temperature display switch (7) to go
back to ordinary display.
★ This is the same operation as that for
changing over to operating on reduced
cylinders.

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6. Working mode default setting function

Sets an operator's favorite working mode which
is automatically set at starting switch ON.
★ The default of factory-set working mode or
on a new machine monitor is the H mode.
1) Changing over to working mode default set-
ting function
Simultaneously press time switch (2) and
working mode right switch (4) at least 2.5
seconds to flash working mode LED.
2) Selecting working mode
Press working mode left switch (5) or work-
ing mode right switch (4) to flash working
mode LED.
3) Ending working mode default setting func-
tion
Simultaneously press time switch (2) and
working mode right switch (4) at least 2.5
seconds to light working mode LED.
★ This is the same operation as that for
changing over to working mode default
setting function.
★ After changing the default setting of the
working mode, be sure to carry out this
operation to go back to the ordinary con-
dition. Otherwise, the new setting will not
be enabled.

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TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

FUNCTION AMD OPERATION OF CGC MONITOR

Functions of the Main Buttons on Screen

* CGC : Color Graphic Console

* VHMS : Vehicle Health Monitoring System

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Ordinary Functions and Special Functions of CGC Monitor

A CGC monitor has ordinary and special functions to allow to check various information or make settings on the
screen of computer graphics.
Depending on the items and contents, some information and settings are displayed automatically by the internal
settings of VHMS, and other are displayed manually by operation on the screen.

1. Ordinary functions: Operator Menu

They are the functions by which an operator can display ordinary contents of information or set them by
operation on the screen.

2. Special functions: Service Menu

They are the functions by which a service person can display the contents not covered by the ordinary func-
tions by special operation. (They are used for special settings, check and adjustment, fault diagnosis, PM
clinic, etc.)

No. Operator Menu No. Service Menu

1 Initial screen 9 Service ID Entry screen
Monitor screen (Ordinary Three screens
2 10 Service Menu Select screen
screen) (for each item)
Six screens (for
3 Brightness adjustment function 11 Real-time monitor function
each item)
Setting function [Screen to go to Service Six screens (for
4 12 PM clinic function
Menu] each item)
Five screens
5 Maintenance function 13 Serial No. setting function
(for each time)
⇒ Erase memory function
6 Track-counter setting function 14 [Screen for going to the service-meter set-
ting function]
Displayed three
7 Fuel consumption function 15 Fault history function
by three items
Maintenance history func- Five screens
⇓ 16
tion (for each time)
8 Abnormality display function 17 Snapshot function
18 Setting change function
⇓
19 Service-meter setting function

★ The numbers in the column "No." represents the order of explanation in this manual. They do not show the
order or priority of the screens displayed.

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TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

OPERATION AND DISPLAY OF OPERATOR MENU (SUMMARY)

★ In this section, only the summary of Operator

Menu is explaned. For more detailed contents
and procedures of operation of each menu, refer
to OPERATION & MAINTENANCE MANUAL.

1. Initial Screen
Turn on the starting switch, and the initial screen
is shown after 20 seconds (and stays about 10
seconds.)

2. Monitor Screen (Ordinary Screen)

After the display of Initial screen came to an
end, it changes to that of Monitor screen (usual
screen) automatically.
This screen shows the conditions of machine,
including oil temperature, coolant temperature
and oil pressure of engine, oil temperature of
PTO, temperature of hydraulic oil.
★ Monitor screen consists of three screens,
each displaying different contents of infor-
mation.
★ Operating each button on this screen chang-
es the screen to that having the function cor-
responding to the icon.

3. Brightness Adjustment Function

Press [Brightness] button on Monitor screen dis-
play, and the screen for brightness adjustment is
displayed.
On this screen, it is possible to adjust contrast
and brightness of computer graphics.

4. Setting Function
Press [Setting] button on Monitor screen display,
and the screen for settings is displayed.
On this screen, it is possible to set a language,
date, time, time difference, unit for display, etc.
★ It is possible to go to Service Menu by a spe-
cial operation on this screen. (Refer to the
section OPERATION AND DISPLAY OF
SERVICE MENU.)
★ Take special care when input data at setting
function screen, because inaccurate data
may cause inconsistency in timing on re-
spective data in VHMS.

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5. Maintenance Function
Press [Maintenance] button on Monitor screen
display, and the screen for the maintenance
function is displayed.
On this screen, it is possible to check the time
duration since the last maintenance of oil and fil-
ters and similar items and reset the time after
their maintenance was completed.

6. Truck Counter function

Press [Truck Counter] button on Monitor screen
display, and the screen for the Truck-counter
function is displayed.
On this screen, it is possible to check and reset
the number of times of operation of the Truck-
counter switches 1 and 2 mounted on the left
work equipment lever.

7. Fuel Consumption Function

Press [Fuel Consumption] button on Monitor
screen display, and the screen for the fuel-con-
sumption function is displayed.
On this screen, it is possible to start and end the
measurement of fuel consumption. When the
measurement is completed, fuel consumption
per hour (L/H) is displayed.

8. Abnormality Display Function

If any abnormality occurs when the machine is
running under Operator Menu, the screen
issues an alarm automatically showing steps to
be taken.
★ The screen shows also the error code and
records it in the system. It is possible to
check it on "Fault History Function" on Serv-
ice Menu.

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OPERATION AND DISPLAY OF SERVICE MENU

9. Service ID Entry Screen (Special operation to

go to Service Menu)
★ To use Service Menu, change the screens
displayed by following the special operation
mentioned below and entering the ID.

1) Display and operation of Setting screen

i) By setting the Operator Menu, the
screen for setting functions is displayed.
★ It is possible to go to Service Menu
only from this screen.
ii) Press the upper right corner and lower
right corner (a) at the same time, and
Service-ID Entry screen is displayed.
★ The corners to be pressed are not
marked on the screen; so press the
positions to be about right.
2) Operation on Service-ID Entry screen
Enter the service ID on the screen for enter-
ing it, and Service Menu screen is dis-
played.
★ Service ID: 7826101001
★ When checking that the ID was entered
correctly, press [Enter] button to deter-
mine it. (If it is determined, the screen
changes to that for selection of Service
Menu.)
★ If a wrong ID was entered, press first
[Clear] button to erase the entered fig-
ures, and enter again.
★ When canceling, press [Return] button,
and you go back to the screen for set-
ting.

10. Service-Menu Selection Screen

On this screen, press the button of the menu
which has the function to use.
★ To exit from Service Menu, press [Return]
button, and the screen goes back to the ordi-
nary screen (Monitor screen) of Operator
Menu.

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11. Real-time Monitor Function

This function allows to monitor real-time the sig-
nals sent from various switches, sensors and
actuators mounted on each part of the machine.
★ The machine monitor is equipped with the
similar function, too.

1) Selection of Real-time Monitor function

Press [Real-time Monitor] button on [Serv-
ice-Menu Selection] screen, and [Real-time
Monitor] screen is displayed.
2) Selection of [Real-time Monitor] screen
Press [Go to Following Screen] or [Go to
Previous Screen] button to choose the
screen to monitor.
★ Real-time Monitor screen consists of six
screens for six corresponding items; re-
fer to the list of monitoring items.
3) Operation for Monitoring
Start engine and operate the machine, and
check the information you want to monitor.
★ The information shown on real-time
monitor may have some time lag in dis-
play, because it is sent through a net-
work between each controller and
VHMS controller. Record the information
monitored after it becomes stable as
much as possible you can.
4) Function to hold the information monitored
Press [PAUSE] button during monitoring,
and the information monitored is held.
★ Press the same button again during
holding, and the holding is released.
5) Exit from monitoring
Press [MENU] button, and it is possible to
go back to Service Menu select screen.

PC1800-6 20-179
TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

★ Cautions When Measuring Front or Rear NC

Pressure
To measure output pressure of front or rear NC
valves (each three in front and rear), connect
and disconnect pressure sensor for measuring
NC pressure; for more details, refer to the sec-
tion of CHECK AND ADJUSTMENT OF PIS-
TON PUMP CONTROL OIL PRESSURE.

k The pressure sensor for measuring NC

pressure is intended only for low-pressure
circuit; never use it for measuring other
than the output pressure of NC valves.

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List of Items Monitored

REAL TIME Unit Range of

Contents Unit(SI) Remarks
MONITOR (1/6) (METRIC) display
1 F. engine speed Rpm of front engine rpm rpm 0 – 3000
F. engine fuel
2 Fuel temperature of front engine degC °C -30 – 100
temp
Fuel injection volume of front Temperature of
3 F. fuel injection mm3/st mm3/st 0 – 600 engine coolant
engine
is monitored on
Common rail pressure of front the machine
4 F. rail press. MPa kg/cm2 0 – 200
engine monitor side.
F. PCV ACT tim-
5 Common rail angle of front engine deg deg 0 – 180
ing
6 F. TVC amp. Current of front TVC mA mA 0 – 1000
REAL TIME Unit Range of
Contents Unit(SI) Remarks
MONITOR (2/6) (METRIC) display
1 R. engine speed Rpm of rear engine rpm rpm 0 – 3000
R. engine fuel
2 Fuel temperature of rear engine degC °C -30 – 100
temp
Temperature of
3 R. fuel injection Fuel injection volume of rear engine mm3/st mm3/st 0 – 600
engine coolant
Common rail pressure of rear is monitored on
4 R. rail press. MPa kg/cm2 0 – 200 the machine
engine
monitor side.
R. PCV ACT tim- Common rail cam angle of rear
5 deg deg 0 – 180
ing engine
6 R. TVC amp. Current of rear TVC mA mA 0 – 1000
REAL TIME Unit Range of
Contents Unit(SI) Remarks
MONITOR (3/6) (METRIC) display
1 F. engine speed Rpm of front engine rpm rpm 0 – 3000
No.1,2 F. pump Pressure of No.1 and No.2 front
2 MPa kg/cm2 0 – 50.0
press. pumps
Temperature of
No.3,4 F. pump Pressure of No.3 and No.4 front 2 engine coolant
3 MPa kg/cm 0 – 50.0
press. pumps is monitored on
swing pump the machine
4 Pressure of swing pump MPa kg/cm2 0 – 50.0 monitor side.
press.
5 F. TVC amp. Current of front TVC mA mA 0 – 1000
6 F. NC press. Pressure of front NC MPa kg/cm2 0 – 5.0

PC1800-6 20-181
TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

REAL TIME Unit Range of

Contents Unit(SI) Remarks
MONITOR (4/6) (METRIC) display
1 R. engine speed Rpm of rear engine rpm rpm 0 – 3000
No.1,2R. pump Pressure of No.1 and No.2 rear
2 MPa kg/cm2 0 – 50.0
press. pumps
Temperature of
No.3,4R. pump Pressure of No.3 and No.4 rear 2 engine coolant
3 MPa kg/cm 0 – 50.0
press. pumps is monitored on
swing pump the machine
4 Pressure of swing pump MPa kg/cm2 0 – 50.0 monitor side.
press.
5 R. TVC amp. Current of rear TVC mA mA 0 – 1000
6 R. NC press. Pressure of rear NC MPa kg/cm2 0 – 5.0
REAL TIME Unit Range of
Contents Unit(SI) Remarks
MONITOR (5/6) (METRIC) display
1 PPC boom raise Boom Raise oil-pressure switch on-off on-off —
2 PPC boom lower Boom Lower oil-pressure switch on-off on-off —
3 PPC arm in Arm IN oil-pressure switch on-off on-off —
4 PPC arm out Arm OUT oil-pressure switch on-off on-off —
5 PPC bucket curl Bucket Curl oil-pressure switch on-off on-off —
6 PPC bucket dump Bucket Dump oil-pressure switch on-off on-off —
REAL TIME Unit Range of
Contents Unit(SI) Remarks
MONITOR (6/6) (METRIC) display
1 PPC RH travel Right travel oil-pressure switch on-off on-off —
2 PPC LH travel Left travel oil-pressure switch on-off on-off —
3 PPC swing Swing oil-pressure switch on-off on-off —
4 ST. travel valve Straight-travel solenoid valve on-off on-off —
5 CO cansel valve CO cancel solenoid valve on-off on-off —
6 swing brake valve Swing parking-brake solenoid valve on-off on-off —

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12. PM Clinic Function

This function allows to measure the PM clinic
i tems wi th th e s ign als s ent fr om va ri ous
switches, sensors and actuators mounted on
each part of the machine.

1) Selection of PM Clinic function

Press [PM Clinic] button on Service Menu
Selection screen, and PM Clinic screen is
displayed.
2) Selection of PM Clinic screen
Press [Go to Following Screen] or [Go to
Previous Screen] button to choose the
screen to be measured.
★ PM Clinic screen consists of six screens
for six corresponding items; refer to the
list of PM clinic items.
3) Operation of PM clinic
Start engine and operate the machine, and
check the PM clinic information.
★ The information may have some time lag
in display, because it is sent through a
network between each controller and
VHMS controller. Record the information
of PM clinic after it becomes stable as
much as possible you can.
4) Function to Hold the information of PM clinic
Press [PAUSE] button during the PM clinic
operation, and the PM clinic information is
held.
★ Press the same button again during the
Hold condition, and it is released.
5) Exit from monitoring
Press [Menu] button, to go back to Service
Menu select screen.

PC1800-6 20-183
TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

★ Cautions When Measuring Front or Rear NC

Pressure
To measure output pressure of front or rear NC
valves (each three in front and rear), connect
and disconnect pressure sensor for measuring
NC pressure; for more details, refer to the sec-
tion of CHECK AND ADJUSTMENT OF PIS-
TON PUMP CONTROL OIL PRESSURE.

k The pressure sensor for measuring NC

pressure is intended only for low-pressure
circuit; never use it for measuring other
than the output pressure of NC valves.

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List of PM Clinic Items

Unit Range of
PM CLINIC (1/6) Unit(SI) Contents Unit Remarks
(METRIC) display
1 Atomospheric temp. degC °C Ambient temperature °C -30 – 80
Coolant temperature of front
2 F. coolant temp. degC °C °C -30 – 150
engine Temperature of
Coolant temperature of rear engine coolant
3 R. coolant temp. degC °C °C -30 – 150
engine is monitored on
4 F. engine oil press. MPa kg/cm2 Oil pressure of front engine MPa 0 – 1.00 the machine
monitor side.
5 R. engine oil press. MPa kg/cm2 Oil pressure of rear engine MPa 0 – 1.00
6 Hydraulic oil temp. degC °C Temperature of hydraulic oil °C -30 – 150
Unit Range of
PM CLINIC (2/6) Unit(SI) Contents Unit Remarks
(METRIC) display
1 F. engine speed rpm rpm Rpm of front engine rpm 0 – 3000
2 F. engine oil temp. degC °C Oil pressure of front engine °C -30 – 50
Boost pressure of front
3 F. boost press. kPa kg/cm2 kPa 0 – 300 Temperature of
engine engine coolant
Blow-by pressure of front is monitored on
4 F. blowby press. kPa kg/cm2 kPa 0 – 20.0
engine the machine
Temperature of front engine monitor side.
5 F. exhaust temp.(F) degC °C °C 0 – 950
exhaust (front side)
Temperature of front engine
6 F. exhaust temp.(R) degC °C °C 0 – 950
exhaust (rear side)
Unit Range of
PM CLINIC (3/6) Unit(SI) Contents Unit Remarks
(METRIC) display
1 R. engine speed rpm rpm Rpm of rear engine rpm 0 – 3000
2 R. engine oil temp. degC °C Oil pressure of rear engine °C -30 – 50
Boost pressure of rear
3 R. boost press. kPa kg/cm2 kPa 0 – 300 Temperature of
engine engine coolant
Blow-by pressure of rear is monitored on
4 R. blowby press. kPa kg/cm2 kPa 0 – 20.0
engine the machine
Temperature of rear engine monitor side.
5 R. exhaust temp.(F) degC °C °C 0 – 950
exhaust (front side)
Temperature of rear engine
6 R. exhaust temp.(R) degC °C °C 0 – 950
exhaust (rear side)

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TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

Unit Range of
PM CLINIC (4/6) Unit(SI) Contents Unit Remarks
(METRIC) display
1 F. engine speed rpm rpm Rpm of front engine rpm 0 – 3000
2 F. PTO oil temp. degC °C Oil temperature of front PTO °C -30 – 150
Pressure of No.1 and No.2 Temperature of
3 No. 1,2 F. pump press. MPa kg/cm2 MPa 0 – 50.0 engine coolant
front pumps
is monitored on
Pressure of No.3 and No.4
4 No. 3,4 F. pump press. MPa kg/cm2 MPa 0 – 50.0 the machine
front pumps
monitor side.
5 F. NC press. MPa kg/cm2 Pressure of front NC MPa 0 – 5.0

6 Swing pump press. MPa kg/cm2 Pressure of swing pump MPa 0 – 50.0
Unit Range of
PM CLINIC (5/6) Unit(SI) Contents Unit Remarks
(METRIC) display
1 R. engine speed rpm rpm Rpm of rear engine rpm 0 – 3000
2 R. PTO oil temp. degC °C Oil temperature of rear PTO °C -30 – 150
Pressure of No.1 and No.2 Temperature of
3 No. 1,2 R. pump press. MPa kg/cm2 MPa 0 – 50.0 engine coolant
rear pumps
is monitored on
Pressure of No.3 and No.4
4 No. 3,4 R. pump press. MPa kg/cm2 MPa 0 – 50.0 the machine
rear pumps
monitor side.
5 R. NC press. MPa kg/cm2 Pressure of rear NC MPa 0 – 5.0

6 Swing pump press. MPa kg/cm2 Pressure of swing pump MPa 0 – 50.0
Unit Range of
PM CLINIC (6/6) Unit(SI) Contents Unit Remarks
(METRIC) display
1 F. engine speed rpm rpm Rpm of front engine rpm 0 – 3000
2 R. engine speed rpm rpm Rpm of rear engine rpm 0 – 3000
Pressure of No.1 and No.2
3 No. 1,2 F. pump press. MPa kg/cm2 MPa 0 – 50.0
front pumps
Pressure of No.3 and No.4
4 No. 3,4 F. pump press. MPa kg/cm2 MPa 0 – 50.0
front pumps
Pressure of No.1 and No.2
5 No. 1,2 R. pump press. MPa kg/cm2 MPa 0 – 50.0
rear pumps
Pressure of No.3 and No.4
6 No. 3,4 R. pump press. MPa kg/cm2 MPa 0 – 50.0
rear pumps

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13. Serial-No. Setting Function

This function allows to set model, engine type,
serial No., etc., in VHMS.
★ Be sure to make these settings after the field
assembly was completed or VHMS control-
ler was replaced.

1) Selection of serial-No. setting function

Press [Serial-No. Setting] button on Service
Menu selection screen, and the screen for
setting serial No. is displayed.
★ After the screen is displayed, press [Ma-
chine model] or [Engine] button to
choose the screen for setting.

2) Setting on the machine model side

i) Setting of model
Press [Machine model] button, and the
models to be set are displayed on the
screen; choose one to set.
ii) Setting of model code
Press [Variation Code] button, and the
variation codes to set are displayed on
the screen; choose one to set.
iii) Setting of type
Press [Type] button, and the types to set
are displayed on the screen; choose
one to set.
iv) Setting of serial No.
Press [Serial No.] button, and the
screen for entering a number is dis-
played on the screen; enter the serial
No.
★ After it is checked that the entry you
made was correct, press [Enter] but-
ton to determine the entry (then the
screen goes back to that for setting).
★ If a wrong entry is made, erase it
with [Clear] button, and enter again.
★ If cancelling entry, press [Return]
button, and go back to the screen for
setting.

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3) Setting on the engine side

i) Setting of engine type
Press [Engine Model] button, and the
engines to set are displayed on the
screen; choose one you want to set.
ii) Setting of serial No. (#1)
Press [#1 s/n] button, and the screen for
entering a number is displayed; enter
the serial No.
★ After it is checked that the entry you
made was correct, press [Enter] but-
ton to determine the entry (then the
screen goes back to that for setting).
★ If a wrong entry is made, erase it
with [Clear] button, and enter again.
★ If cancelling entry, press [Return]
button, and to go back to the screen
for setting.
iii) Setting of serial No. (#2)
Press [#2 s/n] button, and the screen for
entering a number is displayed; enter
the serial No.
★ After that, follow the same proce-
dures as in ii) above.

4) Exit from serial-No. setting

Press [Menu] button, and the screen goes
back to Service Menu Select.

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14. Memory clear Function

This function allows to erase various data accu-
mulated in the memory of VHMS controller.
★ Memorize data into WebCARE by download-
ing , before clearing the memory.
★ Be careful in operation always following the
procedure so that no necessary data may be
erased.

1) Selection of erase-memory function

Press [Memory Clear] button on the Service
Menu selection screen, and the screen for
entering the memory-erasion ID is dis-
played.

2) Entry of memory-clear ID
Enter the memory-clear ID on the screen for
entering it, and the screen for erasing mem-
ory is displayed.
★ Ask Service Section for the memory-
clear ID.
★ After it is checked that the entry you
made was correct, press [Enter] button
to determine the entry (then the screen
goes back to Memory Clear screen).
★ If a wrong entry is made, erase it with
[Clear] button, and enter again.
★ If cancelling entry, press [Menu] button,
and to go back to Service Menu screen.

3) Selection of item, the memory of which to

erase
i) Press the button of the item, the mem-
ory of which to clear; and the button
blinks.
★ If other button blinks, press again
the correct button.
ii) After it is checked that the correct button
blinked, press it again, and the screen
for confirmation is displayed.
★ If cancelling the work, press [Menu]
button, and to go back to Service
Menu screen.

4) Execution of memory erasion

Press [Yes] of [No] button on the screen
asking you for confirming the erasion of the
memory.

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★ Confirmation is asked for twice, so press

[Yes] button twice to erase.
★ If you cancel the work, press [No] button,
and to go back to Memory Clear screen.
5) Completion of memory clear operation
If the screen shown right appears, the mem-
ory clear operation has been completed
(and the screen goes back to Memory Clear
screen).

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15. Failure History Function

This function allows to check a failure code of
abnormality which has occurred in the machine
and the contents of the failure, time of occur-
rence, time of restoration, number of times of
occurrence, etc.

1) Selection of failure-history function

Press [Failure History] button on the Service
Menu selection screen, and Failure-history
screen is displayed.

2) Information shown on Failure-history screen

(1) Number of total items recorded
Number of total failure-history items
recorded is displayed.
(2) Number of failure history
This number represents the sequence
of failures which has occurred. On the
screen, it is displayed in the descending
order (i.e. the newest failure first).
(3) Failure codes and failure phenomena
The failure codes with six digits and
their phenomena are shown.
(4) Time of occurrence
The time and date when the failure
occurred first are shown.
(5) Time of restoration
The time and date when the failure were
fixed are shown. If they are not shown,
the failure has not been fixed.
(6) Number of times of occurrence
Shows how many time the code
occurred in a period from the first occur-
rence of the failure to the restoration
from it (information of history of restora-
tion), or from the first occurrence to the
present time (information of history of
unfixed failures before restoration).

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3) Operation on Failure-history screen

• [Previous Screen] button (7): Go back to
the previous screen one by one
• [Previous Item] button (8): Go back to
the previous item one by one
• [Following Item] button (9): Go to the
next item one by one
• [Following Screen] button (10): Go to the
next screen one by one

4) How to erase failure history

Press the button of the number of failure his-
tory (2), and the button blinks and the failure
history is erased.
★ After the failure history was erased, the
number of the failure history erased is
disposed of automatically.
★ You cannot erase the failure history un-
fixed currently (i.e. the history informa-
tion showing no time of restoration) until
restoration.
★ If you want to erase all the failure-history
information, use the erase-memory
function.
⇓
5) Exit from failure history
Press [Menu] button, and the screen goes
back to Service Menu Select screen.

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List of Failure Codes (arranged in the order of the failure codes)

User code Error code Failure code

No. Contents of abnormality
(machine monitor) (machine monitor) (CGC monitor)
1 6014NX Hydraulic oil filter clogging
2 7@HAKA Break F. pump 1,2 press. sensor failure
3 7@HAKB Short F. pump 1,2 press. sensor failure
4 7@HAZL High relief press. F. pump 1,2
5 7@HBKA Break R. pump 1,2 press. sensor failure
6 7@HBKB Short R. pump 1,2 press. sensor failure
7 7@HBZL High relief press. R. pump 1,2
8 7@HCKA Break F. pump 3,4 press. sensor failure
9 7@HCKB Short F .pump 3,4 press. sensor failure
10 7@HCZL High relief press. F. pump 3,4
11 7@HDKA Break R. pump 3,4 press. sensor failure
12 7@HDKB Short R .pump 3,4 press. sensor failure
13 7@HDZL High relief press. R. pump 3,4
14 E922 A000N1 F. engine overrun
15 EA22 a000N1 R. engine overrun
16 104 AA10NX F. air cleaner clogging
17 105 aA10NX R. air cleaner clogging
18 AB00KE Low F. charge voltage
19 aB00KE Low R. charge voltage
20 E979 AD00L2 F. common rail press. high
21 EA79 aD00L2 R. common rail press. high
22 E97A AD00MA F. common rail press. abnormal
23 EA7A aD00MA R. common rail press. abnormal
24 E97b AD10L3 F. common rail press. low
25 EA7b aD10L3 R. common rail press. low
26 E97d AD10MA F. common rail press. out of control
27 EA7d aD10MA R. common rail press. out of control
28 E97C AD10MB F. common rail press. too low
29 EA7C aD10MB R. common rail press. too low
30 E974 AD11KA F. PCV1 line cut
31 EA74 aD11KA R. PCV1 line cut
32 E970 AD11KB F. PCV1 over current
33 EA70 aD11KB R. PCV1 over current
34 E975 AD51KA F. PCV2 line cut

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User code Error code Failure code

No. Contents of abnormality
(machine monitor) (machine monitor) (CGC monitor)
35 EA75 aD51KA R. PCV2 line cut
36 E971 AD51KB F. PCV2 over current
37 EA71 aD51KB R. PCV2 over current
38 E981 ADA1KA F. TWV#1 line cut
39 EA81 aDA1KA R. TWV#1 line cut
40 E98A ADAZKB F. TWV#1,2,3 line short
41 EA8A aDAZKB R. TWV#1,2,3 line short
42 E982 ADB1KA F. TWV#2 line cut
43 EA82 aDB1KA R. TWV#2 line cut
44 E983 ADC1KA F. TWV#3 line cut
45 EA83 aDC1KA R. TWV#3 line cut
46 E984 ADD1KA F. TWV#4 line cut
47 EA84 aDD1KA R. TWV#4 line cut
48 E98b ADDZKB F. TWV#4,5,6 line short
49 EA8b aDDZKB R. TWV#4,5,6 line short
50 E985 ADE1KA F. TWV#5 line cut
51 EA85 aDE1KA R. TWV#5 line cut
52 E986 ADF1KA F. TWV#6 line cut
53 EA86 aDF1KA R. TWV#6 line cut
54 E924 B@BAZG F. engine oil press. down
55 EA24 b@BAZG R. engine oil press. down
56 B@BAZK Low F. engine oil level
57 b@BAZK Low R. engine oil level
58 108 B@BCNS Abnormal F. coolant temp.
59 111 b@BCNS Abnormal R. coolant temp.
60 B@BCZK Low F. coolant level
61 b@BCZK Low R. coolant level
62 B@CBNS High F. PTO temp.
63 b@CBNS High R. PTO temp.
64 115 B@HANS Abnormal Hydraulic temp.
65 B@HAZK Low Hydraulic oil level
66 E05 D110KB Short in F. battery relay drive sys.
67 D163KB Short in flash light relay sys.
68 D194KZ Break in step light power keep
69 D195KB Short in step light relay sys.

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User code Error code Failure code

No. Contents of abnormality
(machine monitor) (machine monitor) (CGC monitor)
70 E957 D1D0KB F. engine power failure (2)
71 EA57 d1D0KB R. engine power failure (2)
72 101 DA20KT Abnormality in error history data
73 E0E DA2SKA Network overtime error
74 DA2SKQ Machine model selection error
75 E0E DA80MA Auto grease controller error
76 118 DAB0KR Pump controller network overtime error
77 E980 DB20KT F. engine controller failure
78 EA80 dB20KT R. engine controller failure
79 E0E E956 DB22KK F. engine power failure (1)
80 E0E EA56 dB22KK R. engine power failure (1)
81 E920 DB29KQ F. engine type selection error
82 EA20 dB29KQ R. engine type selection error
83 E95A DB2AMA F. engine Q-adjust sw. signal error
84 EA5A dB2AMA R. engine Q-adjust sw. signal error
85 E935 DB2RMC F. KOM-NET/c error
86 EA35 dB2RMC R. KOM-NET/c error
87 E0E E955 DB2SMC F. S-NET error
88 E0E EA55 dB2SMC R. S-NET error
89 DBB0KK VHMS controller power source voltage error
90 DBB0KM Connector mismatch
91 E0E DBB0KP Voltage source sys. error
92 DBB0KQ VHMS machine model selection error
93 E0E 116 DBB0KR VHMS network overtime error
94 DBB0KT VHMS sys. error
95 DBBQKR VHMS KOM-NET/c error
96 E954 DD11KB Short F. engine starter sw.
97 EA54 dD11KB Short R. engine starter sw.
98 E936 DDE2L6 F. engine oil press. sw. error
99 EA36 dDE2L6 R. engine oil press. sw. error
100 E93d DGE4KX F. engine fuel temp. sensor error
101 EA3d dGE4KX R. engine fuel temp. sensor error
102 DGT4KA Exhaust temp. sensor F-F failure
103 dGT4KA Exhaust temp. sensor R-F failure
104 DGT4KB Exhaust temp. sensor F-F failure

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User code Error code Failure code

No. Contents of abnormality
(machine monitor) (machine monitor) (CGC monitor)
105 dGT4KB Exhaust temp. sensor R-F failure
106 DGT5KA Exhaust temp. sensor F-R failure
107 dGT5KA Exhaust temp. sensor R-R failure
108 DGT5KB Exhaust temp. sensor F-R failure
109 dGT5KB Exhaust temp. sensor R-R failure
110 E93C DH30KX F. engine boost press. sensor error
111 EA3C dH30KX F. engine boost press. sensor error
112 E977 DH40KX F. engine common rail press. sensor error
113 EA77 dH40KX F. engine common rail press. sensor error
114 DHE4KB F. engine oil Press. sensor failure
115 dHE4KB R. engine oil Press. sensor failure
116 DHE4KY F. engine oil Press. sensor failure
117 dHE4KY R. engine oil Press. sensor failure
118 DHE5KB F. engine blowby Press. sensor failure
119 dHE5KB R. engine blowby Press. sensor failure
120 DHE5KY F. engine blowby Press. sensor failure
121 dHE5KY R. engine blowby Press. sensor failure
122 E05 E931 DK10KX F. fuel dial sys. error
123 E05 EA31 dK10KX R. fuel dial sys. error
124 DLE2MA F. engine speed sensor sys. error
125 dLE2MA R. engine speed sensor sys. error
126 E91b DLE3LC F. engine Ne sensor problem
127 EA1b dLE3LC R. engine Ne sensor problem
128 E91C DLH1LC F. engine G sensor problem
129 EA1C dLH1LC R. engine G sensor problem
130 E0E DPA0KR Monitor network overtime error
131 102 DV00KY Short circuit in buzzer output
132 DV20KB Short in taravel alarm sys.
133 DW42KZ Auto decel output sys. error
134 E03 DW45KA Break in swing brake sys.
135 E03 DW45KB Short in swing brake sys.
136 DW48KA Break in CO cancel sol. sys.
137 DW48KB Short in CO cancel sol. sys.
138 DW91KA Break in straight travel sol. sys.
139 DW91KB Short in straight travel sol. sys.

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User code Error code Failure code

No. Contents of abnormality
(machine monitor) (machine monitor) (CGC monitor)
140 DWK0KA Break in 2-stage relief sol. sys.
141 DWK0KB Short in 2-stage relief sol. sys.
142 E02 DXA0KA Break in F. TVC sol. sys.
143 E02 dXA0KA Break in R. TVC sol. sys.
144 E02 DXA0KB Short in F. TVC sol. sys.
145 E02 dXA0KB Short in R. TVC sol. sys.
146 F@BBZL High blowby Press. F. engine
147 f@BBZL High blowby Press. R. engine
148 F@BVL6 F. engine stop
149 f@BVL6 R. engine stop
150 F@BYNR High F-F cyl. exhaust temp. 2
151 f@BYNR High R-F cyl. exhaust temp. 2
152 F@BYNS High F-F cyl. exhaust temp. 1
153 f@BYNS High R-F cyl. exhaust temp. 1
154 F@BZNR High F-R cyl. exhaust temp. 2
155 f@BZNR High R-R cyl. exhaust temp. 2
156 F@BZNS High F-R cyl. exhaust temp. 1
157 f@BZNS High R-R cyl. exhaust temp. 1
158 F@HCKA Break swing press. sensor failure
159 F@HCKB Short swing press. sensor failure
160 F@HCZL High relief press. swing pump
161 J100KA Break gear pump Press. sensor failure
162 J100KB Short gear pump Press. sensor failure
163 J100L6 Abnomality gear pump press.
164 MFA0 Manual trigger

★ This List is the same as LIST OF ERROR CODES referred to in SPECIAL FUNCTIONS OF MACHINE MON-
ITOR, though it is arranged in the order of the failure codes considering its use for the CGC monitor.

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16. Maintenance History Function

This function allows to change the time set for
maintenance of oil and filters, etc.
★ Use this function to do maintenance at an
earlier time than usual.
★ If VHMS controller was removed and at-
tached it again, or replaced it, the mainte-
nance time set gets out of the schedule; this
function may be used by entering the re-
maining time interval until the first mainte-
nance after replacement.

1) Selection of maintenance history function

Press [Maintenance] button on the Service
Menu selection screen, and Maintenance-
history screen is displayed.
★ Maintenance-history screen shows al-
ways the screen of 250h first.

2) Selection of maintenance items

Press [Previous Screen] or [Next Screen]
button to change the screen until the main-
tenance item to want is shown.
★ Each screen shown has its own time in-
terval for maintenance.

3) Changing maintenance time

i) Press the button of the item, the setting
to change, and the screen for entry of
maintenance time is shown.
ii) Enter the maintenance time interval to
set.
★ After it is checked that the entry to
be made was correct, press [Enter]
button to determine the entry (then
the screen goes back to History
screen.
★ If a wrong entry is made, erase it
with [Clear] button, and enter again.
★ If entry has been made already,
press [Return] button to go to Histo-
ry screen.

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List of Maintenance Items

Standard time Adjustable time

MAINTENANCE MONITOR 250h Contents
interval interval
Replace breather element of hydraulic
1 Change HYD breather element 250 1 – 250
oil tank
Standard time Adjustable time
MAINTENANCE MONITOR 500h Contents
interval interval
1 Change engine oil Replace engine oil 500 1 – 500
2 Change engine oil filter Replace engine oil filter 500 1 – 500
3 Change Hydraulic filter Replace hydraulic oil filter 500 1 – 500
4 Change Hydraulic drain fiter Replace drain filter of hydraulic oil 500 1 – 500
5 Change fuel filter Replace fuel filter 500 1 – 500
Standard time Adjustable time
MAINTENANCE MONITOR 1000h Contents
interval interval
1 Change swing machinery oil Replace swing machinery oil 1000 1 – 1000
2 Change PTO case oil Replace PTO case oil 1000 1 – 1000
3 Change corrosion resistor Replace corrosion resistor 1000 1 – 1000
Standard time Adjustable time
MAINTENANCE MONITOR 1000h Contents
interval interval
1 Change final drive case oil Replace final drive oil 2000 1 – 2000
2 Clean engine breather element Clean engine breather element 2000 1 – 2000
3 Clean Hydraulic tank strainer Clean strainer of hydraulic oil tank 2000 1 – 2000
Standard time Adjustable time
MAINTENANCE MONITOR 5000h Contents
interval interval
1 Change Hydraulic oil Replace hydraulic oil 5000 1 – 5000

★ It is impossible to set a maintenance interval longer than the standard time intervals.

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17. Snapshot Function

VHMS has both manual and automatic snapshot
functions.
The manual snapshot function allows to accu-
mulate various snapshot data for seven and a
half minutes in VHMS controller used for PM
clinic, etc., by operating CGC monitor.
The automatic snapshot function allows to accu-
mulate automatically the snapshot data of an
item for the same time duration, if any abnormal
data was found in the item monitored by VHMS
controller always.(if the applicable failure code
was occurred)

Manual Snapshot Function

1) Selection of snapshot function
Press [Snapshot] button on the Service
Menu selection screen, and Snapshot
screen is displayed.

2) Preparation of snapshot
If it is ready for snapshot operation, press
[Start] button, and the screen asking for
confirming the start of snapshot is shown.
★ In the snapshot operation, connect a
personal computer to take out data; re-
fer to the section of "PM Clinic" for its
procedure.

3) Starting snapshot
Press [Yes] button, snapshot starts.
★ In the snapshot operation, operate the
machine as specified; refer to the sec-
tion of PM CLINIC for its procedure.

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★ Data of 53 items are recorded and accu-

mulated for seven and a half minutes af-
ter you pressed [Yes] button.
★ Data is recorded at a ten seconds' step
for the first five and a half minutes; then
data is recorded at one second's step for
two minutes.
★ If you cancel snapshot, press [Cancel]
button.

4) Exit from snapshot operation

The screen shown right appears seven and
a half minutes after snapshot operation
started, and the operation completes.
★ After the snapshot operation was over,
the screen goes back to the initial Snap-
shot screen automatically.

5) Example of snapshot data

The figure shows the example data for front
engine rotation speed and exhaust tempera-
ture (front, rear)

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TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

6) Data Items Covered by Manual Snapshot

No. Item Contents Unit Origin of Data Remarks

1 Time Elapsed time sec Inside VHMS
0 – 4000rpm,
2 F Eng Speed Rpm of front engine rpm RTCDB1-0
1rpm/bit
0 – 4000rpm,
3 R Eng Speed Rpm of front engine rpm RTCDB1-0
1rpm/bit
0 – 500l/h,
4 F Fuel Injection Fuel injection volume of front engine mm3/st RTCDB2-8
Step=0.01l/h
0 – 500l/h,
5 R Fuel Injection Fuel injection volume of rear engine mm3/st RTCDB2-8
Step=0.01l/h
6 F Blowly Press Blow-by pressure of front engine mmAq VHMS sensor
Blow-by pressure of front engine (for
7 F Blowly Press (PM) mmAq VHMS sensor
Pm)
8 R Blowly Press Blow-by pressure of rear engine mmAq VHMS sensor
Blow-by pressure of rear engine (for
9 R Blowly Press (PM) mmAq VHMS sensor
Pm)
Temperature of front engine exhaust
10 F Exh Temp (F) degC VHMS sensor
(front side)
Temperature of front engine exhaust
11 F Exh Temp (R) degC VHMS sensor
(rear side)
Temperature of rear engine exhaust
12 R Exh Temp (F) degC VHMS sensor
(front side)
Temperature of rear engine exhaust
13 R Exh Temp (R) degC VHMS sensor
(rear side)
14 F Eng Oil Press Oil pressure of front engine kg/cm2 VHMS sensor
15 R Eng Oil Press Oil pressure of rear engine kg/cm2 VHMS sensor
16 F Eng Oil Temp Oil temperature of front engine degC VHMS sensor
17 R Eng Oil Temp Oil temperature of rear engine degC VHMS sensor
0 – 150°C,
18 F Eng Coolant Temp Coolant temperature of front engine degC RTCDB2-2
1°C/bit
R Eng Coolant 0 – 150°C,
19 Coolant temperature of rear engine degC RTCDB2-2
Temp 1°C/bit
20 F Boost Pre Boost pressure of front engine mmHg 1086 10 – 300kPa
21 R Boost Pre Boost pressure of rear engine mmHg 1086 10 – 300kPa
22 Ambient Temp Ambient temperature degC VHMS sensor
23 F PUMP12 Pre. Front pump pressure (No.1 and No.2) kg/cm2 VHMS sensor

24 F PUMP34 Pre. Front pump pressure (No.3 and No.4) kg/cm2 VHMS sensor

25 R PUMP12 Pre. Rear pump pressure (No.1 and No.2) kg/cm2 VHMS sensor
26 R PUMP34 Pre. Rear pump pressure (No.3 and No.4) kg/cm2 VHMS sensor
27 Swing Pre. Swing pump pressure kg/cm2 VHMS sensor

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No. Item Contents Unit Origin of Data Remarks

28 G PUMP Pre. Gear pump pressure kg/cm2 VHMS sensor
29 HYDRO Temp Temperature of hydraulic oil degC 1161
30 F TVC Amp Current of front TVC mA 1167
31 R TVC Amp Current of rear TVC mA 1167
32 F THROT Vol. Throttle voltage of front engine V 1011
33 R THROT Vol. Throttle voltage of rear engine V 1011
34 F PCV Act. Timing Valve closing time of front engine PCV 0.1deg 1627 0 – 180. 0deg
35 R PCV Act. Timing Valve closing time of rear engine PCV 0.1deg 1627 0 – 180. 0deg

0 – 2000kg/cm2
36 F Rail Press Common rail pressure of front engine kg/cm2 1046
(0 – 200MPa)

0 – 2000kg/cm2
37 R Rail Press Common rail pressure of rear engine kg/cm2 1046
(0 – 200MPa)
38 F PTO Temp. Oil temperature of front PTO degC VHMS sensor
39 R PTO Temp. Oil temperature of rear PTO degC VHMS sensor
PPC BOOM RAISE
40 Boom-RAISE oil-pressure switch on-off 1514
ON
PPC BOOM
41 Boom-LOWER oil-pressure switch on-off 1513
LOWER ON
42 PPC ARM IN ON Arm-IN oil-pressure switch on-off 1670
43 PPC ARM OUT ON Arm-OUT oil-pressure switch on-off 1669
PPC BUCKET
44 Bucket CURL oil-pressure switch on-off 1668
CURL ON
PPC BUCKET
45 Bucket DUMP oil-pressure switch on-off 1524
DUMP ON
PPC RH TRAVEL
46 Right travel oil-pressure switch on-off 1672
ON
PPC LH TRAVEL
47 Left travel oil-pressure switch on-off 1673
ON
48 PPC SWING ON Swing oil-pressure switch on-off 1671
49 PPC SERVICE ON Service oil-pressure switch on-off 1674
Straight Travel
50 Straight-travel solenoid valve on-off 1677
VALVE
51 Main Relief VALVE Two-stage relief solenoid valve on-off 1680
52 CO Cancel VALVE CO cancel solenoid valve on-off 1678
53 Swing Brake VALVE Swing parking-brake solenoid valve on-off 1679

PC1800-6 20-203
TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

Automatic Snapshot Function

1) Operation of the automatic snapshot func-
tion
The automatic snapshot function is per-
formed by VHMS controller automatically
based on the data of items its monitors; you
have not to operate it.

2) How the snapshot data is obtained

If any abnormal value occurs in the data of
the item being monitored, the data is
recorded and accumulated from seven and
a half minutes from the point five and a half
minutes before the occurrence of the abnor-
mality.
★ Data is recorded at a ten seconds' step
for the first five and a half minutes; then
data is recorded at one second's step for
two minutes.

3) Example of snapshot data

The chart below shows an example of the
engine rpm data.

20-204 PC1800-6
TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

4) Items monitored for automatic snapshot

Item monitored Failure code Criteria for determining abnormality

B@BCNS
Abnormal coolant temperature Below specified value
b@BCNS

Below the straight line connecting the following two points:

B@BAZG
Low engine oil pressure • Engine rpm : 730, oil pressure : 49 kPa {0.5 kg/cm2}
b@BAZG
• Engine rpm : 2000, oil pressure : 147 kPa {1.5 kg/cm2}

B@CBNS
High PTO temperature Over 125°C
b@CBNS

F@BYNR
f@BYNR
F@BYNS
f@BYNS
High exhaust gas temperature Over 700°C
F@BZNR
f@BZNR
F@BZNS
f@BZNS

F@BVL6 If engine stopped with start switch ON two minutes after it

Engine stop
f@BVL6 started running.

7@HAZL
7@HBZL
High pump relief pressure 7@HCZL Over 37.3 MPa {380 kg/cm2} for one second
7@HDZL
F@HCZL

Below 2.6 MPa {26 kg/cm2} or over 3.7 MPa {38 kg/cm2}
Abnormal gear pump pressure J100L6 when engine rpm : 1,750 or above and hydraulic oil tem-
perature : 50°C or above

Abnormal hydraulic oil

B@HANS Over 100°C
temperature

PC1800-6 20-205
TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

18. Setting Change Function

This function allows to change language, date,
time, time difference, display unit, etc.
★ Take special care when input data at setting
function screen, because inaccurate data
may cause inconsistency in timing on re-
spective data in VHMS.

1) Selection of setting change function

Press [Setting] button on the Service Menu
selection screen, and Setting-change
screen is displayed.

2) Operation for changing settings

i) Setting of language
Press [Language] button, and the lan-
guages to set (Japanese or English) are
displayed on the screen; select one to
set.
ii) Setting of date
Press [Date] button, and the screen for
entering a number is displayed; enter
[Year], [Month] and [Day] each.
★ After it is checked that the entry you
made was correct, press [Enter] but-
ton to determine the entry (then the
s cr een goes to the n ex t e ntr y
screen).
★ If a wrong entry is made, erase it
with [Clear] button, and enter again.
★ If cancelling entry, press [Return]
button, and to go back to the screen
for setting.
iii) Setting of time
Press [Time] button, and the screen for
entering a number is displayed; enter
[Hour] and [Minute] each.
★ After that, follow the same proce-
dures as in ii) above.
iv) Setting of time difference
Pr es s [G MT Ref.] button, a nd the
screen for entering a number is dis-
played; enter the time difference.
★ Enter the difference from Greenwich
mean time.
★ After that, follow the same proce-
dures as in ii) above.

20-206 PC1800-6
TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

v) Setting of unit
Press [Unit] button, and the unit sys-
tems to set (SI or metric) are displayed
on the screen; select one to set.
★ If to have selected "Japanese" in the
language setting, select only "SI"
here.
vi) Setting of summer time
In the countries or regions where sum-
mer time is used, press [Summer] but-
ton in the summer time period; the
system automatically correct time to dis-
play summer time.

PC1800-6 20-207
TESTING AND ADJUSTING FUNCTION AMD OPERATION OF CGC MONITOR

19. Service-Meter Setting Function

This function allows to reset service-meter when
VHMS controller is replaced.
★ Take special care when input data at serv-
ice-meter setting screen, because inaccu-
rate data may cause inconsistency in timing
on respective data in VHMS.
★ Refer to [Setting Procedure When Replacing
VHMS Controller] when replacing VHMS
controller.

1) Display and operation on memory clear

screen
i) Select the screen for the memory clear
function on Service Menu.
★ It is possible to access to the serv-
ice-meter setting function only from
this screen.
ii) Press the lower center of screen (b),
and the screen for service-meter setting
is shown.
★ The position to have to press are not
marked on the screen; so press the
position you think to be about right.

2) Entry of service-meter
i) Press [Set] button, and the screen for
entry of service-meter is shown.
ii) Enter a number to set in service-meter
with ten-keys.
★ After it is checked that the entry
made was correct, press [Enter] but-
ton to determine the entry (then the
screen goes back to the screen for
setting).
★ If a wrong entry is made, erase it
with [Clear] button, and enter again.
★ If cancelling entry, press [Return]
button, and go back to the screen for
setting.

20-208 PC1800-6
TESTING AND ADJUSTING HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT

HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT

k The engine controller is equipped with high volt-

age circuits (110-130 V) for driving the fuel injec-
tor.
They are connected to the connectors and har-
nesses between the engine controller and the
fuel injector.
★ Normally, a high voltage is only output while the
engine is running. Once the engine is stopped,
the output ceases.
k Touching the high voltage circuit directly may
cause an electric shock. To avoid this, observe
the following precautions when inspecting the
circuits.

1. Connectors containing high voltage circuits:

• Engine controller connector: FE03, RE03
• Relay connector: EM01, EM02
• Injector connector: CN1, CN2, CN3, CN4,
CN5
• Injector head terminal

2. Be sure to connect and disconnect the relevant

connectors with the starting switch off.

3. When diagnosing, do not start the engine with

the T-adapter inserted in or connected to the rel-
evant connector.
★ At that time, the starting switch can be set to
ON and OFF only, but not to START.

PC1800-6 20-209
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

★ Initialization Tools for VHMS Controller 1. Check of Machine Information, Engine Infor-
mation
Symbol Part Number Part Name ★ This step applies to works on the whole ma-
799-608-3101 Service kit chine.
1 799-608-3211 Diskette Check and record machine information, engine
information, VHMS controller information and
799-608-3220 Wiring harness ORBCOMM controller information.
Notebook type
Commercial personal computer Information to be checked
2
L article (OS : Windows98/ No. Information Remarks
2000)
1 Machine name
Coupling assem-
2 Machine serial number 5 digits
21T-06-64590 bly (Accessory
3 tool) 3 Current service meter time Unit 0.1h
Harness (Acces- 4 Front engine serial number 6 digits
21T-06-64392
sory tool) 5 Rear engine serial number 6 digits
VHMS controller serial num-
6 5 digits
★ Before starting operation after completion of lo- ber
cal assembly or before resuming operation after ORBCOMM controller serial
storage for a long period, initialize the VHMS 7 number (For only specification 11 digits
Controller according to the following procedures. with ORBCOMM)
★ Data collected with the VHMS controller as
WebCARE database are accumulated and man-
★ The above No. is the same as in the check
aged. To process data smoothly on the Web-
sheet.
CARE, it is necessary to set the VHMS controller
consistently. If it is not set correctly, data will not
be taken into the WebCARE and data in the
VHMS controller may not be utilized. So, be sure
to carry out the initialization.
★ For the installing method of the VHMS Initializa-
tion Program in the personal computer, refer to
the Operation and Maintenance Manual con-
tained in the package of the service kit L1.
★ In the procedures, it is necessary to use the serv-
ice menu on the CGC monitor. Refer to the par-
agraph of Function and Operation of CGC
Monitor and fully understand the operating pro-
cedures.
★ The initialization procedures cover both "ORB- • (1) Front engine
COMM Specification" and "ORBCOMMLESS • (2) Rear engine
Specification." In case of "ORBCOMMLESS • (3) VHMS controller
Specification", omit the procedures necessary • (4) ORBCOMM controller
for "ORBCOMM Specification" only. • (5) Machine monitor (reference)
★ During the initialization work, make necessary • (6) CGC monitor (reference)
confirmations for each work according to the • (7) Pump controller (reference)
"VHMS Initialization Work Checklist". • (8) Front engine controller (reference)
• (9) Rear engine controller (reference)

20-210 PC1800-6
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

2. Operation Check of ORBCOMM Controller 3. Connection of Personal Computer

(ORBCOMM Specification only) ★ This step applies works in the cab.
★ This step applies to works in the cab and the 1) Make sure that the starting switch is set to
cab under room. the OFF position.
1) Make sure that the starting switch is set to k Be sure to connect and disconnect the
the OFF position. personal computer when the starting
2) Check that the ORBCOMM controller green switch is set to the OFF position.
LED is ON, and make sure that the control- 2) Connect the personal computer L2 and the
ler is operating. download connector C53 with the wiring
★ Since the power is supplied to the ORB- harness [1] of the service kit L1.
COMM controller all the time, the con- ★ The download connector C53 is con-
troller is normal when the green LED is nected to the left side face of CGC mon-
ON while the starting switch is turned off. itor.
★ Connect the personal computer to the
RS232C terminal.

PC1800-6 20-211
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

4. Performance Check of VHMS Controller 5. Startup of VHMS Initialization Tool

★ This step applies to works in the cab and the ★ This step applies to works in the cab (for the
cab under room. personal computer).
1) Set the starting switch to the ON position. 1) Switch on the personal computer and start
2) Check the 7-segment LED of the VHMS the OS.
controller and make sure that the controller 2) Click the icon of [VHMS Setting Tool] on the
is operating normally. personal computer screen to start the
★ Since the switch power is supplied to the VHMS initialization tool.
VHMS controller, it is normal if the 7- 3) Input the 10-digit service ID in [Service ID].
segment LED flashes in rotation after the ★ Service ID : 7826101001
starting switch is turned on and, then, it ★ The Service ID is the same as that to be
counts up. used in the service menu on the CGC
monitor.
4) Select [Data clear and Set up] in the [Select
Function] column.
5) Press the [OK] button to shift to the setup
screen.

20-212 PC1800-6
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

6. Initialization of VHMS Controller 4) When information in the [Machine Informa-

★ This step applies to works in the cab (for the tion] box is not correct, change it according
personal computer). to the following procedures:
★ At the time of initialization, never change i) Press the [Edit] button on the right lower
data of the service meter (SMR). part of the [Machine Information] box to
[Machine Information] display the correction screen.
1) Open the [Machine Information] tab. ii) Change the information to the correct
★ The [Machine Information] tab is dis- one and then press the [OK] button.
played first in the [Data clear and Set up]
menu.
2) Check all the data.

5) After having checked and changed all data

in [Machine Information], press the [Apply]
button to settle the setting.
★ Press the [Apply] button, and the screen
for checking the setting will appear.
Check the setting again and press the
[OK] button when the setting is correct.
★ In case of the ORBCOMM Specification,
3) When information in the [Date/Time] box is execute [Communication Setting] and
not correct, change it according to the fol- settle it.
lowing procedures:
i) Press the [Edit] button on the right lower
part of the [Date/Time] box to display
the correction screen.
ii) Change the information to the correct
one and then press the [OK] button.

PC1800-6 20-213
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

[Communication Setting] (ORBCOMM Specifi- ii) Change the setting and then press the
cation only) [OK] button.
6) Open the [Communication Setting] tab. ★ At initialization, select [20h] at [SMR]
7) Check all the data. screen, and set the function to [ON].

10) After having checked and changed all data

in [Communication Setting], press the
[Apply] button to settle the setting.
8) To change setting in [SHORT FAULT ★ Press the [Apply] button, and the screen
HISTRY], follow the procedures below: for checking the setting will appear.
i) Select [SHORT FAULT HISTRY] on the Check the setting again and then press
screen and press the [Edit] button on the [OK] button when it is correct.
the left lower part of the [File Transfer
Setting] block to display the setting
screen.
ii) Change the setting and then press the
[OK] button.
★ At initialization, select [Occurrence]
at [Timing] screen, and set the func-
tion to [ON].

9) To change setting in [SHORT TREND

ANALYSIS], follow the procedures below:
i) Select [SHORT TREND ANALYSIS] on
the screen and press the [Edit] button
on the left lower part of the [File Trans-
fer Setting] block to display the setting
screen.

20-214 PC1800-6
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

[Exit] 7. Check of Storage Operation of VHMS

11) After having check and changed all data in Controller
[Machine Information] and [Communication ★ This step applies to works in the cab and the
Setting], press the [Exit] button on the right cab under room
lower part of the screen to terminate [VHMS 1) Set the starting switch to the OFF position.
Initialization Tool]. 2) Check the 7-segment LED of the VHMS
controller and make sure that the controller
power has been completely cut off.
★ The VHMS controller records and up-
dates data when the starting switch is
turned OFF.
★ The controller power is retained for stor-
age operation for several seconds after
the starting switch is turned OFF. So,
make sure that the 7-segment LED of
the controller has completely gone out.

PC1800-6 20-215
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

8. Performance Check of VHMS Controller 9. Execution of Quick PM Clinic

★ This step applies to works in the cab and the ★ This step applies to works in the cab.
cab under room. 1) Start the engine and idle it low.
1) Set the starting switch to the ON position. 2) Set the operation mode to the DH Mode and
2) Check the 7-segment LED of the VHMS bring the safety lock lever to the release
controller and make sure that the controller position.
is operating normally. 3) Let the CGC monitor display the service
★ Since the switch power is supplied to the menu select screen.
VHMS controller, it is normal when the 7- ★ See the paragraph of "Function and Op-
segment LED blinks in rotating after the eration of CGC Monitor".
starting switch is turned on and, then, it 4) Select [Snapshot].
counts up.

5) Keep operating the screen and start SNAP-

SHOT.
★ Press the [START] button on the screen
below, and the confirmation message
will appear.
★ Before staring SNAPSHOT, fully under-
stand the SNAPSHOT procedures.

20-216 PC1800-6
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

6) Operate switches and levers for each run ★ Execute the quick PM clinic twice, i.e., once
time according to "Quick PM Clinic Opera- for the front engine system and once for the
tion Procedures" in the table below. rear engine system.
★ Run times are displayed on the machine ★ One set of the coupling assembly, L3, for
control monitor (CGC). measuring NC pressure is available in the
k Since the work equipment and travel toolbox. Connect it to respective measuring
have to be operated practically in the couplers according to the measurement pro-
quick PM clinic, pay sufficient attention cedures.
to safety around during the operation. • NC Pressure Measuring Coupler on the front
engine side
F: No.1 and 2 front pumps NC pressure
R: No.1 and 2 rear pumps NC pressure
S: Front swing pump NC pressure

• NC Pressure Measuring Coupler on the rear

engine side
F: No.3 and 4 front pumps NC pressure
R: No.3 and 4 rear pumps NC pressure
S: Rear swing pump NC pressure

PC1800-6 20-217
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

Quick PM Clinic Operation Procedures

(each engine)

Switch NC pres-
Time in
Se- Work- Auto- sure
Run time snap data Fuel dial Heavy Swing Control lever Data read to PM clinic
quence ing decel- sensor
(sec.) lift lock
Mode eration position
0 sec. –300.00 . Engine speed (Low idling
Low
1 ↓ ↓ DH OFF OFF OFF — All neutral . Engine oil pressure (Low idling)
(MIN)
30 sec. –270.00 . Ambient temperature
. Engine speed (High idling
. Engine oil pressure (High idling)
30 sec. –270.00
High . Control pump oil pressure
2 ↓ ↓ ↑ ↑ ↑ ↑ All neutral
(MAX) . TVC valve output pressure
1 min. 30 sec. –210.00
. NC valve output pressure
. Swing NC valve output pressure
1 min. 30 sec. –210.00
. Engine speed
3 ↓ ↓ ↑ ↑ ON ↑ ↑ All neutral
(Auto-deceleration)
2 min. –180.00
2 min. –180.00 ★ Lift the R.H track with the work
R.H. travel operation
4 ↓ ↓ ↑ ↑ ↑ ↑ ↑ F equipment first.
(R.H. travel full idling)
3 min. 30 sec. –90.00 . Front NC valve output pressure
3 min. 30 sec. –90.00 ★ Lift the L.H track with the work
L.H. travel operation
5 ↓ ↓ ↑ ↑ ↑ ↑ ↑ R equipment first.
(L.H. travel full idling)
5 min. 0.00 . Rear NC valve output pressure
5 min. 0.00
Swing operation
6 ↓ ↓ ↑ ↑ ↑ ↑ ON S . Swing pump oil pressure
(Swing relief)
5 min. 30 sec. 30.00
5 min. 30 sec. 30.00
Boom RAISE opera- . Engine speed (Relief)
7 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (RAISE relief) . TVC valve output pressure
5 min. 45 sec. 45.00
. Engine speed (Relief)
5 min. 45 sec. 45.00
Boom RAISE opera- . Blow-by pressure
8 ↓ ↓ ↑ ↑ ↑ ON ↑
tion (RAISE relief) . Exhaust gas temperature
6 min. 60.00
. TVC valve output pressure
6 min. 60.00
Arm IN operation (IN . Main pump oil pressure
9 ↓ ↓ ↑ ↑ ↑ ↑ ↑
relief) . Boost pressure
6 min. 30 sec. 90.00
6 min. 30 sec. 90.00
Arm OUT operation
10 ↓ ↓ ↑ ↑ ↑ ↑ ↑
(OUT relief)
6 min. 50 sec. 110.00
6 min. 50 sec. 110.00
Bucket DUMP opera-
11 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (DUMP relief)
7 min. 10 sec. 130.00
7 min. 10 sec. 130.00
Bucket digging opera-
12 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (Digging relief)
7 min. 30 sec. 150.00
Low
13 7 min. 30 sec. 150.00 ↑ ↑ ↑ ↑ End
(MIN)

• NC Pressure Measuring Coupler on Front • NC Pressure Measuring Coupler on Rear Engine

Engine Side Side

20-218 PC1800-6
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

10. Check of Record of VHMS Controller 11. Downloading of Set Data

★ This step applies to works in the cab and the ★ This step applies to works in the cab (on the
cab under room personal computer).
1) Set the starting switch to the OFF position. 1) Set the starting switch to the ON position.
2) Check the 7-segment LED of the VHMS 2) Click the icon of [VHMS Technical Analysis
controller and make sure that the controller Tool] on the personal computer to start the
power has been completely cut off. VHMS analysis tool.
★ The VHMS controller records and up- ★ Input [User Name] and [Password].
dates data when the starting switch is ★ For the operation procedures, refer to
turned off. the Operation and Maintenance Manual
★ The controller power is retained for stor- for VHMS Technical Analysis Tool.
age operation for several seconds after
the starting switch is turned off. So, con-
firm that the 7-segment LED of the con-
troller has completely gone out.

3) Use the [Download] function to download

the data recorded in the VHMS controller to
the personal computer.
★ For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
★ Make sure that the downloading has
completed before proceeding to the next
step.

PC1800-6 20-219
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

12. Check of Downloaded Data 13. Setting for Satellite Communication

★ This step applies to works in the cab (on the (ORBCOMM specification only)
personal computer). ★ This step applies to works in the cab (on the
1) Check the set data with the [View] function. personal computer).
★ For the operation procedures, refer to 1) See the procedures in "5. Startup of VHMS
the Operation and Maintenance Manual "Setting Tool" and start the VHMS Setting
for VHMS Technical Analysis Tool. tool.
★ Make sure that the [MFA0] code at the ★ [Select Function] selects [Set up].
time of quick snapshot is displayed in
[Failure History]
★ Make sure that the SNAPSHOT data
has been recorded.

2) After having check the set data, terminate

[VHMS Technical Analysis Tool].

2) Open the [Communication Setting] tab.

3) Check the setting of [Satellite Setting].

20-220 PC1800-6
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

4) To change the setting of [Satellite Setting], 14. Check of Storage Operation of VHMS Con-
follow the procedures below: troller
i) Press the [Edit] button in the [Satellite ★ This step applies to works in the cab and the
Setting] block to display the setting cab under room
screen. 1) Set the starting switch to the OFF position.
ii) Bring GCC Code to the applicable area 2) Check the 7-segment LED of the VHMS
and then press the [OK] button. controller and make sure that the controller
power has been completely cut off.
★ The VHMS controller records and up-
dates data when the starting switch is
turned off.
★ The controller power is retained for stor-
age operation for several seconds after
the starting switch is turned off. So, con-
firm that the 7-segment LED of the con-
troller has completely gone out.

GCC Code and Application Area

Code Applicable Area
1 U.S.A.
120 Italy
121 Malaysia
122 Korea
123 Brazil
130 Japan

PC1800-6 20-221
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

15. Disconnection of Personal Computer 16. Communication to Komatsu

★ This step applies to works in the cab. After having completed Steps 1 to 15 success-
1) Make sure that the starting switch is set to fully, please send the checklist and the VHMS
the OFF position. data to VHMS/WebCARE Support Center of
k Be sure to turn off the starting switch be- Komatsu, Tokyo.
fore connecting and disconnecting the ★ Komatsu, Tokyo, has to arrange the setting
personal computer. for satellite communication on the receive
2) Terminate the OS of the personal computer side, please be sure to inform Komatsu of
L2, and switch off the personal computer. the completion of the setting.
3) Disconnect the wiring harness [1] of the ★ Fax the checklist to Komatsu.
service kit L1, from the download connector ★ Send the VHMS data by Notes (LAN) or E-
C53. mail (WAN).

Contact VHMS/WebCARE Support Center by

Telephone : 81-3-5561-2765
FAX : 81-3-5561-4766
E-mail : [email protected]

20-222 PC1800-6
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
To : VHMS/WebCARE Support Team, Komatsu, Tokyo Set date :
Fax date :
PC1800-6 DB/ Branch name :
VHMS Initialization Work Checklist Person in charge :

Setting Step Check Item Result

1 Machine name
2 Machine serial number (5 digits)
3 Current service meter time (in 0.1h)
Check of Machine Information,
1 4 Front engine serial number (6 digits)
Engine Information and Controller
Information 5 Rear engine serial number (6 digits)
(*:ORBCOMM specification only) 6 VHMS controller serial number (5 digits)
7 ORBCOMM controller serial number (11 digits)[*]

Performance Check of ORBCOMM

2 Is the green LED on? yes no
Controller (ORBCOMM specification only)

3 Connection of Personal Computer Is it connected correctly? yes no

4 Performance Check of VHMS Controller Is the 7-segment LED operating normally? yes no

5 Startup of VHMS Initialization Tool Is [Data clear and Set up] selected as the function of the initialization tool? yes no

Is Date (mm/dd/yyyy) set correctly? yes no

Date/Time Is the Time set correctly? yes no
[Local Time]Is the Time Zone set correctly? yes no
Is the DST (Summer Time) set correctly? yes no
SMR Is the SMR (h) set correctly? No change allowed
Is the Product Group set correctly? yes no
Is the Machine Model set correctly? yes no

Initialization of VHMS Controller Machine Is the Type set correctly? yes no

6 Is the Variation Code set correctly? yes no
(Items marked with * are for Is the Serial No. set correctly? yes no
the ORBCOMM specification only.)
Is the Engine Model set correctly? yes no
Engine Is the Engine Serial No. 1 set correctly? yes no
Is the Engine Serial No. 2 set correctly? yes no
SHORT FAULT Which is the Send set to? On Off
HISTY[*] Is the Number (Default : 10) set?
SHORT TREND Which is the Send set to? On Off
ANALYSIS[*] Is the Number (Default : 160) set? (SMR)

7 Check of Storage Operation of VHMS Controller Did the 7-segment LED go out? yes no

8 Performance Check of VHMS Controller Is the 7-segment LED operating normally? yes no

9 Execution of Quick PM Clinic Have you arranged the snap shot as per the procedures? yes no

10 Check of Storage Operation of VHMS Controller Did the 7-segment LED go out? yes no

11 Downloading of Set Data Have you completed the downloading? yes no

Could you download all files? yes no

What time did you download (by your wrist watch)? Time
12 Check of Downloaded Data Is the [MFAO] code displayed in the Fault History? yes no
Data Check Do SMR and Time match with the set values in the Fault History? yes no
Is no data missing in the Snapshot? yes no

Setting for Satellite Communication

13 Did you set the GCC Code? yes no
(ORBCOMM specification only)

14 Check of Storage Operation of VHMS Controller Did the 7-segment LED go out? yes no

15 Disconnection of Personal Computer Did you disconnect it correctly? yes no

Contact VHMS/WebCARE Support Team, Komatsu, Tokyo by

• Telephone : 03-5561-2765 (Nation Code 81)
16 Communication to Komatsu • FAX:03-5561-4766 (Nation Code 81)
• E-mail:[email protected]

PC1800-6 20-223
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

★ Setting Tools for Replacing VHMS Controller Preparatory Work for Replacing VHMS
Controller
Symbol Part No. Part Name ★ Steps 1–4 apply to works with the current con-
799-608-3101 Service kit troller before replacing the VHMS controller.
1 799-608-3211 • Diskette
1. Connection of Personal Computer
799-608-3220 • Wiring harness ★ This step applies works in the cab.
L Notebook personal 1) Make sure that the starting switch is set to
Commercial computer the OFF position.
k Be sure to connect and disconnect the
2
article (OS : Windows98/
2000) personal computer when the starting
switch is set to the OFF position.
2) Connect the personal computer, L2, and the
★ When it has become necessary to replace the download connector, C53, with the wiring
VHMS controller, set the controller according to harness [1] of the service kit, L1.
the following procedures before and after the re- ★ The download connector, C53, is con-
placement. nected to the left side face of the ma-
★ Accumulate and manage machine data collected chine control monitor (CGC).
with the VHMS controller as WebCARE data- ★ Connect the personal computer to the
base. To process data smoothly on the Web- RS232C terminal.
CARE, set the VHMS controller consistently. If it
is not set correctly, data will not be taken in the
WebCARE and data in the VHMS controller may
not be utilized. So, be sure to set the controller at
the time of replacement.
★ For the installing method of the VHMS Initializa-
tion Program in the personal computer, refer to
the "Operation and Maintenance Manual" con-
tained in the package of the service kit, L1.
★ In the procedures, use the service menu on the
CGC monitor. See the paragraph of "Function
and Operation of CGC Monitor" and fully under-
stand the operating procedures in advance.
★ The setting procedures for replacement cover
both "ORBCOM specification" and "ORBCOMM-
LESS specification". In case of "ORBCOMM-
LESS specification", omit the procedures
necessary for "ORBCOMM specification" only.
★ During the setting work, make necessary confir-
mations for each work according to the "VHMS
Initialization Work Checklist".

20-224 PC1800-6
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

2. Performance Check of VHMS Controller 3. Downloading of Remaining Data

★ This step applies to works in the cab and the ★ This step applies to works in the cab (on the
cab under room. personal computer).
1) Set the starting switch to the ON position. 1) Set the starting switch to the ON position.
2) Check the 7-segment LED of the VHMS 2) Switch on the personal computer and start
controller and make sure that the controller the OS.
is operating normally. 3) Click the icon of [VHMS Technical Analysis
★ Since the switch power is supplied to the Tool] on the personal computer to start the
VHMS controller, it is normal when the 7- VHMS analysis tool.
segment LED blinks in rotating after the ★ Input [User Name] and [Password].
starting switch is turned on and, then, it ★ For the operation procedures, refer to
counts up. the Operation and Maintenance Manual
for VHMS Technical Analysis Tool.

4) Use the [Download] function to download

the remaining data recorded in the VHMS
controller to the personal computer.
★ For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
★ Make sure that the downloading has
completed before proceeding to the next
step.

5) Terminate the VHMS Technical Analysis

Tool.

PC1800-6 20-225
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

4. Check of Set Information

★ This step applies to works in the cab (on the
personal computer).
★ Checking the setting in [Communication Set-
ting] is for ORBCOMM specification only.
1) Click the icon of [VHMS Setting Tool] on the
personal computer to start the VHMS Set-
ting Tool.
2) Input the 10-digit service ID in [Service ID].
★ Service ID : 7826101001
★ The Service ID is the same as the one
used in the service menu of the machine
control monitor (CGC).
3) Select [Data clear and Set up] in the [Select
Function] column.
4) Press the [OK] button and move to the set-
ting screen.
6) Open the [Communication Setting] tab and
check all information.

7) After having check and recorded all informa-

tion, press the [Exit] button on the right
lower part of the screen to terminate [VHMS
Setting Tool].

5) Open the [Machine Information] tab, and

check and record all information.
★ In the [Data clear and Set up] menu, the
[Machine Information] is displayed first.

20-226 PC1800-6
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

8) Terminate the OS of the personal computer Work after Replacement of VHMS Controller
and switch off the personal computer. ★ The steps 5–18 apply to works on the new VHMS
9) Set the starting switch to the OFF position. controller after the replacement.
k When replacing the VHMS controller, it
is acceptable that the personal computer 5. Performance Check of ORBCOMM controller
is connected, but be sure to switch off (ORBCOMM specification only)
the personal computer and to turn off the ★ This step applies to works in the cab and the
starting switch. cab under room.
1) Make sure that the starting switch is set to
the OFF position.
2) Check the green LED of the ORBCOMM
controller and make sure that the controller
is operating.
★ Since the power is supplied to the ORB-
COMM controller all the time, the con-
troller is normal when the green LED is
ON while the starting switch is turned off.

PC1800-6 20-227
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

6. Connection Check of Personal Computer 7. Performance Check of VHMS Controller

★ This step applies to works in the cab. ★ This step applies to works in the cab and the
★ When disconnecting the personal computer cab under room.
during the work, connect it again referring to 1) Set the starting switch to the ON position.
"1. Connection of Personal Computer". 2) Check the 7-segment LED of the VHMS
1) Make sure that the starting switch is set to controller and make sure that the controller
the OFF position. is operating normally.
k Be sure to check the connection of the ★ Since the switch power is supplied to the
personal computer only when the start- VHMS controller, it is normal when the 7-
ing switch is set to the OFF position. segment LED blinks in rotating after the
2) Make sure that the personal computer and starting switch is turned on and, then, it
the download connector C53 are connected counts up.
the wiring harness (1).

20-228 PC1800-6
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

8. Startup of VHMS Setting Tool 9. Resetting of VHMS Controller

★ This step applies to works in the cab (on the ★ This step applies to works in the cab (on the
personal computer). personal computer).
1) Switch on the personal computer and start [Machine Information]
the OS. 1) Open the [Machine Information] tab.
2) Click the icon of [VHMS Setting Tool] on the ★ The [Machine Information] tab is dis-
personal computer to start the VHMS Set- played first in the [Data clear and Set up]
ting tool. menu.
3) Input the 10-digit service ID in [Service ID]. 2) Change all the data to the latest one or to
★ Service ID : 7826101001 the data recorded before the replacement.
★ The Service ID is the same as that to be
used in the service menu on the ma-
chine control monitor (CGC).
4) Select [Data clear and Set up] in the [Select
Function] column.

3) When correcting information in [Date/Time],

follow the procedures below:
★ Change the data in [Date/Time] except
for [Time Zone] to the correct data at the
time of correction.
i) Press the [Edit] button on the right lower
part of the [Date/Time] box to display
the correction screen.
ii) Change the information to the correct
one and then press the [OK] button.

PC1800-6 20-229
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

4) When correcting the information in [SMR], 6) After having checked and changed all data
follow the procedures below: in [Machine Information], press the [Apply]
★ Be sure to set the value obtained by add- button to settle the setting.
ing 0.1h to the data recorded before the ★ Press the [Apply] button, and the screen
replacement to the service meter. for checking the setting will appear.
Example : Check the setting again and press the
123.4h (before replacement)⇒ [OK] button when the setting is correct.
123.5h (for resetting) ★ In case of the ORBCOMM specification,
★ If an incorrect value is set to the service execute [Communication Setting] and
meter, data will come not to be managed settle it.
on the WebCARE database. So, be sure
to set correct values.
Delete the value in the [SMR (h)] and input
the new value to be set.

5) When correcting information in the [Machine

Information], follow the procedures below:
i) Press the [Edit] button on the right lower
part of the [Machine Information] box to
display the correction screen.
ii) Change the information to the one
recorded before the replacement and
then press the [OK] button.

20-230 PC1800-6
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

[Communication Setting] 10) To change setting in [SHORT TREND

(ORBCOMM specification only) ANALYSIS], follow the procedures below:
7) Open the [Communication Setting] tab. i) Select [SHORT TREND ANALYSIS] on
8) Change all the data to the one recorded the screen and press the [Edit] button
before the replacement. on the left lower part of the [File Trans-
fer Setting] block to display the setting
screen.
ii) Change the setting to the one recorded
before the replacement and then press
the [OK] button.

9) To change setting in [SHORT FAULT

HISTRY], follow the procedures below:
i) Select [SHORT FAULT HISTRY] on the
11) After having checked and changed all data
screen and press the [Edit] button on
in [Communication Setting], press the
the left lower part of the [File Transfer
[Apply] button to settle the setting.
Setting] block to display the setting
★ Press the [Apply] button, and the screen
screen.
for checking the setting will appear.
ii) Change the setting to the one recorded
Check the setting again and then press
before the replacement and then press
the [OK] button when the setting is cor-
the [OK] button.
rect.

PC1800-6 20-231
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

[Exit] 10. Check of Storage Operation of VHMS

12) After having changed all the data in Controller
[Machine Information] and [Communication ★ This step applies to works in the cab and the
Setting], press the [Exit] button on the right cab under room
lower part of the screen to terminate [VHMS 1) Set the starting switch to the OFF position.
Initialization Tool]. 2) Check the 7-segment LED of the VHMS
controller and make sure that the controller
power has been completely cut off.
★ The VHMS controller records and up-
dates data when the starting switch is
turned off.
★ The controller power is retained for stor-
age operation for several seconds after
the starting switch is turned off. So,
make sure that the 7-segment LED of
the controller has completely gone out.

20-232 PC1800-6
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

11. Performance Check of VHMS Controller 12. Execution of Quick PM Clinic

★ This step applies to works in the cab and the ★ This step applies to works in the cab.
cab under room. 1) Start the engine and idle it low.
1) Set the starting switch to the ON position. 2) Set the operation mode to the DH Mode and
2) Check the 7-segment LED of the VHMS bring the safety lock lever to the release
controller and make sure that the controller position.
is operating normally. 3) Let the CGC monitor display the service
★ Since the switch power is supplied to the menu select screen.
VHMS controller, it is normal when the 7- ★ See the paragraph of "Function and Op-
segment LED blinks in rotating after the eration of CGC Monitor".
starting switch is turned on and, then, it 4) Select [Snapshot].
counts up.

5) Keep operating the screen and start snap-

shooting.
★ Press the [Start] button on the screen
below, and the confirmation message
will appear.
★ Before staring snapshooting, fully under-
stand the snapshooting procedures.

PC1800-6 20-233
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

6) Operate switches and levers for each run ★ Execute the quick PM clinic twice, i.e., once for
time according to "Quick PM Clinic Opera- the front engine system and once for the rear en-
tion Procedures" in the table below. gine system.
★ Run times are displayed on the machine ★ One NC pressure sensor is available in the tool-
control monitor (CGC). box. Connect it to respective measuring couplers
k Since the work equipment and travel according to the measurement procedures.
have to be operated practically in the • NC Pressure Measuring Coupler on the front en-
quick PM clinic, pay sufficient attention gine side
to safety around during the operation. F: No.1 and 2 front pumps NC pressure
R: No.1 and 2 rear pumps NC pressure
S: Front swing pump NC pressure

• NC Pressure Measuring Coupler on the rear

engine side
F: No.3 and 4 front pumps NC pressure
R: No.3 and 4 rear pumps NC pressure
S: Rear swing pump NC pressure

20-234 PC1800-6
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

Quick PM Clinic Operation Procedures

(For each engine)

Switch NC pres-
Time in
Se- Work- Auto- sure
Run time snap data Fuel dial Heavy Swing Control lever Data read to PM clinic
quence ing decel- sensor
(sec.) lift lock
Mode eration position
0 sec. –300.00 . Engine speed (Low idling
Low
1 ↓ ↓ DH OFF OFF OFF — All neutral . Engine oil pressure (Low idling)
(MIN)
30 sec. –270.00 . Ambient temperature
. Engine speed (High idling
. Engine oil pressure (High idling)
30 sec. –270.00
High . Control pump oil pressure
2 ↓ ↓ ↑ ↑ ↑ ↑ All neutral
(MAX) . TVC valve output pressure
1 min. 30 sec. –210.00
. NC valve output pressure
. Swing NC valve output pressure
1 min. 30 sec. –210.00
. Engine speed
3 ↓ ↓ ↑ ↑ ON ↑ ↑ All neutral
(Auto-deceleration)
2 min. –180.00
2 min. –180.00 ★ Lift the R.H track with the work
R.H. travel operation
4 ↓ ↓ ↑ ↑ ↑ ↑ ↑ F equipment first.
(R.H. travel full idling)
3 min. 30 sec. –90.00 . Front NC valve output pressure
3 min. 30 sec. –90.00 ★ Lift the L.H track with the work
L.H. travel operation
5 ↓ ↓ ↑ ↑ ↑ ↑ ↑ R equipment first.
(L.H. travel full idling)
5 min. 0.00 . Rear NC valve output pressure
5 min. 0.00
Swing operation
6 ↓ ↓ ↑ ↑ ↑ ↑ ON S . Swing pump oil pressure
(Swing relief)
5 min. 30 sec. 30.00
5 min. 30 sec. 30.00
Boom RAISE opera- . Engine speed (Relief)
7 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (RAISE relief) . TVC valve output pressure
5 min. 45 sec. 45.00
. Engine speed (Relief)
5 min. 45 sec. 45.00
Boom RAISE opera- . Blow-by pressure
8 ↓ ↓ ↑ ↑ ↑ ON ↑
tion (RAISE relief) . Exhaust gas temperature
6 min. 60.00
. TVC valve output pressure
6 min. 60.00
Arm IN operation (IN . Main pump oil pressure
9 ↓ ↓ ↑ ↑ ↑ ↑ ↑
relief) . Boost pressure
6 min. 30 sec. 90.00
6 min. 30 sec. 90.00
Arm OUT operation
10 ↓ ↓ ↑ ↑ ↑ ↑ ↑
(OUT relief)
6 min. 50 sec. 110.00
6 min. 50 sec. 110.00
Bucket DUMP opera-
11 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (DUMP relief)
7 min. 10 sec. 130.00
7 min. 10 sec. 130.00
Bucket digging opera-
12 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (Digging relief)
7 min. 30 sec. 150.00
Low
13 7 min. 30 sec. 150.00 ↑ ↑ ↑ ↑ End
(MIN)

• NC Pressure Measuring Coupler on Front • NC Pressure Measuring Coupler on Rear Engine

Engine Side Side

PC1800-6 20-235
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

13. Check of Storage Operation of VHMS 14. Downloading of Set Data

Controller ★ This step applies to works in the cab (on the
★ This step applies to works in the cab and the personal computer).
cab under room 1) Set the starting switch to the ON position.
1) Set the starting switch to the OFF position. 2) Click the icon of [VHMS Technical Analysis
2) Check the 7-segment LED of the VHMS Tool] on the personal computer to start the
controller and make sure that the controller VHMS Technical Analysis Tool.
power has been completely cut off. ★ Input [User Name] and [Password].
★ The VHMS controller records and up- ★ For the operation procedures, refer to
dates data when the starting switch is the Operation and Maintenance Manual
turned off. for VHMS Technical Analysis Tool.
★ The controller power is retained for stor-
age operation for several seconds after
the starting switch is turned off. So, con-
firm that the 7-segment LED of the con-
troller has completely gone out.

3) Use the [Download] function to download

the data recorded in the VHMS controller to
the personal computer.
★ For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
★ Make sure that the downloading has
completed before proceeding to the next
step.

20-236 PC1800-6
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

15. Check of Downloaded Data 16. Setting for Satellite Communication

★ This step applies to works in the cab (on the (ORBCOMM specification only)
personal computer). ★ This step applies to works in the cab (on the
1) Check the set data with the [View] function. personal computer).
★ For the operation procedures, refer to 1) See the procedures in "5. Startup of VHMS
the Operation and Maintenance Manual Setting Tool" and start the VHMS Setting
for VHMS Technical Analysis Tool. tool.
★ Make sure that the [MFA0] code at the ★ [Select Function] selects [Set up].
time of quick snapshot is displayed in
[Fault History]
★ Make sure that the snapshot data has
been recorded.

2) After having check the set data, terminate

[VHMS Technical Analysis Tool].

2) Open the [Communication Setting] tab.

3) Change the setting of [Satellite Setting] to
the setting recorded before the replace-
ment.

PC1800-6 20-237
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

4) To change the setting of [Satellite Setting], 17. Check of Storage Operation of VHMS
follow the procedures below: Controller
i) Press the [Edit] button in the [Satellite ★ This step applies to works in the cab and the
Setting] block to display the setting cab under room
screen. 1) Set the starting switch to the OFF position.
ii) Bring GCC Code to the applicable area 2) Check the 7-segment LED of the VHMS
and then press the [OK] button. controller and make sure that the controller
power has been completely cut off.
★ The VHMS controller records and up-
dates data when the starting switch is
turned off.
★ The controller power is retained for stor-
age operation for several seconds after
the starting switch is turned off. So, con-
firm that the 7-segment LED of the con-
troller has completely gone out.

GCC Code and Application Area

Code Applicable Area
1 U.S.A.
120 Italy
121 Malaysia
122 Korea
123 Brazil
130 Japan

20-238 PC1800-6
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER

18. Disconnection of Personal Computer 19. Communication to Komatsu

★ This step applies to works in the cab. After having completed Steps 1 to 17 success-
1) Make sure that the starting switch is set to fully, please send the checklist and the VHMS
the OFF position. data to Komatsu, Tokyo.
k Be sure to turn off the starting switch be- Komatsu, Tokyo, has to arrange the setting for
fore connecting and disconnecting the satellite communication on the receive side,
personal computer. please be sure to inform Komatsu of the com-
2) Terminate the OS of the personal computer, pletion of the setting.
L2, and switch off the personal computer. ★ Fax the checklist to Komatsu.
3) Disconnect the wiring harness (1) of the ★ Send the VHMS data by Notes (LAN) or E-
service kit, L1, from the download connec- mail (WAN).
tor, C53.
Contact VHMS/WebCARE Support Center by
Telephone : 81-3-5561-2765
FAX : 81-3-5561-4766
E-mail : [email protected]

PC1800-6 20-239
TESTING AND ADJUSTING SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER
To : VHMS/WebCARE Support Team, Komatsu, Tokyo Set date :
Fax date :
PC1800-6 DB/ Branch name :
VHMS Initialization Work Checklist Person in charge :

Setting Step Check Item Result

1 Connection of Personal Computer Is it connected correctly? yes no

2 Performance Check of VHMS Controller Is the 7-segment LED operating normally? yes no

3 Downloading of remaining data Did the downloading complete? yes no

Date(mm/dd/yyyy)
Date/Time Time
[Local Time] Time zone GMT+
DST(Summer Time) On Off
SMR SMR(h)
Product Group
Machine Model
Check of set information Machine Type
4 Variation code
(Items marked with * are for Serial No.
ORBCOMM specification only.)
Engine Model
Engine Engine Serial No.1
Engine Serial No.2
SHORT FAULT Send On Off
HISTY[*] Number (Default : 10)
SHORT TREND Send On Off
ANALYSIS[*] Interval (Default : 180) (SMR)

Performance check of ORBCOMM controller

5 Is the green LED on? yes no
(ORBCOMM specification only)

6 Connection check of personal computer Is it connected correctly? yes no

7 Performance check of VHMS controller Is the 7-segment LED operating normally? yes no

8 Startup of VHMS initialization tool Is [Data clear and Set up] selected as the function of the initialization tool? yes no

Date/Time yes no
Did you match the setting with the record before the replacement?
[Local Time]
SMR Did you add 0.1h to the record before the replacement for the setting? yes no
Resetting of VHMS controller Machine Did you match the setting with the record before the replacement? yes no
9 Engine Did you match the setting with the record before the replacement? yes no
(Items marked with * are for SHORT FAULT
ORBCOMM specification only.) Did you match the setting with the record before the replacement? yes no
HISTY[*]
SHORT TREND
Did you match the setting with the record before the replacement? yes no
ANALYSIS[*]

10 Check of Storage Operation of VHMS Controller Did the 7-segment LED go out? yes no

11 Performance Check of VHMS Controller Is the 7-segment LED operating normally? yes no

12 Execution of Quick PM Clinic Have you arranged the snap shot as per the procedures? yes no

13 Check of Storage Operation of VHMS Controller Did the 7-segment LED go out? yes no

14 Downloading of Set Data Have you completed the downloading? yes no

Could you download all files? yes no

What time did you download (by your wrist watch)? Time
15 Check of Downloaded Data Is the [MFAO] code displayed in the Fault History yes no
Data Check Do SMR and Time match with the set values in the Fault History yes no
Is no data missing in the Snapshot? yes no

Setting for Satellite Communication yes no

16 Did you match the setting with the record before the replacement?
(ORBCOMM specification only)

17 Check of Storage Operation of VHMS Controller Did the 7-segment LED go out? yes no

18 Disconnection of Personal Computer Did you disconnect it correctly? yes no

Contact VHMS/WebCARE Support Team, Komatsu, Tokyo by

• Telephone : 03-5561-2765 (Nation Code 81)
19 Communication to Komatsu
• FAX:03-5561-4766 (Nation Code 81)
• E-mail:[email protected]

20-240 PC1800-6
TESTING AND ADJUSTING TESTING AND ADJUSTING DEVICES RELATED TO VHMS

TESTING AND ADJUSTING DEVICES RELATED TO VHMS

1. Testing engine blow-by pressure sensor

★ The engine blow-by pressure sensor is a fine rel-

ative pressure sensor which introduces the en-
gine crankcase pressure from its end "a" and
atmospheric pressure from intermediate part "b"
of the wiring harness to measure the difference
between those pressures.
★ Accordingly, if oil, dust, water, etc. sticks to part
"b" to introduce atmospheric pressure, the at-
mospheric pressure cannot be introduced stably.
As a result, the atmospheric pressure cannot be
measured normally.
★ If VHMS detects abnormal blow-by pressure and
the sensor seems to be defective, check whole
wiring harness "c" including part "b" to introduce
atmospheric pressure for oil, dust, water, etc. be-
fore replacing the sensor. If part "b" or "c" is not
clear, clean it.

PC1800-6 20-240-1
TESTING AND ADJUSTING TESTING AND ADJUSTING DEVICES RELATED TO VHMS

2. Testing and adjusting fitting position of front engine blow-by pressure sensor

★ As described in 1 above, the blow-by pressure ★ Clamping parts

sensor introduces atmospheric pressure from The part Nos. are subject to change. Accord-
the wiring harness. ingly, when placing an order for a part, be sure
★ Accordingly, if the sensor wiring harness is not to check the part No. of that part with the parts
installed along the correct rout, atmospheric list.
pressure cannot be introduced stably. As a re-
sult, the atmospheric pressure cannot be meas- No. Part No. Part name Q'ty
ured normally. 1 6218-81-4110 Sensor assembly 1
★ If VHMS detects abnormal front engine blow-by
pressure and the sensor seems to be defective, 2 04434-50610 Clip 1
check the installation condition of the wiring har-
3 08034-20519 Band 4
ness before replacing the sensor. If the wiring
harness is installed abnormally, correct it. 4 04434-50610 Clip 1
★ If the blow-by pressure sensor was removed, be
sure to install it according to the drawing. 5 08193-20012 Clip 1
★ Note that the installation condition of the wiring
harness of the front engine is different from that
of the rear engine.

20-240-2 PC1800-6
TESTING AND ADJUSTING TESTING AND ADJUSTING DEVICES RELATED TO VHMS

3. Testing and adjusting fitting position of rear engine blow-by pressure sensor

★ As described in 1 above, the blow-by pressure ★ Clamping parts

sensor introduces atmospheric pressure from The part Nos. are subject to change. Accord-
the wiring harness. ingly, when placing an order for a part, be sure
★ Accordingly, if the sensor wiring harness is not to check the part No. of that part with the parts
installed along the correct rout, atmospheric list.
pressure cannot be introduced stably. As a re-
sult, the atmospheric pressure cannot be meas- No. Part No. Part name Q'ty
ured normally. 1 6218-81-4110 Sensor assembly 1
★ If VHMS detects abnormal rear engine blow-by
pressure and the sensor seems to be defective, 2 04434-50610 Clip 1
check the installation condition of the wiring har-
3 08034-20519 Band 4
ness before replacing the sensor. If the wiring
harness is installed abnormally, correct it. 4 04434-50610 Clip 1
★ If the blow-by pressure sensor was removed, be
sure to install it according to the drawing. 5 08193-20012 Clip 1
★ Note that the installation condition of the wiring
harness of the front engine is different from that
of the rear engine.

PC1800-6 20-240-3
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)

ADJUSTMENT OF WORK EQUIPMENT CONTROLLER

(LOADING SHOVEL)
★ The controller basically does not need adjust-
ment. However, there are variations in compo-
nents other than the controller, so adjust on the
machine in the following cases.
1) When newly assembling the machine
2) When replacing the work equipment potenti-
ometer (or when re-assembling the work
equipment), and the horizontal digging and
bucket angle compensation (if equipped) do
not provide the specified performance.

1. Explanation of controller parts

1) LED display window
The LED display window (1) is peephole to
see the four LED lamps showing the operat-
ing condition of the control box without
opening the cover of the controller. (For
details, see STRUCTURE AND FUNC-
TION.)

2) Adjustment trimmer window

The adjustment trimmer window (2) is a win-
dow with a cover held by four screws. When
adjusting, remove this cover. Inside, there
are seven trimmers. Turn the trimmers indi-
cated where necessary when adjusting.
★ VR1: When carrying out horizontal dig-
ging operations, this is used to
adjust the height of the work
equipment movement so that the
horizontal digging can be carried
out at a higher or lower position
than the machine level.
VR2: With the bucket angle compen-
sation, this trimmer is used to
adjust the compensation (angle)
if it is too large or too small.
VR3: To prevent shock at the end of
the stroke when carrying out hor-
izontal digging operations, the
horizontal path moves slightly
u p wa r d n e ar t h e e n d o f t he
stroke.
Use this trimmer to adjust when
changing the position for the
upward movement.
VR4: This trimmer basically does not
need adjustment; ther efore,
never turn it.

PC1800-6 20-241
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)

VR5: This trimmer can be used to

change the response of BOOM
LOWER when controlling hori-
zontal digging.
★ If it is turned too far clock-
wise, it is liable to cause
hunting (vibration) in the
work equipment when manu-
al intervention is made.
VR6: This trimmer can be used to
adjust the amount of compensa-
tion of the dead band (area of no
feeling) of the EPC valves.
VR7: Spare (no function)

2. Precautions when adjusting

1) Stop the machine on level ground when
adjusting.
2) When removing the screws from the adjust-
ment trimmer window, be careful not to lose
them.
3) Do not allow any water, oil, metal particles
(screws, etc.) or dirt or dust to get inside the
adjustment trimmer window.
For this reason, adjustment must not be car-
ried out when it is raining or snowing.
4) Always turn the starting switch OFF before
turning any trimmer.
5) When turning the trimmer, use a small flat-
head or cross-head screwdriver.
6) When turning the trimmer, be careful not to
let screwdriver touch any other parts inside
the controller.
7) Carry out the adjustment with the hydraulic
oil temperature at 45 to 55°C.
8) Carry out adjustment according to the pro-
cedure given in Step 3.
Do not carry out any adjustment for items
where there is no problem.
9) After completion of adjustment, always put
the cover back on the adjustment trimmer
window and fasten it with the four screws.
3 Screws:
1.5 – 2.0 Nm {0.15 – 0.2 kgm}

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TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)

3. Adjustment methods When path suddenly rises

1) When path suddenly goes down at the
beginning of horizontal digging;
When path suddenly rises at the begin-
ning of horizontal digging;
In the horizontal digging mode, when fine
control in the ARM OUT direction is carried
out from a position where the arm is nearly
perpendicular, if the height (H) of the arm
top pin goes up and down as shown in the
arm top pin goes up and down as shown in
the diagram on the right, adjust trimmer
VR6.
Adjust trimmer VR6 as follows.
• If arm top pin goes UP:
Turn trimmer VR6 CLOCKWISE. When path suddenly goes down
• If arm top pin goes DOWN:
Turn trimmer VR6 COUNTER-
CLOCKWISE.

2) When making the path of digging face up Facing up

compared to the horizontal level;
When making the path of digging face
down compared to the horizontal level;
In horizontal digging mode, when the path of
digging faces up or down compared to the
horizontal level, turn adjustment trimmer
VR1 to make the path horizontal.
Adjust trimmer VR1 as follows.
• When path faces UP:
Turn VR1 CLOCKWISE.
• When path faces DOWN:
Turn VR1 COUNTERCLOCKWISE.
★ Carry out this adjustment at the height
most commonly used by the bucket in
actual operation. Facing down
NOTE: If the arm top pin height (H) is
more than 2.5 m, the horizontal
digging control does not work.

★ It is also possible to set the direction fac-

ing up and down to meet the needs of
the operation. However, it is not possible
to make big changes in the angle to give
angles such as used in slope finishing.
(Possible adjustment range: Approx.
±3°)

PC1800-6 20-243
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)

3) During horizontal digging control, when When boom moves down too far
stopping gradually before the end of the
stroke, if the boom moves down too far;
During horizontal digging control, when
there is manual intervention, if hunting
(vibration) occurs in the work equip-
ment;
In horizontal digging mode, when stopping
gradually before the end of the stroke, if the
delay in the stopping of the BOOM LOWER
movement is too great, and the boom goes
down too far, or at the time of manual inter-
vention, if hunting (vibration) occurs in the
work equipment adjust with VR5 as follows.
• If the boom goes down too far:
Turn trimmer VR5 CLOCKWISE. When there is hunting (vibrarion)
• When there is hunting:
Turn trimmer VR5 COUNTER-
CLOCKWISE.

4) If there is shock when stopping BOOM

LOWER at the end of the stroke in hori-
zontal digging control;
If the path in the upward direction before
the end of the stroke in horizontal dig-
ging control is too large;
In horizontal digging mode, if there is shock
when stopping at the end of the BOOM
LOWER stroke (if width W is too small), or if
the path faces up too much before the end
of the stroke, (if width W is too large), adjust
trimmer VR3 as follows to correct the width.
• If width W is too small (there is shock):
Turn trimmer VR3 CLOCKWISE.
• If width W is too large (path goes up too
much before end of stroke):
Turn trimmer VR3 COUNTER-
CLOCKWISE.

20-244 PC1800-6
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)

5) When the amount of compensation Too large.

(angle) of the bucket angle compensa-
tion is too large;
W hen the amount of compensat ion
(angle) of the bucket angle compensa-
tion is too small;
In the bucket angle compensation mode,
when the amount of compensation of the
bucket angle compensation in BOOM
RAISE operations is too large (load spills
towards operator’s cab) or too small (load
spills out of front of bucket), turn trimmer
VR2 to give a suitable amount of adjust-
ment.
• If the amount of compensation is too
large: Too small
Turn trimmer VR2 CLOCKWISE.
• If the amount of compensation is too
small:
Turn trimmer VR2 COUNTER-
CLOCKWISE.

★ However, the setting can be made slight-

ly larger or slightly smaller to meet the
needs of the operation.

PC1800-6 20-245
Pm-CLINIC SERVICE PC1800-6
BASE INFORMATION
CUSTOMER NAME LOCATION DELIVERY
Month / Day / Year
/ /

CUSTOMER'S No. SERIAL No. ENGINE No.

Front Engine:#
Rear Engine:#

SPECIFICATION
PC1800-6 Back hoe
12(15.5) m3 (cu.yd)
Bucket (SAE)
5040 mm
Arm
8700 mm
Boom
810 mm
Track shoe width 1010 mm

KIND OF JOB
Mining Construction High way & Road Water supply
Forestry Scrap Demolition ( )

KIND OF OPERATION
Digging & Loading Basement digging Crash hard rock Other

KIND OF SOIL
Rock
Gravel Sand Clay Soil

SCHEDULED WORKING HOUR

Shifts/day Hours/shift

1 2 3
hrs.

DISTRIBUTOR NAME

20-246 PC1800-6
 MEASURING PROCEDURES

OUTLINE OF PM CLINIC MEASURING

PROCEDURES

The PM Clinic Measuring Procedures of PC1800-6

cover the following three kinds:
★ These procedures are basically executed in
Measuring Procedures 1 and 2.

1. Measuring Procedures with CGC Monitor

The "PM Clinic Function" of the CGC monitor
enables to read data from the PM clinic screen.

2. Measuring Procedures with Stopwatch,

Scale, etc.
Stopwatch, scale, etc. are used for individual
measurements.

3. Measuring Procedures by Downloading Data

from VHMS Controller
A personal computer is connected to the VHMS
controller, quick PM clinic is executed with the
CGC monitor, and data are downloaded to the
personal computer.
★ The measuring procedures require the fol-
lowing tools:

Symbol Part Number Part Name

799-608-3101 Service kit
1 799-608-3210 • Diskette
799-608-3220 • Wiring harness
Notebook type per-
Commercial sonal computer
2
L article (OS : Windows98/
2000)
Coupling assem-
21T-06-64590 bly (Accessory
3 tool)
Harness
21T-06-64392
(Accessory tool)

PC1800-6 20-247
 MEASURING PROCEDURES

PREPARATORY WORK FOR

PM CLINIC MEASUREMENT

1. Check safety around and start the front engine

and the rear engine.

2. Set the CGC monitor to Service Menu, select

the "PM Clinic" menu and display "PM Clinic (1/
6)".
★ For the operating method, see the paragraph
of Function and Operation of CGC monitor.

3. Warm up the engine and raise engine water

temperature and hydraulic oil temperature.
• Engine water temperature : 40°C min.
• Hydraulic oil temperature : 40°C min.

4. Park the machine on a level ground.

5. Prepare to lock travel.

k When measuring travel relief oil pressure,
fix the sprocket on the measuring side.
k When measuring traveling speed without
load, push up the track shoe on the measur-
ing side.

6. Lower the work equipment completely to the

ground and stop the engine.

20-248 PC1800-6
 MEASURING PROCEDURES

MEASURING PROCEDURES
WITH CGC MONITOR

1. Starting the engine

1) Make sure that the CGC monitor is not dis-
playing any abnormal screen.
2) Prepare a PM clinic sheet, check safety
ar ound, sound the hor n and start the
engine.
3) Set the swing lock switch to the OFF posi-
tion.
4) Set the safety lock lever to the release posi-
tion.

2. Checking indications on engine water tem-

perature gauge and PTO oil temperature
gauge.
1) Display the monitor screen (1/2) on the
machine control monitor .
2) Check indications on the engine water tem-
perature gauge and the PTO oil temperature
gauge.

3. Changing display on CGC monitor

Set the service menu on the CGC monitor and
select the "PM Clinic" menu.
★ For the operating method, see the paragraph
of Function and Operation of CGC monitor .

4. Measuring on "PM Clinic (1/6)"

1) Display "PM Clinic (1/6)".
2) Measure ambient temperature, engine
water temperature, engine oil pressure and
hydraulic oil temperature.
★ For the measuring conditions, see the
checklist."

PC1800-6 20-249
 MEASURING PROCEDURES

5. Measuring on "PM Clinic (2/6)"

1) Display "PM Clinic (2/6)".
2) Measure front engine speed, boost pres-
sure, blow-by pressure and exhaust gas
temperatures (front side and rear side).
★ For the measuring conditions, see the
checklist.

6. Measuring on "PM Clinic (3/6)"

1) Display "PM Clinic (3/6)".
2) Measure rear engine speed, boost pres-
sure, blow-by pressure and exhaust gas
temperatures (front side and rear side).
★ For the measuring conditions, see the
checklist."

7. Measuring on "PM Clinic (4/6)"

1) Display "PM Clinic (4/6)".
2) Measure front engine PTO oil temperature,
front work equipment & travel pump pres-
sure, front NC pressure, front swing pump
pressure and front TVC pressure.
★ For the measuring conditions, see the
checklist.
★ Before measuring front NC pressure,
connect the coupling assembly L3 to the
respective NC measuring couplers of
No. 2 front pump, No. 4 front pump and
front swing pump.
★ NC pressure measuring coupler on the
front engine side
F: No.1 and 2 front pumps' NC pressure
R: No.1 and 2 rear pumps' NC pressure
S: Rear swing pump NC pressure
★ When measuring TVC pressure, con-
nect the NC pressure sensor to the front
TVC pressure measuring coupler and
read indication of NC pressure.

20-250 PC1800-6
 MEASURING PROCEDURES

8. Measuring on "PM Clinic (5/6)"

1) Display "PM Clinic (5/6)".
2) Measure rear engine PTO oil temperature,
rear work equipment & travel pump pres-
sure, rear NC pressure, rear swing pump
pressure and rear TVC pressure.
★ For the measuring conditions, see the
checklist.
★ Before measuring rear NC pressure,
connect the coupling assembly L3 to the
respective NC measuring couplers of
No. 2 rear pump, No. 4 rear pump and
rear swing pump.
★ NC pressure measuring coupler on the
rear engine side
F: No.3 and 4 front pumps' NC pressure
R: No.3 and 4 rear pumps' NC pressure
S: Rear swing pump NC pressure
★ When measuring TVC pressure, con-
nect the NC pressure sensor to the rear
TVC pressure measuring coupler and
read indication of NC pressure.

9. Measuring on "PM Clinic (6/6)"

Use "PM Clinic (6/6)" when you would like to
check engine speeds and work equipment &
travel pump pressures at the same time.
★ PM clinic items can be measured from (1/6)
to (5/6).

10. Measuring work equipment speed and

hydraulic drift
Use stopwatch and scale to measure work
equpment speed and hydraulic drift.

PC1800-6 20-251
 MEASURING PROCEDURES

MEASURING PROCEDURES BY
DOWNLOADING DATA FROM
VHMS CONTROLLER

1. Connecting personal computer

1) Make sure that the starting switch is set to
the OFF position.
k Be sure to connect or disconnect the
personal computer only when the start-
ing switch is set to the OFF position.
2) Connect the personal computer L2 and the
download connector C53 with the wiring
harness [1] in the service kit L1.
★ The download connector C53 is fitted on
the left side face of the CGC monitor .
★ Connect the personal computer side to
the RS232C terminal.

2. Starting engine
1) Make sure that the CGC monitor is not dis-
playing any abnormal screen.
2) Prepare a PM clinic sheet, check safety
around, s ound the horn and start the
engine.
3) Set the swing lock switch to the OFF posi-
tion.
4) Set the safety lock lever to the release posi-
tion.

3. Changing display on CGC monitor

1) Let the CGC monitor display the service
menu select screen.
★ See the paragraph of "Function and Op-
eration of CGC monitor".
2) Select "Snapshot".

4. Snapshooting
1) Keep operating the screen and start snap-
shooting.
★ Press the [Start] button on the screen
shown on the right side and display he
confirmation message.
★ Before starting snapshooting, fully un-
derstand the snapshooting procedures.

20-252 PC1800-6
 MEASURING PROCEDURES

2) Operate switches and levers for each run

time according to the "Quick PM Clinic
Operating Procedures" in the table below.
★ Run times are shown on the machine
control monitor .
k For quick PM clinic, the work equipment
and travel have to be operated practical-
ly. So, pay necessary attention to safety
around during the work.

★ Execute the quick PM clinic twice, once for

the front engine system and once for the rear
engine system.
★ One NC pressure sensor is available in the
toolbox. Connect it to respective measuring
couplers according the measuring proce-
dures.
• NC pressure measuring coupler on the front
engine side
F : No. 1 and 2 front pumps' NC pressure
R : No. 1 and 2 rear pumps' NC pressure
S : Rear swing pump NC pressure
• NC pressure measuring coupler on the rear
engine side
F : No. 3 and 4 front pumps' NC pressure
R : No. 3 and 4 rear pumps' NC pressure
S : Rear swing pump NC pressure

PC1800-6 20-253
 MEASURING PROCEDURES

Quick PM Clinic Operation Procedures (For each engine)

Switch NC pres-
Time in
Se- Work- Auto- sure
Run time snap data Fuel dial Heavy Swing Control lever Data read to PM clinic
quence ing decel- sensor
(sec.) lift lock
Mode eration position
0 sec. –300.00 . Engine speed (Low idling
Low
1 ↓ ↓ DH OFF OFF OFF — All neutral . Engine oil pressure (Low idling)
(MIN)
30 sec. –270.00 . Ambient temperature
. Engine speed (High idling
. Engine oil pressure (High idling)
30 sec. –270.00
High . Control pump oil pressure
2 ↓ ↓ ↑ ↑ ↑ ↑ All neutral
(MAX) . TVC valve output pressure
1 min. 30 sec. –210.00
. NC valve output pressure
. Swing NC valve output pressure
1 min. 30 sec. –210.00
. Engine speed
3 ↓ ↓ ↑ ↑ ON ↑ ↑ All neutral
(Auto-deceleration)
2 min. –180.00
2 min. –180.00 ★ Lift the R.H track with the work
R.H. travel operation
4 ↓ ↓ ↑ ↑ ↑ ↑ ↑ F equipment first.
(R.H. travel full idling)
3 min. 30 sec. –90.00 . Front NC valve output pressure
3 min. 30 sec. –90.00 ★ Lift the L.H track with the work
L.H. travel operation
5 ↓ ↓ ↑ ↑ ↑ ↑ ↑ R equipment first.
(L.H. travel full idling)
5 min. 0.00 . Rear NC valve output pressure
5 min. 0.00
Swing operation
6 ↓ ↓ ↑ ↑ ↑ ↑ ON S . Swing pump oil pressure
(Swing relief)
5 min. 30 sec. 30.00
5 min. 30 sec. 30.00
Boom RAISE opera- . Engine speed (Relief)
7 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (RAISE relief) . TVC valve output pressure
5 min. 45 sec. 45.00
. Engine speed (Relief)
5 min. 45 sec. 45.00
Boom RAISE opera- . Blow-by pressure
8 ↓ ↓ ↑ ↑ ↑ ON ↑
tion (RAISE relief) . Exhaust gas temperature
6 min. 60.00
. TVC valve output pressure
6 min. 60.00
Arm IN operation (IN . Main pump oil pressure
9 ↓ ↓ ↑ ↑ ↑ ↑ ↑
relief) . Boost pressure
6 min. 30 sec. 90.00
6 min. 30 sec. 90.00
Arm OUT operation
10 ↓ ↓ ↑ ↑ ↑ ↑ ↑
(OUT relief)
6 min. 50 sec. 110.00
6 min. 50 sec. 110.00
Bucket DUMP opera-
11 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (DUMP relief)
7 min. 10 sec. 130.00
7 min. 10 sec. 130.00
Bucket digging opera-
12 ↓ ↓ ↑ ↑ ↑ ↑ ↑
tion (Digging relief)
7 min. 30 sec. 150.00
Low
13 7 min. 30 sec. 150.00 ↑ ↑ ↑ ↑ End
(MIN)

• NC Pressure Measuring Coupler on Front • NC Pressure Measuring Coupler on Rear Engine

Engine Side Side

20-254 PC1800-6
 MEASURING PROCEDURES

5. Downloading snapshot data

1) Switch on the personal computer and start
the OS.
2) Click the icon of [VHMS Analysis Tool] on
the personal computer and start the VHMS
analysis tool.
★ Input [User Name] and [Password].
★ For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Analysis Tool.
3) Use the function of [Download] and down-
load the data recorded in the VHMS control-
ler to the personal computer.
★ For the operation procedures and the
data analyzing method, refer to the Op-
eration and Maintenance Manual for
VHMS Analysis Tool.

PC1800-6 20-255
 Pm-CLINIC SERVICE PC1800-6
SERIAL No.
#
ENGINE No.(SAA6D140E-3)
Back hoe
HOUR INSPECTION (F)# (R)#

WORK ORDER No. CARRIED OUT DATE SERVICE METER INSPECTED BY

OPERATOR'S OPINION & WORK AROUND CHECK Sat Us

Before starting, Any abnormally?

(F) Coolant Temp. max. range? (F) PTO oil Temp. max. range? Ambient Temp.
Blue Red Blue Red Max. ˚C(˚F)
Min. ˚C(˚F)
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 Altitude m(Ft)
(during operation) (during operation)
(R) Coolant Temp. max. range? (R) PTO oil Temp. max. range?
Blue Red Blue Red
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
(during operation) (during operation)
STD.: Standard Value
PMS.: Permissible Value
ITEM Condition Unit STD. PMS. Result Sat Us
AFTER STARITING ENGINE Front Rear —
1 ENGINE

1-1 Eng. Low idling 775 – 875 775 – 875

Eng. High idling 1930 – 2030 1930 – 2030
Eng. Full
Boom RAISE relief 1650 – 1850 1650 – 1850
Eng. Speed rpm
Eng. Full
(DH Mode) Boom RAISE relief + Heavy Lift ON 1650 – 1850 1650 – 1850
Auto - deceleration swith ON
Fuel control dial Max. 1300 – 1500 1300 – 1500
Control levers at neutral
1-2 Eng. Fully, DH Mode, kPa Max. 1.96 Max. 3.92
Blow - by Press. Boom RAISE relief {mmH2O} {Max. 200} {Max. 400}
1-3 Min. 0.1 Min. 0.07
Eng. Oil Press. Eng. Low idling (SAE10W) {Min. 1.0} {Min. 0.7}
MPa Min. 0.12 Min. 0.08
Eng. Low idling (SAE30) {kg/cm2} {Min. 1.2} {Min. 0.8}
0.34 – 0.54 Min. 0.21
Eng. High idling (SAE30) {3.5 – 5.5} {Min. 2.1}
1-4 Eng. Full, DH Mode, kPa Min. 117 Min. 93.3
Boost Press. Arm IN relief {mmHg} {Min. 880} {Min. 700}
1-5 Eng. Full, DH Mode Max. 650 Max. 700
Exhaust Gas Temp. Boom RAISE relief + Heavy Lift ON ˚C
Ambient Temp. — — — —
2-1
2 PTO

Filter visual check — No excessive metaric

2-2
Center bearing THERMO - LABEL check Not 120˚C Range Blackened
˚C
2-3
PTO Temp. Max. 120˚C Max. 120˚C

Boom RAISE 6.8 – 8.2 6.8 – 8.2

3 CYCLE TIME

Boom LOWER Eng. Full 4.7 – 5.7 4.7 – 5.7

DH Mode
Arm IN 6.9 – 8.5 6.9 – 8.5
Oil temp. : 45 – 55˚C
Arm DUMP 4.9 – 5.9 4.9 – 5.9
Bucket CURL Sec. 4.8 – 5.8 4.8 – 5.8
Swing : Swing one turn then measure
Bucket DUMP time taken to swing next 5 turns 3.6 – 4.4 3.6 – 4.4
Swing 5 Turns Travel : Raise track on one side at a time, 62.0 – 72.0 Max. 74.0
Travel 5 Turns (R.H.) rotate one turn, then measure time 93.5 – 113.5 Max. 115.0
Travel 5 Turns (L.H.) taken for next 5 turns with no load 93.5 – 113.5 Max. 115.0

20-256 PC1800-6
 Pm-CLINIC SERVICE
ITEM Condition Unit STD. PMS. Result Sat Us
Set measuring posture for work equipment, then stop the engine.
4 HYD. DRIFT

Hydraulic drift at tip Max. 1200 Max. 1800

Whole of work equipment Work equipment {Max. 650} {Max. 1000}
posture : Boom, Arm, of bucket teeth
horizontal Amount of retraction Max. 60 Max. 90
Boom Cylinder {Max. 35} {Max. 50}
Bucket : CURL of cylinder mm/15min
Rated load of work Amount of extension Max. 165 Max. 250
Arm Cylinder of cylinder {Max. 70} {Max. 105}
equipment {no load}
Amount of retraction Max. 50 Max. 80
Bucket Cylinder oil temp.: 45-55˚C of cylinder {Max. 15} {Max. 30}
Result
ITEM Condition Unit STD. PMS. Us
F Engine R Engine Sat
5-1 Control levers 3.13 – 3.47 3.13 – 3.47
5 HYDRAULIC PRESSURE

Control Pump Oil Press. at neutral {32 – 35.5} {32 – 35.5}

5-2 Control levers 2.05 – 2.45 Min. 1.76
at neutral {21 – 25} {Min. 18}
TVC Valve Output Boom RAISE relief 1.32 – 1.72 1.28 – 1.68
(normal) {13.4 – 17.4} {13.0 – 17.0}
Press.
Boom RAISE relief 1.26 – 1.66 1.21 – 1.61
(Heavy lift ON) {12.8 – 16.8} {12.3 – 16.3}
5-3 Control levers Max. 0.4 Max. 0.55
Front Pump NC Valve neutral {Max. 4} {Max. 5.5}
Output Press. R.H. Travel lever Full Min. 1.8 Min. 1.8
Tracks rotating under no load ( 1) {Min. 18.0} {Min. 18.0}
5-4 Control levers Max. 0.4 Max. 0.55
Oil Temp. : at neutral {Max. 4} {Max. 5.5}
Rear Pump NC Valve MPa
45-55˚C L.H. Travel lever Full {kg/cm2} Min. 1.8 Min. 1.8
Press.
DH Mode Tracks rotating under no load ( 1) {Min. 18.0} {Min. 18.0}
5-5 Eng. Full
Swing Pump NC Valve Control levers Max. 0.4 Max. 0.55
at neutral {Max. 4} {Max. 5.5}
Press.
5-6 28.4 – 30.85 28.4 – 30.85
Swing relief {290 – 315} {290 – 315}
Swing Pump Oil Press.
5-7 28.4 – 30.4 27.4 – 30.4
Arm IN relief {290 – 310} {280 – 310}
No.1 & 2F Pump Press.
5-8 28.4 – 30.4 27.4 – 30.4
Arm IN relief {290 – 310} {280 – 310}
No.1 & 2R Pump Press.
5-9 28.4 – 30.4 27.4 – 30.4
Arm IN relief {290 – 310} {280 – 310}
No.3 & 4F Pump Press.
5-10 28.4 – 30.4 27.4 – 30.4
Arm IN relief {290 – 310} {280 – 310}
No.3 & 4R Pump Press.
5-11 DH Mode
Bucket DUMP relief ˚C(˚F) Max. 100 Max. 100
Hydraulic Oil Press. Eng. Full

6 Hyd. Tank Strainer Visual check (Every 2000 hours) No excessive Metallic Powder & Rubber Pieces

Note : Write - down any phenomena or information, you found by your six sences during today's inspection.

PC1800-6 20-257
 MEASURING PROCEDURES

Pm-CLINIC SERVICE

Sight check of welded structural part

★ If crack is found, illustrate the shape of the crack in the figure.

1. Arm cylinder bracket 5. Boom top bracket 9. Boom bracket

Left Right Left Right Left Right
2. Arm foot 6. Boom cylinder bracket 10. Circle bracket
Left Right Top plate Left Right Front Rear
3. Top boss 7. Boom lower plate Left Right
Left Right Left Right 11. Leg mount
4. Arm cylinder bracket 8. Boom foot Front Rear
Left Right Left Right Left Right

20-258 PC1800-6
 TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-302

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-303
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-304
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-312
CLASSIFICATION AND PROCEDURE OF TROUBLESHOOTING ........................................................... 20-314
CONNECTOR ARRANGMENT DIAGRAM AND ELECTRICAL CIRCUIT DIAGRAM
FOR EACH SYSTEM ........................................................................................................................... 20-318
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-344
T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-366

TROUBLESHOOTING AT DISPLAY OF FAILURE CODE OR ERROR CODE [CODE DISPLAY MODE] 20-401
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-701
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ................................. 20-801
TROUBLESHOOTING OF WORK EQUIPMENT AUTOMATIC CONTROL SYSTEM (W-MODE)
[LOADING SHOVEL]............................................................................................................................ 20-901

PC1800-6 20-301
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or ★ When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the ★ The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1)Start from the simple points.
problems with the machine condition before 2)Start from the most likely points.
this? 3)Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.

20-302 PC1800-6
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

PC1800-6 20-303
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

1. Points to remember when handling electric

equipment

1) Handling wiring harnesses and connectors

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

Main failures occurring in wiring harness

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

2) Defective crimping or soldering of connec-

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

20-304 PC1800-6
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

4) High-pressure water entering connector

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

5) Oil or dirt stuck to connector

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

PC1800-6 20-305
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors

and wiring harnesses

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

2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
★ If the connector is twisted up and down
or to the left or right, the housing may
break.

3) Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
★ If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.

20-306 PC1800-6
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.

2) Fix the connector securely.

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

3) Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
★ If the connector cannot be corrected
easily, remove the clamp and adjust the
position.

4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.

• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal):a, b, d
• Incomplete locking state (Diagonal):c

PC1800-6 20-307
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

• Drying wiring harness

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

If water gets directly on the connector, do as fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.

2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
★ Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.

3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector,
blow it with contact restorer and reas-
semble.

20-308 PC1800-6
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box

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

3) Do not place objects on top of the control

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

6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.

2. Points to remember when troubleshooting electric circuits

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

PC1800-6 20-309
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. Points to remember when handling hydraulic

equipment

With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.

1) Be careful of the operating environment.

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

2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.

3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.

4) Do not let any dirt or dust get in during refill-

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

20-310 PC1800-6
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.

6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.

7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.

PC1800-6 20-311
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil,

4. Check hydraulic oil strainer — Clean, drain

coolant

5. Check swing machinery oil level — Add oil

6. Check engine oil level (oil pan oil level) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
mechanical equipment

1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Hydraulic, Electrical

2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment

1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace
2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment

3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention — Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)

20-312 PC1800-6
TROUBLESHOOTING CLASSIFICATION AND PROCEDURE OF TROUBLESHOOTING

CLASSIFICATION AND PROCEDURE OF TROUBLESHOOTING

Classification of troubleshooting

Mode Content
Code display Troubleshooting at display of failure code or error code
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical system
W mode Troubleshooting of work equipment automatic control system
(Engine) Troubleshooting of engine (Refer to the 140-3 Series Engine Shop Manual.)

Procedure of troubleshooting
If a phenomenon assumed to be a failure occurs in the machine, follow the procedure below to narrow down
troubleshooting items, and then go to the appropriate troubleshooting.

1. When a user code is displayed on the machine monitor or an abnormality is displayed on the CGC
monitor:
Operate the service menu of the machine monitor or CGC monitor, and check the error code or failure code.
Follow the displayed error code or failure code to carry out the troubleshooting of the appropriate code dis-
play.
★ For the operation method, refer to Special Functions of Machine Monitor or Special Functions of CGC
Monitor.

2. When an error code or failure code is memorized:

If no user code is displayed on the machine monitor or no abnormality is displayed on the CGC monitor,
operate the service menu of the machine monitor or CGC monitor, and check the error code or failure code.
If an error code or failure code is memorized, carry out the troubleshooting of the appropriate code display.
★ For the operation method, refer to Special Functions of Machine Monitor or Special Functions of CGC
monitor (CGC).

3. When no error code or failure code is memorized:

If no error code is displayed on the machine monitor and no failure code is displayed on the CGC monitor, a
failure which the machine cannot carry out self-diagnose for is assumed to be detected in the electrical sys-
tem or hydraulic or mechanical system. In this case, reconfirm the failure and chose the item on the Table of
Phenomenon Assumed to be Failure and Troubleshooting. Then carry out the troubleshooting in the E
mode, H mode or W mode related to the phenomenon.

20-314 PC1800-6
TROUBLESHOOTING CLASSIFICATION AND PROCEDURE OF TROUBLESHOOTING

Phenomenon assumed to be failure and troubleshooting

Troubleshooting
No. Phenomenon assumed to be failure Code
E mode H mode W mode (Engine)
display
User code, error code, and failure code
1 A user code is displayed on the machine monitor.
Confirm the error code or failure code.
2 An abnormality is displayed on the CGC monitor.
3 An error code is memorized on the machine monitor. ●
4 A failure code is memorized on the CGC monitor. ●
Engine
Engine starting performance is low(starting always takes
5 S-1
time)
6 Engine does not rotate E-1 S-2 a)
Engine rotates, but exhaust smoke
7 Engine does not S-2 b)
does not come out
start
Exhaust smoke comes out, but engine
8 S-2 c)
does not start
9 Engine does not pick up smoothly(follow-up is poor) S-3
10 Engine stops during operations H-2 S-4
11 Engine does not rotate smoothly(hunting). S-5
12 Engine lacks output(or lacks power) H-1 S-6
13 Exhaust smoke is black(incomplete combustion) S-7
14 Oil consumption is excessive (or exhaust smoke is blue) S-8
15 Oil becomes contaminated quickly S-9
16 Fuel consumption is excessive S-10
Oil is in cooling water, or water spurs black, or water level
17 S-11
goes down
18 Oil level increases(water or fuel is mixing) S-13
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheating is not carried out E-2
22 Automatic deceleration is not carried out E-3
Work equipment, swing, or travel
Speed of travel, swing and all work equipment is slow or
23 H-1 S-6
lacks power
24 Engine speed goes down extremely or engine stops H-2 S-4
25 All work equipment, travel and swing do not work H-3
26 Abnormal noise is made around hydraulic pump H-4
Work equipment
Speed of work equipment (boom, arm and/or bucket) is
27 H-5
slow.
Work equipment (boom, arm and/ or bucket) does not
28 H-6
work.
Excessive hydraulic drift of work equipment (boom, arm,
29 H-7
and/or bucket)

PC1800-6 20-315
TROUBLESHOOTING CLASSIFICATION AND PROCEDURE OF TROUBLESHOOTING

Troubleshooting
No. Phenomenon assumed to be failure Code
E mode H mode W mode (Engine)
display
Excessive time lag of work equipment (boom, arm, and/or
30 H-8
bucket)
31 Boom shockless function does not work normally. E-4 H-9
32 Machine push-up function does not work normally. E-5 H-10
33 Heavy lift function does not work normally. H-11
Work equipment automatic control function does not work
34 ●
normally. (Loading shovel)
Travel
35 Travel deviation is excessive at compound operation. H-12
36 Machine naturally curves to one side at travel. H-13
37 Machine naturally curves extremely at start. H-14
38 Travel speed is slow. H-15
39 Travel does not work on one side. H-16
40 Travel alarm does not sound. E-6
Swing
41 Work equipment does not swing. H-17
42 Swing speed is slow or acceleration is poor. H-18
43 Excessive overrun at stop of swing. H-19
44 Excessive shock at stop of swing. H-20
45 Abnormal sound is made at stop of swing. H-21
46 Excessive drift of swing H-22
Machine monitor (Operator menu: Normal display)
Machine monitor does not light up for 3 seconds when
47 E-7
starting switch is turned ON
Machine monitor does not go off as all of them remain lit on
48 E-8
when Starting switch is turned ON
Light-on items on machine monitor are different from the
49 E-9
machine condition when starting switch is turned ON
Basic check items on machine monitor flash when starting
50 E-10
switch is turned ON
Caution items on machine monitor flash when engine is
51 E-11
running
Emergency stop items on machine monitor flash while
52 E-12
working
Preheating monitor lights up or flashes without preheating
53 E-13
operation.
Swing lock monitor on machine monitor does not display
54 E-14
normally.
Engine water temperature gauge on machine monitor does
55 E-15
not indicate normally.
Hydraulic oil temperature gauge on machine monitor does
56 E-16
not indicate normally.
Fuel gauge on machine monitor does not indicate nor-
57 E-17
mally.

20-316 PC1800-6
TROUBLESHOOTING CLASSIFICATION AND PROCEDURE OF TROUBLESHOOTING

Troubleshooting
No. Phenomenon assumed to be failure Code
E mode H mode W mode (Engine)
display
58 Alarm buzzer on machine monitor does not work normally. E-18
Clock and service meter on machine monitor do not work
59 E-19
normally.
Machine monitor (Service menu: Special function display)
Boom RAISE bit indicator on machine monitor does not
60 E-20
work normally.
Boom LOWER bit indicator on machine monitor does not
61 E-21
work normally.
Arm IN bit indicator on machine monitor does not work nor-
62 E-22
mally.
Arm OUT bit indicator on machine monitor does not work
63 E-23
normally.
Bucket CURL bit indicator on machine monitor does not
64 E-24
work normally.
Bucket DUMP bit indicator on machine monitor does not
65 E-25
work normally.
Swing bit indicator on machine monitor does not work nor-
66 E-26
mally.
Left travel bit indicator on machine monitor does not work
67 E-27
normally.
Right travel bit indicator on machine monitor does not work
68 E-28
normally.
Service bit indicator on machine monitor does not work
69 normally. E-29
(Backhoe)
Bottom OPEN bit indicator on machine monitor does not
70 work normally. E-30
(Loading shovel)
Others
71 Air conditioner does not work. E-31

PC1800-6 20-317
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit

(6)
A09 M 1 Left headlamp (Left) D3-7 G6-2

20-318
A10 M 1 Left headlamp (Right) D3-8 G6-2
A20 DT 2 Intermediate connector G11-7 H14-9
AC DT 2 Air cleaner pressure switch (Front engine) R10-4 K-8 G-2 Connector table
AC DT 2 Air cleaner pressure switch (Rear engine) S10-4 L-2 H-2
AC2 terminal 1 Engine GND (Front engine) R8-5 G-2
TROUBLESHOOTING

AC2 terminal 1 Engine GND (Rear engine) S8-5

AF1 DT 12 Intermediate connector D11-6
AF2 DT 6 Intermediate connector D11-6
AG1 SWP 16 Auto grease controller Q7-1 Q9-3 C-8
AG2 4 Grease pump solenoid valve Q4-2 E-8
AG3 X 3 Grease pressure switch Q6-4 D-8
AGD KES1 2 Diode E-8
AGSW 6 Grease system selector switch Q5-5 C-8
AR1 DT 12 Intermediate connector D12-6
AR2 DT 6 Intermediate connector D12-6
B03 KES1 2 Diode B-8
B04 KES1 2 Diode B-8
B05 KES1 2 Diode B-8 K-3 G-9 G-9 A-3 A-6
B06 M 2 Resistor D13-7 D-9
B07 S 10 Emergency pump drive switch D10-4 D-9
B08 DT 6 Emergency swing holding brake release switch D10-4 E-9
B09 DT 6 Machine selection connector (Pump controller) C1-7 D10-4 B-9
B12 DT 6 Machine selection connector (VHMS controller) D13-8 H9-7 A-1
CONNECTOR ARRANGMENT DIAGRAM AND

B13 DT 2 Boom bottom shockless solenoid valve D5-8 B-2

B14 KES1 1 Diode D6-8 B-2
B15 DT 2 Boom head shockless solenoid valve D5-8 B-2
B16 DT 2 Swing holding brake solenoid valve D5-8 B-2
B17 KES1 1 Diode D6-8 B-2
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

B18 DT 2 Swing holding brake solenoid valve D5-8 B-2

B19 DT 3 Intermediate connector [Loading shovel specification] D6-9
B20 KES1 1 Diode [Loading shovel specification]
B21 KES1 1 Diode [Loading shovel specification]
B22 DT 2 Machine pushup solenoid valve D5-8 B-1
B23 KES1 1 Diode D6-7 B-1
B24 DT 2 CO cancel solenoid valve D5-8 B-1

PC1800-6
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit
B25 DT 2 Diode D6-7 B-1

PC1800-6
B26 KES1 1 Straight travel solenoid valve D5-8 B-1
B27 KES1 1 Diode D6-8 B-1
B28 DT 2 2-stage relief solenoid valve D5-8 B-1
B29 KES1 1 Diode D6-8 B-1
B30 X 2 Boom EPC valve [Loading shovel specification] D5-7 E-9
TROUBLESHOOTING

B31 X 2 Bucket EPC valve [Loading shovel specification] D5-7 E-9

B32 X 2 Boom RAISE oil pressure switch G1-4 H14-8 E-3
B33 X 2 Boom LOWER oil pressure switch G1-5 H14-8 E-3
B34 X 2 Bucket CURL oil pressure switch G2-4 H14-8 E-3
B35 X 2 Bucket DUMP oil pressure switch G2-5 H14-8 E-3
B36 X 2 R.H. travel forward oil pressure switch G2-4 H14-7 E-3
B37 X 2 R.H. travel reverse oil pressure switch G2-5 H14-7 E-2
B38 X 2 L.H. travel forward oil pressure switch G3-4 H14-7 E-2
B39 X 2 L.H. travel reverse oil pressure switch G3-5 H14-7 E-2
B40 X 2 Arm OUT oil pressure switch G3-4 H14-6 E-2
B41 X 2 Arm IN oil pressure switch G4-5 H14-6 E-2
B42 X 2 Swing LEFT oil pressure switch G4-4 H14-6 E-2
B43 X 2 Swing RIGHT oil pressure switch G4-5 H14-6 E-2
B44 X 2 Boom RAISE oil pressure switch [Loading shovel specification] H12-8 E-8
B45 X 2 Boom LOWER oil pressure switch [Loading shovel specification] H12-8 E-8
B46 X 2 Bucket CURL oil pressure switch [Loading shovel specification] H12-8 E-7
B47 X 2 Bucket DUMP oil pressure switch [Loading shovel specification] H12-8 E-7
B48 X 2 Arm IN oil pressure switch [Loading shovel specification] H12-7 E-6
B49 X 2 Arm OUT oil pressure switch [Loading shovel specification] H12-7 E-6
B50 DT 3 Spare connector G8-2 C-8
B52 DT 2 Air temperature sensor G7-2 F-8
D11-7 H8-8 Q1-6
B56 DT 2 Intermediate connector
Q13-1
B57A DT 2 Intermediate connector D10-7 H9-8 P1-6 B-9
B57B DT 2 Intermediate connector P9-7 B-9
B57C DT 2 Ladder switch P8-6 A-9
B58.1 DT 2 Exhaust temperature signal amplifier (Front engine) G6-3 J-5
B58.2 DT 2 Exhaust temperature signal amplifier (Front engine) G7-2 J-5
B59.1 DT 2 Exhaust temperature signal amplifier (Rear engine) G6-3 J-4

(6)
B59.2 DT 2 Exhaust temperature signal amplifier (Rear engine) G8-2 J-4
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

20-319
a The component position indicates a rough connector position in the connector arrangement diagram (Section 90).
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit

(6)
B60A DT 1 Intermediate connector [+55°C specification] K3-1 K12-1

20-320
B60B terminal 1 Circuit breaker G1-8 K9-3 D-7 H-9 H-9 F-8 F-3
B61A terminal 1 Circuit breaker G1-8 K9-3 D-7 H-9 H-9 F-8 E-3
B61B DT 1 Intermediate connector [+55°C specification] K13-3
B62A DT 1 Intermediate connector [+55°C specification] K4-3 K12-2
B62B terminal 1 Circuit breaker G1-8 K11-3 D-6 H-4 H-9 H-9 F-8 F-3
TROUBLESHOOTING

B63A terminal 1 Circuit breaker G1-8 K10-3 D-6 H-4 H-9 H-9 F-8 E-3
B63B DT 1 Intermediate connector [+55°C specification] K13-3
B67 DT 1 Intermediate connector D11-6 Q1-6 Q13-2 E-7
B68A DT 1 Intermediate connector [+55°C specification] K3-1 K12-1
B68B terminal 1 Circuit breaker G1-8 K9-3 F-8
B69A terminal 1 Circuit breaker G1-8 K10-3 F-8
B69B DT 1 Intermediate connector [+55°C specification] K14-3
B70 KES1 2 Diode
B70A DT 1 Intermediate connector [+55°C specification] K3-1 K11-1
B70B terminal 1 Circuit breaker G3-8 K9-2
B71 KES1 2 Diode
B71A terminal 1 Circuit breaker G3-8 K9-2 D-7
B71B DT 1 Intermediate connector [+55°C specification] K13-3
B72A DT 1 Intermediate connector [+55°C specification] K4-2 K11-2
B72B terminal 1 Circuit breaker G3-8 K10-1
B73A terminal 1 Circuit breaker G3-8 K10-1
B73B DT 1 Intermediate connector [+55°C specification] K14-3
B83A DT 1 Intermediate connector [+55°C specification] K4-3 K11-2
B83B terminal 1 Circuit breaker G3-8 K9-2 D-7 H-4 F-8 B-5
B84A terminal 1 Circuit breaker G3-8 K9-2 H-4 F-8 C-5
B84B DT 1 Intermediate connector [+55°C specification] K14-3
BD01 X 2 Bottom OPEN oil pressure switch [Loading shovel specification] E12-3 E-1
BD02 X 2 Bottom CLOSE oil pressure switch [Loading shovel specification] E12-3 E-1
C01 M 2 Buzzer A6-5 A-6
C02 M 2 Network bus A9-6 A-6
C03 M 2 Fuel control dial (Front engine) A5-6 B8-9 J-9
C04 terminal 2 Starting switch A6-8 B-9 L-3 L-9 L-9 H-9 A-2 A-3
C05 KES1 2 Engine selector switch A6-8 B8-9 D-9 J-9 J-9 K-9
C06 M 2 Fuel control dial (Rear engine) A6-8 B8-9 J-9
C07 PA 2 Radio A6-8 B9-7

PC1800-6
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit
C08 Plug connector 2 Left speaker A10-6 A11-6 B12-1

PC1800-6
A10-5 A11-5 A11-6
C09 Plug connector 3 Right speaker
B13-9
C11 Plug connector 2 Cigarette lighter A6-8 B9-7
C12 2 Working lamp switch A6-8 B9-9 A-3
C14 2 Working lamp and headlamp relay A6-5
TROUBLESHOOTING

C15 2 Right and left headlamp relay A6-6

C16 Relay 2 Boom right lamp relay A7-5
C17 M 2 Swing lock switch A7-8 B9-9 A-3 L-7
C18 M 2 Resistor A12-1 L-7
C19 M 2 Machine pushup switch A7-8 B10-9 L-9
C20 M 2 Fog lamp switch A7-8 B10-9
C21 6 Fog lamp relay A7-6
C22 250 3 Boom shockless switch A7-8 B10-9 L-9
C23 M 2 Rotary lamp switch A8-8 B10-9
C24 M 2 Buzzer cancel switch A8-8 B11-9 A-2
C25 M 2 Step lamp switch A7-8 B9-9 L-9
C27 Relay 5 Rear lamp relay (Step lamp relay) A7-5 I-9
C28 KES1 4 Wiper and washer switch A8-8 B11-9
C29 Relay 5 Wiper relay A8-5
C30 Relay 5 Wiper relay A7-6
C31 S 10 Greasing switch A8-8 B11-9
C32 M 6 Auto grease timer A7-5
C33 M 2 Automatic level digging switch [Loading shovel specification] A9-8 B11-9 E-5
C34 M 2 Bucket angle correction switch [Loading shovel specification] A9-8 B11-9 E-4
C37 M 2 Cab room lamp switch A7-8 B9-9
C40 Plug connector 1 Intermediate connector [Loading shovel specification]
C41 Plug connector 1 Intermediate connector [Loading shovel specification]
C42 KES1 2 Diode A8-5
C43 Plug connector 1 Intermediate connector [Loading shovel specification]
C44 Plug connector 1 Intermediate connector [Loading shovel specification]
C45 KES1 2 Diode A7-5
C46 — — Fuse box A10-7 A13-7 B13-8 D-7 I-9 I-9 G-8 D-3
C48 BENDIX 10 Machine control monitor (CGC) B2-5 B2-9 A-1 I-1
C50 Relay 5 Rotary lamp relay A7-6

(6)
C51 Relay 5 Boom shockless relay A7-5 I-9
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

20-321
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit

(6)
C52 KES1 2 Diode A6-8 C-9

20-322
C53 M 5 Download PC connector B3-7 B4-4 J-1
C54 KES1 2 Diode A5-5 A-6
C55 KES1 2 Diode D12-4 D-9
C56 KES1 2 Diode A9-5 L-7
C57 Relay 5 Flash lamp relay A6-6 L-6
TROUBLESHOOTING

C58 M 4 Hydraulic oil filter clogging timer C1-4 G6-3 C-1 A-8
C59 8 Engine selector relay A9-6 D-9 J-9 J-9 I-9
C60 8 Starting switch R1 signal cancel relay A9-6 A-5 L-3 L-9 L-9 J-9 B-2 A-1
C61 Relay 5 Engine preheater cutout relay A8-5 A-5
C62 8 Engine stop relay A9-6 A-4 L-2 K-9 K-9 J-9 C-2 B-1
C63 Relay 5 Engine stop relay A8-5 A-4 K-9 K-9 K-9
C64 Relay 5 Engine room lamp relay A13-2
C65 6 Wiper intermittent relay A12-3
C66 6 Wiper intermittent relay A11-3
C67 Plug connector 1 Engine stop caution lamp B7-7 B-2
C68 Plug connector 1 Ladder caution lamp A5-7 B7-9 P3-9 G-9
C69 Plug connector 1 Ladder caution lamp A5-6 B7-9 P3-9 G-9
C70 terminal 1 Circuit breaker B3-1 C-7 D-5
C71 terminal 1 Circuit breaker B3-1 D-7 D-5
C72 terminal 1 Circuit breaker B1-1
C73 terminal 1 Circuit breaker B1-1
C74 terminal 1 Circuit breaker B3-2 C-6 H-8 D-5
C75 terminal 1 Circuit breaker B3-2 D-6 G-8 D-5
C76 Relay 5 Grease caution lamp relay A12-2 D-2
C77 Relay 5 Wiper relay A12-2
C78 terminal 1 Circuit breaker B3-2 C-6 I-4 I-9 I-9 H-7 D-6 D-3
C79 terminal 1 Circuit breaker B3-2 D-6 I-4 I-9 I-9 G-7 D-6 D-3
C80 terminal 1 Circuit breaker B1-2 C-6 I-4
C81 terminal 1 Circuit breaker B1-2 D-6 I-4
C82 2 Glow switch A5-6 B8-7 A-3
C83 5 Wiper relay A13-2
C84 terminal 1 Circuit breaker B1-2 I-4 H-8
C85 terminal 1 Circuit breaker B1-1 I-4 G-8
C86 Plug connector 1 Grease lamp (Automatic) A9-8 E-2
C87 Plug connector 1 Grease lamp (Automatic) A9-8 E-2

PC1800-6
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit
C88 Plug connector 1 Grease lamp (Manual) A9-7 F-2

PC1800-6
C89 Plug connector 1 Grease lamp (Manual) A9-7 E-2
C90 Plug connector 1 Grease caution lamp B7-7 F-2
C91 Plug connector 1 Grease caution lamp B7-7 F-2
C92 Plug connector 1 Dump count lamp B7-9 L-4
C93 Plug connector 1 Dump count lamp B7-9 L-4
TROUBLESHOOTING

C94 DT 3 CAN terminal resistor D11-2 H-2 H-8 I-7 I-7 D-1
C95 DT 3 CAN terminal resistor D13-6 D-1 B-1
C96 DT 3 CAN terminal resistor D13-6 D-1 B-1 K-7 K-7 D-1
C97 Plug connector 1 Engine stop caution lamp B7-7 B-2
C98 Relay 5 Engine preheater relay A8-6 C-9
C99 Relay 5 Swing safety relay A12-3 K-9
C100 DT 2 Working load selector connector D13-7 B-1
CM01 KES1 2 Diode A9-7 L-8
CM02 KES1 2 Diode A9-4 K-2
CM03 KES1 2 Diode A8-4 L-2
CM04 Plug connector 3 Dump count switch M9-7 L-1
CM04-1 Plug connector 1 Dump count switch M11-7 L-1
CM04-2 Plug connector 1 Dump count switch M11-7 L-1
CM04-3 Plug connector 1 Dump count switch M11-6 L-1
CM05 KES1 2 Diode A9-5 L-8
CM06 X 3 Intermediate connector A11-5 B12-7 M11-8 K-1
CM07 Relay 5 Power holding relay D11-3 B-8
CM08 KES1 2 Diode D12-4 C-9
CM09 KES1 2 Diode D12-3 C-9 A-3
CM10 KES1 2 Diode D11-4 C-9 A-4
CM11 6 Horn switch relay A8-5 L-7
CM12 SHINAGAWA 5 Controller power supply relay (Front engine) H2-2 C-9
CM13 SHINAGAWA 5 Controller power supply relay (Relay engine) H2-2 C-9
CM14 DT 6 Machine selection connector (Front engine) H5-3 B-9
CM15 DT 6 Machine selection connector (Rear engine) H5-3 B-9
CM21 terminal 1 Circuit breaker B3-1 I-9 I-9
CM22 terminal 1 Circuit breaker B3-1 I-9 I-9
CM25 DT 12 Dispatch system connector B3-5 B3-7 B-2 I-1
CM29 70 10 ORBCOMM communication controller J6-1 B-8

(6)
CM30 70 14 ORBCOMM communication controller J6-1 B-8
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

20-323
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit

(6)
CM31 DT 12 Connector to add communication terminal D13-8 F-1 D-8

20-324
CM32 DT 12 Connector for troubleshooting D13-8 F-1 E-8
CM36 DT 2 Air suspension seat switch B12-6
CM37 2 Resistor D12-6 D-8
CM38 KES1 2 Diode C-9 A-4
D11-3
CM39 KES1 2 Diode C-9
TROUBLESHOOTING

CN1 2 No. 1 injector (Front engine) R2-7 L-3

CN1 2 No. 1 injector (Rear engine) S2-7 L-3
CN2 2 No. 2 injector (Front engine) R3-7 L-2
CN2 2 No. 2 injector (Rear engine) S3-7 L-2
CN3 2 No. 3 injector (Front engine) R3-7 L-3
CN3 2 No. 3 injector (Rear engine) S3-7 L-3
CN4 2 No. 4 injector (Front engine) R4-7 L-2
CN4 2 No. 4 injector (Rear engine) S4-7 L-2
CN5 2 No. 5 injector (Front engine) R4-7 L-3
CN5 2 No. 5 injector (Rear engine) S4-7 L-3
CN6 2 No. 6 injector (Front engine) R5-7 L-3
CN6 2 No. 6 injector (Rear engine) S5-7 L-3
D1 6 Wiper motor (Lower right) A1-5 B4-7 O6-8
D2 6 Wiper motor (Lower left) A1-5 B4-4 O7-8
D03 5 Wiper motor (Upper) O3-9
D04 Plug connector 1 Cab rotary lamp O13-9
D05 Plug connector 1 Headlamp O11-9
D06 Plug connector 1 Headlamp O11-9
D07 Plug connector 1 Headlamp O11-9
D08 Plug connector 1 Headlamp O11-9
D09 Plug connector 1 Left fog lamp O10-8
D10 Plug connector 1 Left fog lamp O10-8
D11 2 Rear lamp (Step lamp) O14-8 E-9
D12 Plug connector 1 Cab room lamp O7-4
D13 Plug connector 1 Cab room lamp O7-3
D14 Plug connector 1 Cab room lamp O7-3
E8-6 H4-9 K12-6
E22 HD30 31 Engine intermediate connector (Front engine) J-7 J-8 J-6 G-3
R11-2
E8-6 H4-8 K12-7
E23 HD30 14 Engine intermediate connector (Front engine)
R11-1

PC1800-6
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit
E3-2 E10-6 K14-6
E27 HD30 31 Engine intermediate connector (Rear engine) J-3 J-8 J-6 H-3

PC1800-6
S11-2
E3-2 E10-6 K14-7
E28 HD30 14 Engine intermediate connector (Rear engine)
S11-1
EA01 HD30 14 Intermediate connector E13-1 K6-1 G-5 J-8 F-5
EA02 HD30 31 Intermediate connector E13-1 K6-1 G-5 J-3 H-8 H-8 F-5 B-2 B-6
TROUBLESHOOTING

EA03 HD30 31 Intermediate connector E13-1 K6-1 G-4 I-7

EB01 HD30 31 Intermediate connector H2-1 J-6 J-9 E-7 E-7 F-6
EB02 HD30 31 Intermediate connector (Front engine) H2-1 J-5 E-2
EB03 HD30 31 Intermediate connector H3-1 J-5 J-9 E-5 E-5
EB04 HD30 31 Intermediate connector (Rear engine) H4-1 J-4 E-2
E8-6 H4-9 K12-6
EM01 HD30 31 Engine intermediate connector (Front engine) J-3
R11-2
E3-2 E10-6 K14-6
EM02 HD30 31 Engine intermediate connector (Rear engine) J-3
S11-2
ENBP DT 3 Blow-by pressure sensor (Front engine) R1-3 K-6
ENBP DT 3 Blow-by pressure sensor (Rear engine) S1-4 K-6
ENE DT 2 Engine speed sensor (Front engine) R6-4 G-2
ENE DT 2 Engine speed sensor (Rear engine) S6-4 H-2
ENGP DT 3 Engine oil pressure sensor (Front engine) R5-2 K-7
ENGP DT 3 Engine oil pressure sensor (Rear engine) S5-2 K-6
ENGT DT 2 Engine oil temperature sensor (Front engine) R13-2 K-6
ENGT DT 2 Engine oil temperature sensor (Rear engine) S13-2 K-5
F01 terminal 1 Cab floor GND A7-5 B10-7 B-2 J-1 K-8 L-6 D-2
F02 KES1 2 Diode A9-6 D-9 L-8
F03 KES1 2 Diode A9-6 E-9 L-8
FA1 40 20 Air conditioner unit (Front) C8-3
FA2 40 12 Air conditioner unit (Front) C8-3
FA3 M 6 Air conditioner unit (Front) C8-3
FC01 DRC 24 Pump controller D13-2 E-8 G-8 A-8
FC02 DRC 40 Pump controller D12-2 F-8 G-8 K-6 K-7 A-6
FC03 DRC 40 Pump controller D12-2 A-4
FE01 DRC 24 Engine controller (Front engine) H2-4 K-6 A-6 A-8 K-5
FE02 DRC 40 Engine controller (Front engine) H2-4 K-6 L-9 A-5 A-7 K-5
FE03 DRC 40 Engine controller (Front engine) H2-4 A-3

(6)
G YAZAKI 2 G sensor (Front engine) R1-3 K-4
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

20-325
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit

(6)
G YAZAKI 2 G sensor (Rear engine) S1-3 K-4

20-326
H01 HD30 8 Intermediate connector D3-9 D11-5 F-7 B-3
H02 DT 12 Intermediate connector D2-9 D10-5 C-4 K-2 I-8 I-8 F-7 C-2 C-5
H03 DT 8 Intermediate connector D2-9 D10-5 C-4 I-7 I-8 F-7 D-5
H04A DT 8 Intermediate connector D3-9 D11-5 F-6
H04B DT 8 Intermediate connector D3-9 D10-5 C-4 F-6
TROUBLESHOOTING

H05 DT 3 Intermediate connector D3-9 D11-5

H06 DT 2 Intermediate connector D3-9 D11-5
H07 HD30 8 Intermediate connector D10-6 H8-9 G-3
H09 DT 12 Intermediate connector D10-7 H8-9 C-3 G-2
H10 KES1 2 Intermediate connector A9-4 A13-4 B12-9 G-9
H11 S 12 Intermediate connector A7-4 B-2 I-3
H12 DT 12 Intermediate connector D12-6 G-3 F-6 J-6 J-6
H14A DT 8 Intermediate connector D13-7 H8-8 F-5
H14B DT 8 Intermediate connector D13-7 H8-8 G-4 F-6
H15 DT 2 Intermediate connector D11-7 H8-8
H16 DT 3 Intermediate connector D12-8 H8-8
H17 DT 8 Intermediate connector D10-7 H8-8 E-8
H18 DT 6 Intermediate connector D1-9 D10-4 C-3 F-6 F-6
A9-4 A13-4 B12-9
H20 KES1 8 Intermediate connector
O2-3
H21 DT 3 Front NC pressure sensor input connector E6-5 I4-6 I7-2 C-1
H22 DT 3 Rear NC pressure sensor input connector E9-4 F9-1 I11-2 D-1
H23 DT 2 Engine stop switch (above catwalk) E6-4 K10-4 H-2
H51 KES1 4 Intermediate connector A4-5 B7-9
HM01 DT 6 Intermediate connector D2-9 D10-5 F-6
HM02 DT 4 Intermediate connector D2-9 D11-5 I-8 I-9
HM04 DT 3 NC pressure sensor (used to pick up NC pressure) I3-8
HT terminal 1 Heater relay (Front engine) R5-4 K-8
HT terminal 1 Heater relay (Rear engine) S5-4 K-3
J05B DT 3 Boom potentiometer [Loading shovel specification] B-7
J06A DT 4 Intermediate connector [Loading shovel specification] D6-9 C-7
J06B DT 4 Intermediate connector [Loading shovel specification] B-7
J06C DT 3 Arm potentiometer [Loading shovel specification] B-7
JC04 DT 8 Junction connector G2-2 H11-9
JC05 DT 6 Junction connector G3-2 H11-7

PC1800-6
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit
JC06 DT 6 Junction connector G4-2 H11-6

PC1800-6
JC07 DT 8 Junction connector G1-2 H11-9
JC10 DT 8 Junction connector G5-6
JC11 DT 8 Junction connector G6-5
JC12 DT 8 Junction connector G6-4
JC16 DT 8 Junction connector G5-5
TROUBLESHOOTING

JC17 DT 8 Junction connector G5-5

JC18 DT 8 Junction connector G6-5
JC35 DT 8 Junction connector G2-2 H11-7
JC36 DT 6 Junction connector G4-2 H11-7
JC37 DT 8 Junction connector G2-2 H11-9
JC41 DT 8 Junction connector G6-5
JC42 DT 8 Junction connector G6-4
JC47 DT 8 Junction connector H5-3
JC48 DT 8 Junction connector H5-3
JC49 DT 8 Junction connector H5-2
JC50 DT 8 Junction connector H5-2
JC51 DT 8 Junction connector H5-2
JC52 DT 8 Junction connector H5-2
JC53 DT 8 Junction connector H5-2
JC54 DT 8 Junction connector H5-2
JC59 DT 6 Junction connector E13-7
JC60 DT 8 Junction connector H3-7
JC61 DT 8 Junction connector H3-7
JC62 DT 8 Junction connector H3-7
JC63 DT 8 Junction connector H3-7
JC65 DT 8 Junction connector E2-1
JC66 DT 8 Junction connector E2-1
JC67 DT 8 Junction connector E2-2
JC68 DT 8 Junction connector E2-2
JC73 DT 8 Junction connector E6-6 K10-6
JC79 DT 6 Junction connector E13-6
JC80 DT 6 Junction connector G10-7 J6-1
JC90 DT 8 Junction connector G6-4
JC91 DT 8 Junction connector G5-5

(6)
J05A DT 3 Intermediate connector [Loading shovel specification] D6-9 B-7
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

20-327
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit

(6)
L01 SWP 8 Work equipment controller [Loading shovel specification] D10-9 B-9

20-328
L02 SWP 12 Work equipment controller [Loading shovel specification] D1-7 H8-8 A-8
M02 KES1 2 Diode
M03 KES1 2 Diode
M23 Plug connector 2 Horn switch B6-7
M23A X 2 Intermediate connector A9-5 A12-5 M11-8
TROUBLESHOOTING

M23B-1 Plug connector 1 Horn switch M11-7 G-9

M23B-2 Plug connector 1 Horn switch M11-7 G-8
MC60 Plug connector 1 Intermediate connector B2-3
MC61 Plug connector 1 Intermediate connector B2-3
MC62 Plug connector 1 Intermediate connector B1-4
MC63 Plug connector 1 Intermediate connector B2-4
N/C DT 3 NC pressure sensor (Sensor unit) I4-8 CD-1 G-9
NE YAZAKI 2 Ne sensor (Front engine) R6-3 K-4
NE YAZAKI 2 Ne sensor (Front engine) S6-3 K-4
OL DT 2 Engine oil level switch (Front engine) R3-2 K-7 H-2
OL DT 2 Engine oil level switch (Rear engine) S3-2 K-2 I-2
OP1 — — Additional fuse box G11-7
OP2 terminal 1 Additional service power supply terminal (30A) G3-7
OP3 terminal 1 Additional service power supply terminal (10A) G3-7
OP4 terminal 1 Additional service power supply terminal (10A) G3-7
OP5 terminal 1 Additional service power supply terminal (10A) G3-7
OP6 terminal 1 Additional service power supply terminal (20A) G3-7
OP7 terminal 1 Additional service power supply terminal (20A) G2-7
OPT DT 2 Intermediate connector H12-7 E-1
P01 40 20 Machine monitor B2-3 B2-6 A-9 L-4 K-8 G-9
P02 40 16 Machine monitor B1-4 B2-6 A-7
E8-4 F8-2 K11-4
P03 DT 2 Front TVC valve K-2
L10-2
E9-4 F11-3 K13-4
P04 DT 2 Rear TVC valve K-2
L12-3
P05.1 2 Radiator coolant level switch (Front engine) F6-5 L8-5 I-2 K-2
P05.2 2 Radiator coolant level switch (Front engine) F7-5 L8-5 I-2 K-2
P06.1 2 Radiator coolant level switch (Rear engine) F8-5 L9-5 J-2 K-2
P06.2 2 Radiator coolant level switch (Rear engine) F8-5 L9-5 I-2 L-2
P07 DT 2 Front PTO temperature sensor E7-4 F7-1 I8-2 E-1

PC1800-6
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit
P08 DT 2 Rear PTO temperature sensor E9-4 F9-1 I11-2 D-1

PC1800-6
E8-5 F8-1 I1-2
P15 DT 3 Gear pump pressure sensor K-7
K12-5 L10-1
P19 M 2 Pump room lamp switch E8-5 H10-4 K12-5
P22 X 2 Engine stop switch (in engine compartment) H10-5 H-2
P23 X 2 Engine stop switch (in engine compartment) H10-5
TROUBLESHOOTING

P24 Plug connector 1 LED H10-4 H-2

P25 Plug connector 1 LED H10-4 I-2
P26 Plug connector 1 Pump room lamp E8-4 H10-4 K12-4
P27.1 DT 2 Exhaust temperature signal amplifier (Front engine) G6-4 K-5
P27.2 DT 2 Exhaust temperature signal amplifier (Front engine) G9-4 K-4
P28.1 DT 2 Exhaust temperature signal amplifier (Rear engine) G6-4 K-5
P28.2 DT 2 Exhaust temperature signal amplifier (Rear engine) G9-4 K-4
P29.1 DT 2 Exhaust temperature sensor (Front engine) E8-7 H3-7 R12-1 K-5
P29.2 DT 2 Exhaust temperature sensor (Front engine) E8-7 H4-9 R11-2 K-4
P30.1 DT 2 Exhaust temperature sensor (Rear engine) E3-2 E10-7 S12-1 K-5
P30.2 DT 2 Exhaust temperature sensor (Rear engine) E3-2 E10-7 S11-2 K-4
PCV1 2 Fuel supply pump PCV1 (Front engine) R1-4 L-2
PCV1 2 Fuel supply pump PCV1 (Rear engine) S1-4 L-2
PCV2 2 Fuel supply pump PCV2 (Front engine) R1-4 L-2
PCV2 2 Fuel supply pump PCV2 (Rear engine) S1-4 L-2
PFUEL AMP 3 Common rail pressure sensor (Front engine) R4-3 K-6
PFUEL AMP 3 Common rail pressure sensor (Rear engine) S4-3 K-6
PIM SUMITOMO 3 Boost pressure sensor (Front engine) R6-4 K-5
PIM SUMITOMO 3 Boost pressure sensor (Rear engine) S6-4 K-5
PS1 DT 1 Intermediate connector D4-9 D11-9 D-7 I-9 I-9 G-8 E-3
PS1A DT 1 Intermediate connector [+55°C specification] K6-4
PS2A DT 1 Intermediate connector [+55°C specification] K6-4
PS2 DT 1 Intermediate connector D4-9 D11-9 G-8
PS3 DT 1 Intermediate connector D3-8 D11-9 D-7 H-4 G-8 C-5
PS3A DT 1 Intermediate connector [+55°C specification] K6-4
PS4A DT 1 Intermediate connector [+55°C specification] K6-4
PS4 DT 1 Intermediate connector D3-8 D11-9 D-6 H-4 I-9 I-9 G-8 E-3
PS5 DT 1 Intermediate connector G2-1 G10-5
PS5A DT 1 Intermediate connector [+55°C specification] K6-4

(6)
PS6 DT 1 Intermediate connector G1-1 G10-5
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

20-329
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit

(6)
PS6A DT 1 Intermediate connector [+55°C specification] K6-4

20-330
PSH terminal 1 High engine oil pressure switch (Front engine) R4-2 K-8 L-4
PSH terminal 1 High engine oil pressure switch (Rear engine) S4-2 K-2 L-4
PSL terminal 1 Low engine oil pressure switch (Front engine) R4-2 K-8 L-5
PSL terminal 1 Low engine oil pressure switch (Rear engine) S4-2 K-2 L-5
R6 M 1 Boom working lamp (Left)
TROUBLESHOOTING

R7 M 1 Boom working lamp (Right)

RA1 40 20 Air conditioner unit (Rear) C10-2 D4-4
RA2 40 12 Air conditioner unit (Rear) C10-2 D5-4
RA3 M 6 Air conditioner unit (Rear) C11-2 D5-4
RE01 DRC 24 Engine controller (Rear engine) H2-3 K-5 A-8 A-6 K-5
RE02 DRC 40 Engine controller (Rear engine) H2-3 K-5 L-9 A-7 A-5 K-5
RE03 DRC 40 Engine controller (Rear engine) H2-4 A-3
S01F DT 1 Kerosene mode connector D11-2 E-7
S01M DT 1 Kerosene mode connector D11-2 E-8
ST DT 2 Starting motor (Front engine) R12-2 K-7
ST DT 2 Starting motor (Rear engine) S12-2 K-2
SW1 40 16 Air conditioner control panel (Front) A7-6 B10-7
SW2 40 12 Air conditioner control panel (Front) A7-6 B10-7
SW3 40 16 Air conditioner control panel (Rear) A8-8 A11-7 B10-7
SW4 40 12 Air conditioner control panel (Rear) A8-8 A11-6 B10-7
T01 E7-8
T01A DT 6 Intermediate connector F8-6 K11-8 L9-6
T01B DT 12 Intermediate connector F8-5 K11-8 L9-5 H-7 J-8 I-5
E8-7 F9-7 H6-2
T02 DT 2 Air conditioner compressor (Front engine)
K12-7 L10-7
T03 terminal 6 Revolving frame GND G11-4 E-5 H-3 G-7 G-7 E-8 F-4 F-1
E4-4 E8-8 F8-9
T04 Plug connector 1 Engine compartment lamp
K11-8 L9-9
T05 Plug connector 1 Rotary lamp E5-2 E10-9 K14-9
T06 Plug connector 1 Right fog lamp E2-9 F2-8 L4-8
T07 M 1 Right headlamp E2-9 F1-6 K4-9
T08 M 1 Right headlamp E2-9 F1-6 K4-9
E6-7 F6-7 K9-8
T09 DT 2 Intermediate connector
L7-7
T10 DT 2 Hydraulic oil level switch E3-7 F3-8 L4-8 I-8 J-2

PC1800-6
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit
E10-5 F10-1 K14-5
T11 DT 2 Travel alarm I-2

PC1800-6
L12-1
E9-5 E10-9 F11-7
T12 DT 2 Fuel level sensor I-8 J-2
K14-9 L12-7
E2-4 F9-9 K13-6
T13 M 2 Engine compartment lamp switch
L10-9
TROUBLESHOOTING

E8-7 F8-8 H6-3

T15 DT 2 Air conditioner compressor (Rear engine)
K12-7 L10-8
E5-9 F5-7 F14-6
T16 DT 2 Hydraulic oil temperature sensor H-8 J-2
K8-9 L6-7
T17 DT 2 Hydraulic oil filter clogging switch E5-8 F5-8 H-8 J-2
T18 DT 2 Low hydraulic oil temperature switch E5-8 F5-9 H-8 I-2
T19 terminal 3 Revolving frame GND E14-2 K1-3 E-5 H-3 G-7 G-7 E-8 F-1
T20 terminal Revolving frame GND E14-2 K1-3
THL DT 2 Fuel temperature sensor (Front engine) R3-2 K-4
THL DT 2 Fuel temperature sensor (Rear engine) S3-2 K-4
TWH DT 2 High engine coolant temperature sensor (Front engine) R10-4 J-8 K-8 K-5
TWH DT 2 High engine coolant temperature sensor (Rear engine) S10-4 J-2 K-8 K-5
TWL DT 2 Low engine coolant temperature sensor (Front engine) R10-4 K-5
TWL DT 2 Low engine coolant temperature sensor (Rear engine) S10-4 K-5
V01 DT 3 V1 control valve pressure sensor E6-5 F-2
V02 DT 3 V2 control valve pressure sensor E6-5 F6-1 E-2
V03 DT 3 V3 control valve pressure sensor E8-5 I3-2 I10-3 E-2
V04 DT 3 V4 control valve pressure sensor E8-4 I1-3 I10-4 E-2
V05 DT 3 Swing control valve pressure sensor E6-5 F7-1 E-2
V1 70 20 VHMS controller D13-9 A-7
V2A 70 18 VHMS controller D13-9 E-1 A-6
V2B 70 12 VHMS controller D13-9 A-5
V3A 70 18 VHMS controller D13-8 E-1 A-4 K-6
V3B 70 12 VHMS controller D13-8 A-3
V4A 70 14 VHMS controller D13-9 E-1 A-3 K-6 K-6 D-1
V4B 70 10 VHMS controller D13-9 A-2
W01 DT 8 Intermediate connector C3-5 D3-7 B-8
W02 X 2 Air conditioner condenser (Front engine) C1-7 D1-9 G5-6
W03 X 2 Air conditioner condenser (Rear engine) C1-6 G6-6

(6)
W04 M 1 Lower lamp C4-6 C8-5 D3-6
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

20-331
 Connector Number Location M C FE RE P G W
Type Device name
No. of pins (See Section 90) circuit circuit circuit circuit circuit circuit circuit

(6)
W05 M 1 Flash lamp C4-6 C8-5 D3-6
W06 Plug connector 1 Grease valve C1-3 G8-2

20-331-1
W07 Plug connector 1 Grease valve C2-4 G8-2
W08 Plug connector 1 Horn valve C5-7 C8-7 D2-4 B-9
W09 Plug connector 1 Horn valve C5-7 C9-7 D3-4 B-8
W10 KES0 2 Windshield washer motor C9-5
TROUBLESHOOTING

W11 KES0 2 Windshield washer motor C10-5

W12 KES1 2 Diode C10-5
W13 Plug connector 1 Base room lamp C12-5
W14 KES1 2 Base room lamp switch C7-3
W15 Plug connector 1 24-V outlet C7-3
W16 Plug connector 1 24-V outlet C7-3
W17 DT Automatic drain valve E9-8 F9-6 L10-6

PC1800-6
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
 Connector No. Detailed information
M YAZAKI M type connector (08056-0XXXX)

PC1800-6
S YAZAKI S type connector (08056-1XXXX)
L YAZAKI L type connector (08056-2XXXX)
X YAZAKI X type connector (08055-0XXXX)
TROUBLESHOOTING

SWP YAZAKI SWP type connector (08055-1XXXX)

KES0 KES 0 type connector (08027-0XXXX)
KES1 KES 1 type connector (08027-1XXXX)
040 NIPPON AMP 040 type connector
070 NIPPON AMP 070 type connector
MIC MIC type connector (287-06-16430)
SHINAGAWA SHINAGAWA SR-5P type connector
DT NIPPON DEUTSCH DT type connector (08192-XXXXX)
HD30 NIPPON DEUTSCH HD30 type connector (08191-XXXXX)
DRC NIPPON DEUTSCH DRC type connector
BENDIX BENDIX type connector
Relay Relay type connector
One pin connector Round-bottle type one pin connector
Terminal Round terminal or terminal

(6)
CONNECTOR ARRANGMENT DIAGRAM AND
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

20-331-2
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

MACHINE MONITOR SYSTEM ELECTRICAL CIRCUIT (M CIRCUIT)

20-332 PC1800-6
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

★ This circuit diagram is created by extracting the machine monitor, engine preheating-starting-stop, and com-
munication network systems from the general electric circuit diagram.

PC1800-6 20-333
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

CGC MONITOR & VHMS CONTROLLER SYSTEM ELECTRICAL CIRCUIT (C CIRCUIT)

20-334 PC1800-6
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

★ This circuit diagram is created by extracting the CGC monitor and VHMS controller systems from the general
electric circuit diagram.

PC1800-6 20-335
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

FRONT ENGINE CONTROLLER SYSTEM ELECTRICAL CIRCUIT (FE CIRCUIT)

20-336 PC1800-6
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

★ This circuit diagram is created by extracting the front engine controller system from the general electric circuit
diagram.

PC1800-6 20-337
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

REAR ENGINE CONTROLLER SYSTEM ELECTRICAL CIRCUIT (RE CIRCUIT)

20-338 PC1800-6
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

★ This circuit diagram is created by extracting the rear engine controller system from the general electric circuit
diagram.

PC1800-6 20-339
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

PUMP CONTROLLER SYSTEM ELECTRICAL CIRCUIT (P CIRCUIT)

20-340 PC1800-6
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

★ This circuit diagram is created by extracting the pump controller, heavy lift, and machine push-up systems
from the general electric circuit diagram.

PC1800-6 20-341
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

AUTOMATIC GREASING CONTROLLER SYSTEM ELECTRICAL CIRCUIT (G CIRCUIT)

★ This circuit diagram is created by extracting the automatic greasing controller system from the general elec-
tric circuit diagram.

20-342 PC1800-6
 CONNECTOR ARRANGMENT DIAGRAM AND
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM

WORK EQUIPMENT AUTOMATIC CONTROL SYSTEM CIRCUIT DIAGRAM (W CIRCUIT)

[LOADING SHOVEL]
★ This circuit diagram is created by extracting the work equipment automatic control system from the general
electric circuit diagram.

PC1800-6 20-343
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.

X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010

2 799-601-7020

Part No.: 08055-00282 Part No.: 08055-00292

3 799-601-7030

Part No.: 08055-00381 Part No.: 08055-00391

4 799-601-7040

Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
Terminal part No.: 79A-222-3380 Terminal part No.: 79A-222-3410
• Electric wire size: 2.0 • Electric wire size: 2.0
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-344 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

6 799-601-7050

Part No.: 08055-10681 Part No.: 08055-10691

8 799-601-7060

Part No.: 08055-10881 Part No.: 08055-10891

12 799-601-7310

Part No.: 08055-11281 Part No.: 08055-11291

14 799-601-7070

Part No.: 08055-11481 Part No.: 08055-11491

PC1800-6 20-345
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No. of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

16 799-601-7320

Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
• Electric wire size: 1.25 • Electric wire size: 1.25
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-346 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080

2 799-601-7090

Part No.: 08056-00271 Part No.: 08056-00281

3 799-601-7110

Part No.: 08056-00371 Part No.: 08056-00381

4 799-601-7120

Part No.: 08056-00471 Part No.: 08056-00481

6 799-601-7130

Part No.: 08056-00671 Part No.: 08056-00681

8 799-601-7390

Part No.: 08056-00871 Part No.: 08056-00881

PC1800-6 20-347
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

8 799-601-7140

Part No.: 08056-10871 Part No.: 08056-10881

10
799-601-7150
(White)

Part No.: 08056-11071 Part No.: 08056-11081

12
799-601-7350
(White)

Part No.: 08056-11271 Part No.: 08056-11281

16
799-601-7330
(White)

Part No.: 08056-11671 Part No.: 08056-11681

20-348 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

10
—
(Blue)

— —

12
799-601-7160
(Blue)

Part No.: 08056-11272 Part No.: 08056-11282

16
799-601-7170
(Blue)

Part No.: 08056-11672 Part No.: 08056-11682

PC1800-6 20-349
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —

5 799-601-2710

Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)

9 799-601-2950

Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)

13 799-601-2720

Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)

20-350 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

17 799-601-2730

Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)

21 799-601-2740

Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)

PC1800-6 20-351
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

8 799-601-7180

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

12 799-601-7190

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

16 799-601-7210

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

20 799-601-7220

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

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

20-352 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

10 799-601-7510

— Part No.: 08195-10210

12 799-601-7520

— Part No.: 08195-12210

14 799-601-7530

— Part No.: 08195-14210

18 799-601-7540

— Part No.: 08195-18210

20 799-601-7550

— Part No.: 08195-20210

PC1800-6 20-353
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

2 —

— —

Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

9 —

— —

Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

10 799-601-3460

— —

20-354 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

2 —

Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)

3 —

Part No.:08027-10310 Part No.:08027-10360

4 —

Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)

6 —

Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)

PC1800-6 20-355
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

8 —

Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)

Connector for relay (Socket type)

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

5 799-601-7360

— —

6 799-601-7370

— —

20-356 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

4 —

— —

PC1800-6 20-357
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9210

Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)

799-601-9210

Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
Pin (male terminal) Pin (female termial)

799-601-9220

Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Pin (female terminal) Pin (male termial)

799-601-9220

Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106

20-358 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9230

18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

(3) Pin (female terminal) Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

Pin (male terminal) Pin (female termial)

799-601-9240

18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

(4) Pin (female terminal) Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102

PC1800-6 20-359
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9250

24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

(5) Pin (female terminal) Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

Pin (male terminal) Pin (female termial)

799-601-9260

Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
(6) Pin (female terminal) Pin (male termial)

799-601-9260

Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106

20-360 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9270

Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
(7) Pin (female terminal) Pin (male termial)

799-601-9270

Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
Pin (male terminal) Pin (female termial)

799-601-9280

Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
(8) Pin (female terminal) Pin (male termial)

799-601-9280

Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106

PC1800-6 20-361
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male termial) Pin (female terminal)

799-601-9290

Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
(9) Pin (female terminal) Pin (male termial)

799-601-9290

Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106

20-362 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.

2 799-601-9020

Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)

3 799-601-9030

Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)

4 799-601-9040

Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)

6 799-601-9050

Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)

PC1800-6 20-363
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.

8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090

Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)

12GR: 799-601-9110
12B: 799-601-9120
10
12G: 799-601-9130
12BR: 799-601-9140

Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)

20-364 PC1800-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

DTM Series connector

No.of
pins T-adapter Part
Body (plug) Body (receptacle)
No.

799-601-9010
2

Part No.: 08192-02200 Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)]

DTHD Series connector

No.of
pins T-adapter Part
Body (plug) Body (receptacle)
No.

2 —

Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)

PC1800-6 20-365
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE

T-BRANCH BOX AND T-BRANCH TABLE

★ The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or

—
Part No. No. of pins
part name

799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3370 Plate For MS box
799-601-3380 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P

20-366 PC1800-6
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or

—
Part No. No. of pins
part name

799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DEUTSCH 40P
799-601-9360 DEUTSCH 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P

PC1800-6 20-367
 TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE]

Information in Troubleshooting Table .......................................................................................................... 20-404

Failure Code 6014NX ................................................................................................................................. 20-407
Failure Code 7@HAKA ............................................................................................................................... 20-409
Failure Code 7@HAKB ............................................................................................................................... 20-410
Failure Code 7@HAZL................................................................................................................................ 20- 411
Failure Code 7@HBKA ............................................................................................................................... 20-412
Failure Code 7@HBKB ............................................................................................................................... 20-413
Failure Code 7@HBZL................................................................................................................................ 20-414
Failure Code 7@HCKA............................................................................................................................... 20-415
Failure Code 7@HCKB............................................................................................................................... 20-416
Failure Code 7@HCZL ............................................................................................................................... 20-417
Failure Code 7@HDKA............................................................................................................................... 20-418
Failure Code 7@HDKB............................................................................................................................... 20-419
Failure Code 7@HDZL ............................................................................................................................... 20-420
Failure Code A000N1 or Error Code E922 ................................................................................................. 20-421
Failure Code a000N1 or Error Code EA22 ................................................................................................. 20-422
Failure Code AA10NX or Error Code 104 ................................................................................................... 20-423
Failure Code aA10NX or Error Code 105 ................................................................................................... 20-424
Failure Code AB00KE ................................................................................................................................. 20-425
Failure Code aB00KE ................................................................................................................................. 20-426
Failure Code AD00L2 or Error Code E979 ................................................................................................. 20-427
Failure Code aD00L2 or Error Code EA79 ................................................................................................. 20-428
Failure Code AD00MA or Error Code E97A ............................................................................................... 20-429
Failure Code aD00MA or Error Code EA7A ............................................................................................... 20-429
Failure Code AD10L3 or Error Code E97b ................................................................................................. 20-430
Failure Code aD10L3 or Error Code EA7b ................................................................................................. 20-432
Failure Code AD10MA or Error Code E97d ................................................................................................ 20-434
Failure Code aD10MA or Error Code EA7d ................................................................................................ 20-434
Failure Code AD10MB or Error Code E97C ............................................................................................... 20-435
Failure Code aD10MB or Error Code EA7C ............................................................................................... 20-435
Failure Code AD11KA or Error Code E974................................................................................................. 20-436
Failure Code aD11KA or Error Code EA74................................................................................................. 20-437
Failure Code AD11KB or Error Code E970................................................................................................. 20-438
Failure Code aD11KB or Error Code EA70................................................................................................. 20-439
Failure Code AD51KA or Error Code E975 ................................................................................................ 20-440
Failure Code aD51KA or Error Code EA75 ................................................................................................ 20-441
Failure Code AD51KB or Error Code E971 ................................................................................................ 20-442
Failure Code aD51KB or Error Code EA71 ................................................................................................ 20-443
Failure Code ADA1KA or Error Code E981 ................................................................................................ 20-444
Failure Code aDA1KA or Error Code EA81 ................................................................................................ 20-445
Failure Code ADAZKB or Error Code E98A ............................................................................................... 20-446
Failure Code aDAZKB or Error Code EA8A ............................................................................................... 20-448
Failure Code ADB1KA or Error Code E982 ................................................................................................ 20-450
Failure Code aDB1KA or Error Code EA82 ................................................................................................ 20-451
Failure Code ADC1KA or Error Code E983 ................................................................................................ 20-452
Failure Code aDC1KA or Error Code EA83 ................................................................................................ 20-453

PC1800-6 20-401
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE]

Failure Code ADD1KA or Error Code E984 ................................................................................................ 20-454

Failure Code aDD1KA or Error Code EA84 ................................................................................................ 20-455
Failure Code ADDZKB or Error Code E98b................................................................................................ 20-456
Failure Code aDDZKB or Error Code EA8b................................................................................................ 20-458
Failure Code ADE1KA or Error Code E985 ................................................................................................ 20-460
Failure Code aDE1KA or Error Code EA85 ................................................................................................ 20-461
Failure Code ADF1KA or Error Code E986 ................................................................................................ 20-462
Failure Code aDF1KA or Error Code EA86 ................................................................................................ 20-463
Failure Code B@BAZG or Error Code E924............................................................................................... 20-464
Failure Code b@BAZG or Error Code EA24............................................................................................... 20-465
Failure Code B@BAZK ............................................................................................................................... 20-466
Failure Code b@BAZK................................................................................................................................ 20-467
Failure Code B@BCNS or Error Code 108................................................................................................. 20-468
Failure Code b@BCNS or Error Code 111.................................................................................................. 20-469
Failure Code B@BCZK ............................................................................................................................... 20-470
Failure Code b@BCZK ............................................................................................................................... 20-472
Failure Code B@CBNS............................................................................................................................... 20-474
Failure Code b@CBNS ............................................................................................................................... 20-475
Failure Code B@HANS or Error Code 115 ................................................................................................. 20-476
Failure Code B@HAZK ............................................................................................................................... 20-477
Failure Code D110KB ................................................................................................................................. 20-478
Failure Code D163KB ................................................................................................................................. 20-479
Failure Code D194KZ ................................................................................................................................. 20-480
Failure Code D195KB ................................................................................................................................. 20-481
Failure Code D1D0KB or Error Code E957 ................................................................................................ 20-482
Failure Code d1D0KB or Error Code EA57................................................................................................. 20-484
Failure Code DA20KT or Error Code 101 ................................................................................................... 20-486
Failure Code DA2SKA ................................................................................................................................ 20-488
Failure Code DA2SKQ ................................................................................................................................ 20-490
Failure Code DA80MA ................................................................................................................................ 20-492
Failure Code DAB0KR or Error Code 118................................................................................................... 20-494
Failure Code DB20KT or Error Code E980................................................................................................. 20-496
Failure Code dB20KT or Error Code EA80 ................................................................................................. 20-497
Failure Code DB22KK or Error Code E956................................................................................................. 20-498
Failure Code dB22KK or Error Code EA56................................................................................................. 20-500
Failure Code DB29KQ or Error Code E920 ................................................................................................ 20-502
Failure Code dB29KQ or Error Code EA20 ................................................................................................ 20-503
Failure Code DB2AMA or Error Code E95A ............................................................................................... 20-504
Failure Code bB2AMA or Error Code EA5A ............................................................................................... 20-504
Failure Code DB2RMC or Error Code E935 ............................................................................................... 20-506
Failure Code dB2RMC or Error Code EA35 ............................................................................................... 20-508
Failure Code DB2SMC or Error Code E955 ............................................................................................... 20-510
Failure Code dB2SMC or Error Code EA55................................................................................................ 20-512
Failure Code DBB0KK ................................................................................................................................ 20-514
Failure Code DBB0KM................................................................................................................................ 20-515
Failure Code DBB0KP ................................................................................................................................ 20-516
Failure Code DBB0KQ ................................................................................................................................ 20-518
Failure Code DBB0KR or Error Code 116................................................................................................... 20-520
Failure Code DBB0KT................................................................................................................................. 20-522
Failure Code DBBQKR ............................................................................................................................... 20-524
Failure Code DD11KB or Error Code E954................................................................................................. 20-526
Failure Code dD11KB or Error Code EA54 ................................................................................................. 20-528
Failure Code DDE2L6 or Error Code E936................................................................................................. 20-530
Failure Code dDE2L6 or Error Code EA36 ................................................................................................. 20-532
Failure Code DGE4KX or Error Code E93d................................................................................................ 20-534
Failure Code dGE4KX or Error Code EA3d ................................................................................................ 20-535
Failure Code DGT4KA ................................................................................................................................ 20-536
Failure Code dGT4KA................................................................................................................................. 20-538
Failure Code DGT4KB ................................................................................................................................ 20-540

20-402 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE]

Failure Code dGT4KB................................................................................................................................. 20-542

Failure Code DGT5KA ................................................................................................................................ 20-544
Failure Code dGT5KA................................................................................................................................. 20-546
Failure Code DGT5KB ................................................................................................................................ 20-548
Failure Code dGT5KB................................................................................................................................. 20-550
Failure Code DH30KX or Error Code E93C................................................................................................ 20-552
Failure Code dH30KX or Error Code EA3C ................................................................................................ 20-553
Failure Code DH40KX or Error Code E977 ................................................................................................ 20-554
Failure Code dH40KX or Error Code EA77 ................................................................................................ 20-555
Failure Code DHE4KB ................................................................................................................................ 20-556
Failure Code dHE4KB................................................................................................................................. 20-557
Failure Code DHE4KY ................................................................................................................................ 20-558
Failure Code dHE4KY................................................................................................................................. 20-559
Failure Code DHE5KB ................................................................................................................................ 20-560
Failure Code dHE5KB................................................................................................................................. 20-561
Failure Code DHE5KY ................................................................................................................................ 20-562
Failure Code dHE5KY................................................................................................................................. 20-563
Failure Code DK10KX or Error Code E931 ................................................................................................ 20-564
Failure Code dK10KX or Error Code EA31................................................................................................. 20-565
Failure Code DLE2MA ................................................................................................................................ 20-566
Failure Code dLE2MA................................................................................................................................. 20-567
Failure Code DLE3LE or Error Code E91b ................................................................................................. 20-568
Failure Code dLE3LE or Error Code EA1b ................................................................................................. 20-569
Failure Code DLH1LC or Error Code E91C ................................................................................................ 20-570
Failure Code dLH1LC or Error Code EA1C ................................................................................................ 20-571
Failure Code DPA0KR ................................................................................................................................ 20-572
Failure Code DV00KY or Error Code 102 ................................................................................................... 20-573
Failure Code DV20KB................................................................................................................................. 20-574
Failure Code DW42KZ ................................................................................................................................ 20-575
Failure Code DW45KA................................................................................................................................ 20-576
Failure Code DW45KB................................................................................................................................ 20-578
Failure Code DW48KA................................................................................................................................ 20-580
Failure Code DW48KB................................................................................................................................ 20-581
Failure Code DW91KA................................................................................................................................ 20-582
Failure Code DW91KB................................................................................................................................ 20-583
Failure Code DWK0KA ............................................................................................................................... 20-584
Failure Code DWK0KB ............................................................................................................................... 20-585
Failure Code DXA0KA ................................................................................................................................ 20-586
Failure Code dXA0KA ................................................................................................................................. 20-588
Failure Code DXA0KB ................................................................................................................................ 20-590
Failure Code dXA0KB ................................................................................................................................. 20-592
Failure Code F@BBZL................................................................................................................................ 20-594
Failure Code f@BBZL................................................................................................................................. 20-594
Failure Code F@BVL6................................................................................................................................ 20-595
Failure Code f@BVL6 ................................................................................................................................. 20-595
Failure Code F@BYNR............................................................................................................................... 20-596
Failure Code f@BYNR................................................................................................................................ 20-597
Failure Code F@BYNS............................................................................................................................... 20-598
Failure Code f@BYNS ................................................................................................................................ 20-599
Failure Code F@BZNR............................................................................................................................... 20-600
Failure Code f@BZNR ................................................................................................................................ 20-601
Failure Code F@BZNS ............................................................................................................................... 20-602
Failure Code f@BZNS ................................................................................................................................ 20-603
Failure Code F@HCKA............................................................................................................................... 20-604
Failure Code F@HCKB............................................................................................................................... 20-605
Failure Code F@HCZL ............................................................................................................................... 20-606
Failure Code J100KA .................................................................................................................................. 20-607
Failure Code J100KB .................................................................................................................................. 20-608
Failure Code J100L6................................................................................................................................... 20-609

PC1800-6 20-403
TROUBLESHOOTING AT DISPLAY OF FAILURE INFORMATION CONTAINED IN
CODE OR ERROR CODE [CODE DISPLAY MODE] TROUBLESHOOTING TABLE

INFORMATION IN TROUBLESHOOTING TABLE

★ Tables and related circuit diagrams concerning troubleshooting contains the following information. Please
understand the contents sufficiently before carrying out troubleshooting.

Failure Code Error Code

Failure
CGC Monitor Machine Monitor Phenomenon on Machine
Phenomenon
Display Display
Failure Content State when the panel or the controller detected a failure.
Action Taken by Action to be taken for protecting systems and devices when the panel or the controller detected a fail-
Panel or Controller ure.
Failure Phenome-
Phenomenon on machine when the panel or the controller took action(above).
non on Machine
Related
Information concerning to failure or troubleshooting.
Information

Cause Standard value, Remarks for Troubleshooting

<Contents>
• Standard values for judgement of possible causes.
• Remarks for judgement
1
<Phenomenon of Defective Wiring Harness>
• Disconnection
Connector is disconnected or disconnection in wiring harness
Possible Causes and Standard Values

• Short circuit with ground

Wiring harness isolated from the ground is short circuited with the ground
2 • Short circuit with power supply line
Wiring harness isolated from the power supply line is short circuited with the
power supply line
Possible causes of failure
(The sequence number is only <Points to Remember at Troubleshooting>
for reference and does not state 1) Indication of connector number and handling method of T-adapter
3 priority.) Unless otherwise specified, insert or connect T-adapter as follows before trou-
bleshooting:
• When (Male) or (Female) is not indicated to Connector No., disconnect the
connector and insert T-adapter in both the male side and the female side.
• When (Male) or (Female) is indicated to Connector No., disconnect the con-
nector and connect T-adapter to either of the male side or the female side.
2) Pin number and handling of tester lead wire
Unless otherwise specified, contact the tester (+) lead wire and (-) lead wire as
4 follows before troubleshooting:
• Contact the (+) lead wire to the pin of the number or the wiring harness stated
first
• Connect the (-) lead wire to the pin of the number or the wiring harness stated
at second

20-404 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE INFORMATION CONTAINED IN
CODE OR ERROR CODE [CODE DISPLAY MODE] TROUBLESHOOTING TABLE

Relative Electrical Circuit Diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred.

• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.

PC1800-6 20-405
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (6014NX)

Failure Code 6014NX

Failure Code Error Code Failure Hydraulic oil filter clogging

6014NX — Phenomenon (Pump controller system)
• While the engine is running, the signal circuit of the hydraulic oil filter clogging switch became opened
Failure Content
(isolated from GND).
Controller
• An abnormality (red screen) is displayed on the CGC monitor to warn the operator for abnormality.
Reaction
Phenomenon on
Machine
Related • The input state of the hydraulic oil filter sensor signal can be monitored on the machine monitor.
Information Monitoring Code : 25

Cause Standard value, Remarks for Troubleshooting

Hydraulic oil filter clogging
1 Check the hydraulic oil filter and clean or replace the filter if it is clogged.
(when the system is normal)
★Turn off the starting switch for preparation and troubleshoot while keeping it off
or after starting the engine. (Hydraulic oil temperature : 20ºC min. for trouble-
Defective hydraulic oil filter shooting)
2 clogging switch T17 (Male) Hydraulic oil filter Resistance value
(Internal disconnection)
At normal time 1Ω max.
Between 1 and 2
At clogging time 1MΩ min.
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Defective hydraulic oil low T18 (Male) Hydraulic oil temperature Resistance value
3 temperature switch
(internal short-circuit) Between 1 and sensor 13ºC max. 1Ω max.
Possible Cause and Standard value

body 25ºC min. 1MΩ min.

★Turn off the starting switch and troubleshoot after starting the engine.
C58 Signal Voltage
Defective hydraulic oil filter Between 3 and 1 Input 1V max.
4
clogging timer (Internal defect) Between 4 and 1 Output 1V max.
Start troubleshooting 10 sec. or more after the engine started. When the input
signal is normal but the output signal is abnormal, the timer is defective.
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between C58 (female) 3 and T17
Disconnection of wiring harness Resistance
(female) 1 and between C58 (female) 3 and T18 1Ω max.
5 (Disconnection, or defective value
(female) 1
contact of connector)
Wiring harnesses between T17 (female) 2 and Resistance
1Ω max.
ground value
Short circuit with power supply ★Turn off the starting switch for preparation and troubleshoot after starting engine.
6 line of wiring harness (contact Wiring harness between FC02 (female) E and C58
with 24V circuit) Voltage 1V max.
(female) 4 and ground
★Turn off the starting switch and troubleshoot while keeping it off or after starting
the engine.
FC02 Hydraulic oil filter Voltage
7 Defective pump controller
At normal time 1V max.
Between E and ground
At clogging time 20 – 30V
Start troubleshooting 10 sec. or more after the engine started.

PC1800-6 20-407
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (6014NX)

Related electrical circuit of hydraulic oil filter clogging switch and timer

20-408 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HAKA)

Failure Code 7@HAKA

Failure Code Error Code Failure Break F. pump 1,2 press. sensor failure
7@HAKA — Phenomenon (VHMS controller system)
Failure Content • Signal voltages of No. 1 and No. 2 front pump pressure sensors dropped below 0.3V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Pressures of No. 1 and 2 front pumps cannot be monitored on the CGC monitor.
Machine
Related • Pressures of No. 1 and 2 front pumps can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (3/6), PM clinic (4/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power
1 Check if the failure code (DBB0KP) is displayed. If displayed, troubleshoot it.
system
★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Defective pressure sensors of
Possible Cause and Standard value

2 No. 1 and 2 front pumps V01 Voltage

(Internal defect) Between B and A 4.5 – 5.5V
Between C and A 0.3 – 4.7V
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between V1 (female) 4 and V01
(female) B
Disconnection of wiring harness Resistance
1Ω max.
3 (Disconnection or defective value
contact of connector) Wiring harnesses between V2A (female) 1 and V01
(female) C
Resistance
1Ω max.
value
Short circuit with ground in ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
4 wiring harness Wiring harness between V2A (female) 1 and V01
(female) C and ground
Resistance
(Contact with GND circuit) 1MΩ min.
value
★Turn off the starting switch for preparation and turn it on or start the engine for
troubleshooting.
5 Defective VHMS controller
V2A Voltage
Between 1 and BC 0.3 – 4.7V

Circuit Diagram related to Pressure Sensors of No. 1 and 2 Front Pumps

PC1800-6 20-409
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HAKB)

Failure Code 7@HAKB

Failure Code Error Code Failure Short F. pump 1,2 press. sensor failure
7@HAKB — Phenomenon (VHMS controller system)
Failure Content • Signal voltages of No. 1 and No. 2 front pump pressure sensors risen more than 4.7V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Pressures of No. 1 and 2 front pumps cannot be monitored on the CGC monitor.
Machine
Related • Pressures of No. 1 and 2 front pumps can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (3/6), PM clinic (4/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power
1 Check if the failure code (DBB0KP) is displayed. If displayed, troubleshoot it.
system
Possible Cause and Standard value

★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Defective pressure sensors of
2 No. 1 and 2 front pumps V01 Voltage
(Internal defect) Between B and A 4.5 – 5.5V
Between C and A 0.3 – 4.7V
Short circuit with power supply ★Turn off the starting switch for preparation and turn it on for troubleshoot.
3 line of wiring harness Wiring harness between V2A (female) 1 and V01
(female) C and ground
(Contact with 24V circuit) Voltage 1V max.

★Turn off the starting switch for preparation and turn it on or start the engine for
troubleshooting.
4 Defective VHMS controller
V2A Voltage
Between 1 and BC 0.3 – 4.7V

Circuit Diagram related to Pressure Sensors of No. 1 and 2 Front Pumps

20-410 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HAZL)

Failure Code 7@HAZL

Failure Code Error Code Failure High relief press. F. pump 1,2
7@HAZL — Phenomenon (VHMS controller system)
• The signal circuits of No. 1 and 2 front pump pressure sensors detected more than 37.3MPa (380kg/
Failure Content
cm2).
Controller
• Display of an abnormality (red) on CGC control monitor to warn the operator of abnormality.
Reaction
Phenomenon on
• A continuous operation may possibly damage the hydraulic equipment.
Machine
Related • Pressures of No. 1 and 2 front pumps can be monitored on CGC monitor.
Information Monitoring screen : Real time monitor (3/6), PM clinic (4/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Abnormal pressure rise of No. 1
Check the relief pressures of No. 1 and 2 front pumps and repair the pump if the
Possible Cause and Standard value

1 and 2 front pumps

pressures are abnormal.
(when the system is in order)
Check if the failure code (7@HAKA) is displayed.
If displayed, troubleshoot it.
Defective pressure sensor
Check if the failure code (7@HAKB) is displayed.
2 system of No. 1 and 2 front
If displayed, troubleshoot it.
pumps
Check if the failure code (DBB0KP) is displayed.
If displayed, troubleshoot it.
★Turn off the starting switch for preparation and start the engine for troubleshoot-
ing.
3 Defective VHMS controller No. 1, 2 F. pump
V2A Voltage
pressure
Between 1 and BC 37.3MPa (380kg/cm2). 3.42 – 3.54V

Circuit Diagram related to Pressure Sensors of No. 1 and 2 Front Pumps

PC1800-6 20-411
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HBKA)

Failure Code 7@HBKA

Failure Code Error Code Failure Break R. pump 1,2 press. sensor failure
7@HBKA — Phenomenon (VHMS controller system)
Failure Content • Signal voltages of No. 1 and No. 2 rear pump pressure sensors dropped below 0.3V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Pressures of No. 1 and 2 rear pumps cannot be monitored on the CGC monitor.
Machine
Related • Pressures of No. 1 and 2 rear pumps can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (4/6), PM clinic (5/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power
1 Check if the failure code (DBB0KP) is displayed. If displayed, troubleshoot it.
system
★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Defective pressure sensors of
Possible Cause and Standard value

2 No. 1 and 2 rear pumps V02 Voltage

(Internal defect) Between B and A 4.5 – 5.5V
Between C and A 0.3 – 4.7V
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between V1 (female) 4 and V02
(female) B
Disconnection of wiring harness Resistance
1Ω max.
3 (Disconnection or defective value
contact of connector) Wiring harnesses between V2B (female) 4 and V02
(female) C
Resistance
1Ω max.
value
Short circuit with ground in ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
4 wiring harness Wiring harness between V2B (female) 4 and V02
(female) C and ground
Resistance
(Contact with GND circuit) 1MΩ min.
value
★Turn off the starting switch for preparation and turn it on or start the engine for
troubleshooting.
5 Defective VHMS controller
V2A, V2B Voltage
Between V2B4 and V2ABC 0.3 – 4.7V

Circuit Diagram related to Pressure Sensors of No. 1 and 2 Rear Pumps

20-412 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HBKB)

Failure Code 7@HBKB

Failure Code Error Code Failure Short R. pump 1,2 press. sensor failure
7@HBKB — Phenomenon (VHMS controller system)
Failure Content • Signal voltages of No. 1 and No. 2 rear pump pressure sensors risen more than 4.7V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Pressures of No. 1 and 2 rear pumps cannot be monitored on the CGC monitor.
Machine
Related • Pressures of No. 1 and 2 rear pumps can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (4/6), PM clinic (5/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power
1 Check if the failure code (DBB0KP) is displayed. If displayed, troubleshoot it.
system
Possible Cause and Standard value

★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Defective pressure sensors of
2 No. 1 and 2 rear pumps V02 Voltage
(Internal defect) Between B and A 4.5 – 5.5V
Between C and A 0.3 – 4.7V
Short circuit with power supply ★Turn off the starting switch for preparation and turn it on for troubleshooting.
3 line of wiring harness Wiring harness between V2B (female) 4 and V02
(female) C and ground
(Contact with 24V circuit) Voltage 1V max.

★Turn off the starting switch for preparation and turn it on or start the engine for
troubleshooting.
4 Defective VHMS controller
V2A, V2B Voltage
Between V2B4 and V2ABC 0.3 – 4.7V

Circuit Diagram related to Pressure Sensors of No. 1 and 2 Rear Pumps

PC1800-6 20-413
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HBZL)

Failure Code 7@HBZL

Failure Code Error Code Failure High relief press. R. pump 1,2
7@HBZL — Phenomenon (VHMS controller system)
• The signal circuits of No. 1 and 2 rear pump pressure sensors detected more than 37.3MPa (380kg/
Failure Content
cm2).
Controller
• Display of an abnormality (red) on CGC control monitor to warn the operator of abnormality.
Reaction
Phenomenon on
• A continuous operation may possibly damage the hydraulic equipment.
Machine
Related • Pressures of No. 1 and 2 rear pumps can be monitored on CGC monitor.
Information Monitoring screen : Real time monitor (4/6), PM clinic (5/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Abnormal pressure rise of No. 1
Check the relief pressures of No. 1 and 2 rear pumps and repair the pump if the
1 and 2 rear pumps
Possible Cause and Standard value

pressures are abnormal.

(when the system is in order)
Check if the failure code (7@HBKA) is displayed.
If displayed, troubleshoot it.
Defective pressure sensor
Check if the failure code (7@HBKB) is displayed.
2 system of No. 1 and 2 rear
If displayed, troubleshoot it.
pumps
Check if the failure code (DBB0KP) is displayed.
If displayed, troubleshoot it.
★Turn off the starting switch for preparation and start the engine for troubleshoot-
ing.
No. 1, 2 R. pump
3 Defective VHMS controller V2A, V2B Voltage
pressure
Between V2B4 and
37.3MPa (380kg/cm2). 3.42 – 3.54V
V2ABC

Circuit Diagram related to Pressure Sensors of No. 1 and 2 Rear Pumps

20-414 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HCKA)

Failure Code 7@HCKA

Failure Code Error Code Failure Break F. pump 3,4 press. sensor failure
7@HCKA — Phenomenon (VHMS controller system)
Failure Content • Signal voltages of No. 1 and No. 2 front pump pressure sensors dropped below 0.3V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Pressures of No. 3 and 4 front pumps cannot be monitored on the CGC monitor.
Machine
Related • Pressures of No. 3 and 4 front pumps can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (3/6), PM clinic (4/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power
1 Check if the failure code (DBB0KP) is displayed. If displayed, troubleshoot it.
system
★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Defective pressure sensors of
Possible Cause and Standard value

2 No. 3 and 4 front pumps V03 Voltage

(Internal defect) Between B and A 4.5 – 5.5V
Between C and A 0.3 – 4.7V
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between V1 (female) 4 and V03
(female) B
Disconnection of wiring harness Resistance
1Ω max.
3 (Disconnection or defective value
contact of connector) Wiring harnesses between V2B (female) 5 and V03
(female) C
Resistance
1Ω max.
value
Short circuit with ground in ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
4 wiring harness Wiring harness between V2B (female) 5 and V03
(female) C and ground
Resistance
(Contact with GND circuit) 1MΩ min.
value
★Turn off the starting switch for preparation and turn it on or start the engine for
troubleshooting.
5 Defective VHMS controller
V2A, V2B Voltage
Between V2B5 and V2ABC 0.3 – 4.7V

Circuit Diagram related to Pressure Sensors of No. 3 and 4 Front Pumps

PC1800-6 20-415
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HCKB)

Failure Code 7@HCKB

Failure Code Error Code Failure Short F. pump 3,4 press. sensor failure
7@HCKB — Phenomenon (VHMS controller system)
Failure Content • Signal voltages of No. 3 and No. 4 front pump pressure sensors rose more than 4.7V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Pressures of No. 3 and 4 front pumps cannot be monitored on the CGC monitor.
Machine
Related • Pressures of No. 3 and 4 front pumps can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (3/6), PM clinic (4/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power
1 Check if the failure code (DBB0KP) is displayed. If displayed, troubleshoot it.
system
Possible Cause and Standard value

★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Defective pressure sensors of
2 No. 3 and 4 front pumps V03 Voltage
(Internal defect) Between B and A 4.5 – 5.5V
Between C and A 0.3 – 4.7V
Short circuit with power supply ★Turn off the starting switch for preparation and turn it on for troubleshooting.
3 line of wiring harness Wiring harness between V2B (female) 5 and V03
(female) C and ground
(Contact with 24V circuit) Voltage 1V max.

★Turn off the starting switch for preparation and turn it on or start the engine for
troubleshooting.
4 Defective VHMS controller
V2A, V2B Voltage
Between V2B5 and V2ABC 0.3 – 4.7V

Circuit Diagram related to Pressure Sensors of No. 3 and 4 Front Pumps

20-416 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HCZL)

Failure Code 7@HCZL

Failure Code Error Code Failure High relief press. F. pump 3,4
7@HCZL — Phenomenon (VHMS controller system)
• The signal circuits of No. 3 and 4 front pump pressure sensors detected more than 37.3MPa (380kg/
Failure Content
cm2).
Controller
• Display an abnormality (red) on CGC control monitor to warn the operator of abnormality.
Reaction
Phenomenon on
• A continuous operation may possibly damage the hydraulic equipment.
Machine
Related • Pressures of No. 3 and 4 front pumps can be monitored on CGC monitor.
Information Monitoring screen : Real time monitor (3/6), PM clinic (4/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Abnormal pressure rise of No. 3
Check the relief pressures of No. 3 and 4 front pumps and repair the pump if the
1 and 4 front pumps
Possible Cause and Standard value

pressures are abnormal.

(when the system is in order)
Check if the failure code (7@HCKA) is displayed.
If displayed, troubleshoot it.
Defective pressure sensor
Check if the failure code (7@HCKB) is displayed.
2 system of No. 3 and 4 front
If displayed, troubleshoot it.
pumps
Check if the failure code (DBB0KP) is displayed.
If displayed, troubleshoot it.
★Turn off the starting switch for preparation and start the engine for troubleshoot-
ing.
No. 3, 4 F. pump
3 Defective VHMS controller V2A, V2B Voltage
pressure
Between V2B5 and
37.3MPa (380kg/cm2). 3.42 – 3.54V
V2ABC

Circuit Diagram related to Pressure Sensors of No. 3 and 4 Front Pumps

PC1800-6 20-417
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HDKA)

Failure Code 7@HDKA

Failure Code Error Code Failure Break R. pump 3,4 press. sensor failure
7@HDKA — Phenomenon (VHMS controller system)
Failure Content • Signal voltages of No. 3 and No. 4 rear pump pressure sensors dropped below 0.3V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Pressures of No. 3 and 4 rear pumps cannot be monitored on the CGC monitor.
Machine
Related • Pressures of No. 3 and 4 rear pumps can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (4/6), PM clinic (5/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power
1 Check if the failure code (DBB0KP) is displayed. If displayed, troubleshoot it.
system
★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Defective pressure sensors of
Possible Cause and Standard value

2 No. 3 and 4 rear pumps V04 Voltage

(Internal defect) Between B and A 4.5 – 5.5V
Between C and A 0.3 – 4.7V
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between V1 (female) 4 and V04
(female) B
Disconnection of wiring harness Resistance
1Ω max.
3 (Disconnection or defective value
contact of connector) Wiring harnesses between V2B (female) A and V04
(female) C
Resistance
1Ω max.
value
Short circuit with ground in ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
4 wiring harness Wiring harness between V2B (female) A and V04
(female) C and ground
Resistance
(Contact with GND circuit) 1MΩ min.
value
★Turn off the starting switch for preparation and turn it on or start the engine for
troubleshooting.
5 Defective VHMS controller
V2A, V2B Voltage
Between V2BA and V2ABC 0.3 – 4.7V

Circuit Diagram related to Pressure Sensors of No. 3 and 4 Rear Pumps

20-418 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HDKB)

Failure Code 7@HDKB

Failure Code Error Code Failure Short R .pump 3,4 press. sensor failure
7@HDKB — Phenomenon (VHMS controller system)
Failure Content • Signal voltages of No. 3 and No. 4 rear pump pressure sensors dropped more than 4.7V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Pressures of No. 3 and 4 rear pumps cannot be monitored on the CGC monitor.
Machine
Related • Pressures of No. 3 and 4 rear pumps can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (4/6), PM clinic (5/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power
1 Check if the failure code (DBB0KP) is displayed. If displayed, troubleshoot it.
system
Possible Cause and Standard value

★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Defective pressure sensors of
2 No. 3 and 4 rear pumps V04 Voltage
(Internal defect) Between B and A 4.5 – 5.5V
Between C and A 0.3 – 4.7V
Short circuit with power supply ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 line of wiring harness Wiring harness between V2B (female) A and V04
(female) C and ground
(Contact with 24V circuit) Voltage 1V max.

★Turn off the starting switch for preparation and turn it on or start the engine for
troubleshooting.
4 Defective VHMS controller
V2A, V2B Voltage
Between V2BA and V2ABC 0.3 – 4.7V

Circuit Diagram related to Pressure Sensors of No. 3 and 4 Rear Pumps

PC1800-6 20-419
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (7@HDZL)

Failure Code 7@HDZL

Failure Code Error Code Failure High relief press. R. pump 3,4
7@HDZL — Phenomenon (VHMS controller system)
• The signal circuits of No. 3 and 4 rear pump pressure sensors detected more than 37.3MPa (380kg/
Failure Content
cm2).
Controller
• Display an abnormality (red) on CGC control monitor to warn the operator of abnormality.
Reaction
Phenomenon on
• A continuous operation may possibly damage the hydraulic equipment.
Machine
Related • Pressures of No. 3 and 4 rear pumps can be monitored on CGC monitor.
Information Monitoring screen : Real time monitor (4/6), PM clinic (5/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Abnormal pressure rise of No. 3
Check the relief pressures of No. 3 and 4 rear pumps and repair the pump if the
1 and 4 rear pumps
Possible Cause and Standard value

pressures are abnormal.

(when the system is in order)
Check if the failure code (7@HDKA) is displayed.
If displayed, troubleshoot it.
Defective pressure sensor
Check if the failure code (7@HDKB) is displayed.
2 system of No. 3 and 4 rear
If displayed, troubleshoot it.
pumps
Check if the failure code (DBB0KP) is displayed.
If displayed, troubleshoot it.
★Turn off the starting switch for preparation and start the engine for troubleshoot-
ing.
No. 3, 4 R. pump
3 Defective VHMS controller V2A, V2B Voltage
pressure
Between V2BA and
37.3MPa (380kg/cm2). 3.42 – 3.54V
V2ABC

Circuit Diagram related to Pressure Sensors of No. 3 and 4 Rear Pumps

20-420 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (A000N1) or Error Code (E922)

Failure Code A000N1 or Error Code E922

Failure Code Error Code Failure F. engine overrun

A000N1 E922 Phenomenon (Front engine controller system)
Failure Content • While the front engine is running, the controller detected the engine speed of over 2,500rpm.
Controller
• No action is taken.
Reaction
Phenomenon on
• If being used continuously as it is, the front engine will probably be damaged.
Machine
• Front engine speed can be monitored on the machine monitor and the CGC monitor.
Related
Monitoring code : 10, 70
Information
Monitoring screen : Real time monitor (1/6) & (3/6), PM clinic (2/6) & (4/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

Front engine overrun

1 Check the front engine, and repair it if it is abnormal.
(when the system is normal)
Defective front engine Ne Check if the failure code (DLE3LC) or the error code (E91b) is displayed.
2
sensor system When it is displayed, troubleshoot it.
Defective front engine G sensor Check if the failure code (DLH1LC) or the error code (E91C) is displayed.
3
system When it is displayed, troubleshoot it.
★Turn off the starting switch for preparation and start the engine for troubleshoot-
ing.
4 Defective front engine controller
CGC monitor Front engine Engine speed
Real time monitor (1/6) High idling 1,930 – 2,030rpm

PC1800-6 20-421
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (a000N1) or Error Code (EA22)

Failure Code a000N1 or Error Code EA22

Failure Code Error Code Failure R. engine overrun

a000N1 EA22 Phenomenon (Rear engine controller system)
Failure Content • While the rear engine is running, the controller detected the engine speed of over 2,500rpm.
Controller
• No action is taken.
Reaction
Phenomenon on
• If being used continuously as it is, the rear engine will probably be damaged.
Machine
• Rear engine speed can be monitored on the machine monitor and the CGC monitor.
Related
Monitoring code : 11, 90
Information
Monitoring screen : Real time monitor (2/6) & (4/6), PM clinic (3/6) & (5/6) & (6/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

Rear engine overrun

1 Check the rear engine, and repair it if it is abnormal.
(when the system is normal)
Defective rear engine Ne Check if the failure code (dLE3LC) or the error code (EA1b) is displayed.
2
sensor system When it is displayed, troubleshoot it.
Defective rear engine G sensor Check if the failure code (dLH1LC) or the error code (EA1C) is displayed.
3
system When it is displayed, troubleshoot it.
★Turn off the starting switch for preparation and start the engine for troubleshoot-
ing.
4 Defective rear engine controller
CGC monitor Front engine Engine speed
Real time monitor (2/6) High idling 1,930 – 2,030rpm

20-422 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (AA10NX) or Error Code (104)

Failure Code AA10NX or Error Code 104

Failure Code Error Code Failure F. air cleaner clogging

AA10NX 104 Phenomenon (Pump controller system)
• While the engine is running, the signal circuit of the front air cleaner pressure switch became opened
Failure Content
(isolated from GND).
Controller
• Abnormality (yellow screen) is displayed on the CGC monitor to warn the operator for abnormality.
Reaction
Phenomenon on
• If the machine is kept operating, the front engine will probably be damaged.
Machine
• The input state of the front air cleaner pressure switch signal can be monitored on the machine mon-
Related
itor.
Information
Monitoring Code : 24

Cause Standard value, Remarks for Troubleshooting

Front air cleaner clogging
1 Check the front air cleaner and clean or replace the filter if it is clogged.
(when the system is normal)
★Turn off the starting switch for preparation and troubleshoot while keeping it off
Possible Cause and Standard value

or after starting the engine.

Defective front air cleaner
2 pressure switch (Internal AC (Male) F. air cleaner Resistance value
disconnection) At normal time 1Ω max.
Between 1 and 2
At clogging time 1MΩ min.
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Disconnection of wiring harness Wiring harnesses between FC02 (female) 6 and AC Resistance
1Ω max.
3 (Disconnection, or defective (female) 1 value
contact of connector) Wiring harnesses between AC (female) 2 and Resistance
1Ω max.
ground value
★Turn off the starting switch and start the engine for troubleshooting.
FC02 F. air cleaner Voltage
4 Defective pump controller
At normal time 1V max.
Between 6 and ground
At clogging time 20 – 30V

Circuit Diagram related to Pressure Switch of Front Air Cleaner

PC1800-6 20-423
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aA10NX) or Error Code (105)

Failure Code aA10NX or Error Code 105

Failure Code Error Code Failure R. air cleaner clogging

aA10NX 105 Phenomenon (Pump controller system)
• While the engine is running, the signal circuit of the rear air cleaner pressure switch became opened
Failure Content
(isolated from GND).
Controller
• Abnormality (yellow screen) is displayed on the CGC monitor to warn the operator for abnormality.
Reaction
Phenomenon on
• If the machine is kept operating, the rear engine will probably be damaged.
Machine
Related • The input state of the rear air cleaner pressure switch signal can be monitored on the machine monitor.
Information Monitoring Code : 54

Cause Standard value, Remarks for Troubleshooting

Rear air cleaner clogging (when
1 Check the rear air cleaner and clean or replace the filter if it is clogged.
the system is normal)
★Turn off the starting switch for preparation and troubleshoot while keeping it off
Possible Cause and Standard value

or after starting the engine.

Defective rear air cleaner
2 pressure switch (Internal AC (Male) R. air cleaner Resistance value
disconnection) At normal time 1Ω max.
Between 1 and 2
At clogging time 1MΩ min.
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Disconnection of wiring harness Wiring harnesses between FC01 (female) B and AC Resistance
1Ω max.
3 (Disconnection, or defective (female) 1 value
contact of connector) Wiring harnesses between AC (female) 2 and Resistance
1Ω max.
ground value
★Turn off the starting switch and start the engine for troubleshooting.
FC01 R. air cleaner Voltage
4 Defective pump controller
At normal time 1V max.
Between B and ground
At clogging time 20 – 30V

Circuit Diagram related to Pressure Switch of Rear Air Cleaner

20-424 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (AB00KE)

Failure Code AB00KE

Failure Code Error Code Failure Low F. charge voltage

AB00KE — Phenomenon (Pump controller system)
Failure Content • While the front engine is running, the signal pressure of the front alternator dropped below 20V.
Controller • Abnormality (yellow screen) is displayed on the CGC monitor to warn the operator for abnormality and
Reaction the voltage is also displayed.
Phenomenon on
• If the machine is kept operating, the battery will probably come not to be charged.
Machine
Related • The alternator generating voltage can be monitored on the machine monitor.
Information Monitoring Code : 43

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation and start the engine for troubleshoot-
ing.
F. alternator Front engine Voltage
Possible Cause and Standard value

Defective front alternator

1
(internal defect) Between R terminal and
Over low idling speed 20V min.
ground
When the voltage is abnormal, check tension of the fan belt.
Disconnection of wiring harness ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
2 (Disconnection, or defective Wiring harnesses between FC01 (female) E and Resistance
contact of connector) 1Ω max.
front alternator R terminal value
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Short circuit with ground in
3 wiring harness Wiring harnesses between FC01 (female) E and
Resistance
(Contact with GND circuit) front alternator R terminal, and other related circuits 1MΩ min.
value
and ground.
★Turn off the starting switch and start the engine for troubleshooting.
4 Defective pump controller FC01 Front engine Voltage
Between E and ground Over low idling speed 20V min.

Circuit Diagram related to Front Alternator

PC1800-6 20-425
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aB00KE)

Failure Code aB00KE

Failure Code Error Code Failure Low R. charge voltage

aB00KE — Phenomenon (VHMS controller system)
Failure Content • While the rear engine is running, the signal pressure of the rear alternator dropped below 20V.
Controller • Abnormality (yellow screen) is displayed on the CGC monitor to warn the operator for abnormality and
Reaction the voltage is also displayed.
Phenomenon on
• If the machine is kept operating, the battery will probably come not to be charged.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation and start the engine for troubleshoot-
ing.
Defective rear alternator R. alternator Rear engine Voltage
Possible Cause and Standard value

1
(internal defect) Between R terminal and
Over low idling speed 20V min.
ground
When the voltage is abnormal, check tension of the fan belt.
Disconnection of wiring harness ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
2 (Disconnection, or defective Wiring harnesses between V2A (female) 4 and rear Resistance
contact of connector) 1Ω max.
alternator R terminal value
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Short circuit with ground in
3 wiring harness Wiring harnesses between V2A (female) 4 and rear
Resistance
(Contact with GND circuit) alternator R terminal, and other related circuits and 1MΩ min.
value
ground.
★Turn off the starting switch and start the engine (over the medium speed) for
troubleshooting.
4 Defective VHMS controller
V2A Rear engine Voltage
Between 4 and ground Over low idling speed 20V min.

Circuit Diagram related to Rear Alternator

20-426 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (AD00L2) or Error Code (E979)

Failure Code AD00L2 or Error Code E979

Failure Code Error Code Failure F. common rail press. high

AD00L2 E979 Phenomenon (Front engine controller system)
Failure Content • The signal circuit of the front engine common rail pressure sensor detected a high pressure (Level 1).
Controller
• Operate the machine by limiting the front engine output.
Reaction
Phenomenon on
• The front engine output drops.
Machine
• The front engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 75
Information
Monitoring screen : Real time monitor (1/6)

Cause Standard value, Remarks for Troubleshooting

Check if any failure code or error code is displayed.
1 Defective system concerned
When any other code is displayed, troubleshoot it first.
Possible Cause and Standard value

The fuel in use is supposed to be improper.

2 Use of improper fuel
Check it directly.
Defective electrical system of
3 front engine common rail Troubleshoot Failure Code (DH40KX).
pressure sensor
Defective mechanical system of
The common rail pressure sensor is supposed to be mechanically defective.
4 front engine common rail
Check it directly.
pressure sensor
The spring, the seat and the ball of the overflow valve are supposed to be dam-
Defective front engine overflow
5 aged, worn or adhered respectively.
valve
Check them directly.
Clogging of front engine The overflow pipe is supposed to be clogged.
6
overflow pipe Check it directly.
Defective front engine The pressure limiter is supposed to be mechanically defective.
7
pressure limiter Check it directly.

PC1800-6 20-427
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD00L2) or Error Code (EA79)

Failure Code aD00L2 or Error Code EA79

Failure Code Error Code Failure R. common rail press. high

aD00L2 EA79 Phenomenon (Rear engine controller system)
Failure Content • The signal circuit of the rear engine common rail pressure sensor detected a high pressure (Level 1).
Controller
• Operate the machine by limiting the rear engine output.
Reaction
Phenomenon on
• The rear engine output drops.
Machine
• The rear engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 95
Information
Monitoring screen : Real time monitor (2/6)

Cause Standard value, Remarks for Troubleshooting

Check if any failure code or error code is displayed.
1 Defective system concerned
When any other code is displayed, troubleshoot it first.
Possible Cause and Standard value

The fuel in use is supposed to be improper.

2 Use of improper fuel
Check it directly.
Defective electrical system of
3 rear engine common rail Troubleshoot Failure Code (dH40KX).
pressure sensor
Defective mechanical system of
The common rail pressure sensor is supposed to be mechanically defective.
4 rear engine common rail
Check it directly.
pressure sensor
The spring, the seat and the ball of the overflow valve are supposed to be dam-
Defective rear engine overflow
5 aged, worn or adhered respectively.
valve
Check them directly.
Clogging of rear engine The overflow pipe is supposed to be clogged.
6
overflow pipe Check it directly.
Defective rear engine The pressure limiter is supposed to be mechanically defective.
7
pressure limiter Check it directly.

20-428 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE Failure Code (AD00MA) or Error Code (E97A)
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD00MA) or Error Code (EA7A)

Failure Code AD00MA or Error Code E97A

Failure Code Error Code Failure F. common rail press. abnormal

AD00MA E97A Phenomenon (Front engine controller system)
Failure Content • The signal circuit of the front engine common rail pressure sensor detected a high pressure (Level 2).
Controller
• Operate the front engine by limiting the output and the speed.
Reaction
Phenomenon on
• The front engine output and speed drop.
Machine
• Front engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 75
Information
Monitoring screen : Real time monitor (1/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause
and Standard Equipment related to front
value 1 engine common rail is Troubleshoot Failure Code (AD00L2)
defective.

Failure Code aD00MA or Error Code EA7A

Failure Code Error Code Failure R. common rail press. abnormal

aD00MA EA7A Phenomenon (Rear engine controller system)
Failure Content • The signal circuit of the rear engine common rail pressure sensor detected a high pressure (Level 2).
Controller
• Operate the rear engine by limiting the output and the speed.
Reaction
Phenomenon on
• The rear engine output and speed drop.
Machine
• Rear engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 95
Information
Monitoring screen : Real time monitor (2/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause
and Standard Equipment related to rear
value 1 engine common rail is Troubleshoot Failure Code (aD00L2)
defective.

PC1800-6 20-429
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (AD10L3) or Error Code (E97b)

Failure Code AD10L3 or Error Code E97b

Failure Code Error Code Failure F. common rail press. low

AD10L3 E97b Phenomenon (Front engine controller system)
Failure Content • Non-pressure feeding (Level 1) occurred to the front engine fuel supply pump.
Controller
Reaction
Phenomenon on
• Display Error Code only
Machine
• The front engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 75
Information
Monitoring screen : Real time monitor (1/6)

Cause Standard value, Remarks for Troubleshooting

Check if any failure code or error code is displayed.
1 Defective system concerned
When any other code is displayed, troubleshoot it first.
2 Use of improper fuel The fuel in use is supposed to be improper. Check it directly.
Possible Cause and Standard value

Defective equipment of front The equipment of the low pressure circuit is supposed to be defective.
3
engine fuel low pressure circuit Troubleshoot it referring to Note 1.
Clogging of front engine fuel The filter or the strainer is supposed to be clogged.
4
filter or strainer Troubleshoot it referring to Note 2.
Defective electrical system of
5 front engine fuel supply pump Troubleshoot Failure Codes (AD11KA), [AD11KB], [AD51KA] and [AD51KB].
(F. PCV)
Defective front engine fuel The fuel supply pump is supposed to be defective.
6
supply pump Check it directly.
Defective front engine common The common rail pressure sensor is supposed to be defective.
7
rail pressure sensor Check it directly.
Defective front engine pres- The pressure limiter is supposed to be mechanically defective.
8
sure limiter Check it directly.
Defective front engine fuel The fuel injector is supposed to be defective.
9
injector Troubleshoot it referring to Note 3.

Note 1 : When the low pressure circuit equipment is defective, check the following points:
1) Fuel level
2) Adhesion and wear of feed pump, and clogging of filter
3) Leak from and clogging of low pressure fuel pipe
4) Defective operation of bypass valve and incorrect assembly of other parts (See Fig. 1.)
5) Clogging of fuel filter
6) Mixing of fuel in oil pan (fuel leak inside head cover)
• Fuel pressure of low pressure circuit: 0.15–0.3MPa {1.5–3.0kg/cm2}

20-430 PC1800-6
(4)
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (AD10L3) or Error Code (E97b)

Fig. 1 : Mounting Positions of Overflow Valve 1, Bypass Valve 2 and Fuel Inlet Joint 3
• Overflow Valve 1 : The spring can be seen through the holes on the both sides.
• Bypass Valve 2 : The spring can be seen through the hole on the nut side.
• Fuel Inlet Joint 3 : The gauze filter can be seen through the holes on the both sides.

Note 2 : Check, clean and replace the filters and strainers according to the following procedures:
1) Gauze filter : Disassemble, check and clean it if clogged.
2) Strainer on upper side of gauze filter : When the gauze filter is clogged, clean the upper strainer.
3) Fuel filter : When any problem still remains even after executing the above 1) and 2), replace the fuel filter.

Note 3 : To check if the fuel injector is defective, ★ Limit of Fuel Spill Flow (Total of six cylinders)
measure the fuel spill from the injector.
k Since the temperature of spilt fuel is high (90°C Stall speed (rpm) Spill limit (cc/min.)
max.), be careful not to get scalded during the 1,600 1,960
work. 1,700 1,020
1) Disconnect the hose connected to the spill tube 1,800 1,080
return assembly (on the rear side of the engine). 1,900 1,140
2) Connect another hose to the end of the spill 2,000 1,200
tube so that spilt fuel enters a container.
3) Start the engine and measure spilt fuel in a
minute after stalling it at each speed.

PC1800-6 20-431
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD10L3) or Error Code (EA7b)

Failure Code aD10L3 or Error Code EA7b

Failure Code Error Code Failure R. common rail press. low

aD10L3 EA7b Phenomenon (Rear engine controller system)
Failure Content • Non-pressure feeding (Level 1) occurred to the rear engine fuel supply pump.
Controller
• Operate the machine by limiting the rear engine output.
Reaction
Phenomenon on
• The rear engine output drops.
Machine
• The rear engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 95
Information
Monitoring screen : Real time monitor (2/6)

Cause Standard value, Remarks for Troubleshooting

Check if any failure code or error code is displayed.
1 Defective system concerned
When any other code is displayed, troubleshoot it first.
2 Use of improper fuel The fuel in use is supposed to be improper. Check it directly.
Possible Cause and Standard value

Defective equipment of rear The equipment of the low pressure circuit is supposed to be defective.
3
engine fuel low pressure circuit Troubleshoot it referring to Note 1.
Clogging of rear engine fuel The filter or the strainer is supposed to be clogged.
4
filter or strainer Troubleshoot it referring to Note 2.
Defective electrical system of
5 rear engine fuel supply pump Troubleshoot Failure Codes (aD11KA), [aD11KB], [aD51KA] and [aD51KB].
(R. PCV)
Defective rear engine fuel The fuel supply pump is supposed to be defective.
6
supply pump Check it directly.
Defective rear engine common The common rail pressure sensor is supposed to be defective.
7
rail pressure sensor Check it directly.
Defective rear engine pressure The pressure limiter is supposed to be mechanically defective.
8
limiter Check it directly.
Defective rear engine fuel The fuel injector is supposed to be defective.
9
injector Troubleshoot it referring to Note 3.

Note 1 : When the low pressure circuit equipment is defective, check the following points:
1) Fuel level
2) Adhesion and wear of feed pump, and clogging of filter
3) Leak from and clogging of low pressure fuel pipe
4) Defective operation of bypass valve and incorrect assembly of other parts (See Fig. 1.)
5) Clogging of fuel filter
6) Mixing of fuel in oil pan (fuel leak inside head cover)
• Fuel pressure of low pressure circuit: 0.15–0.3MPa {1.5–3.0kg/cm2}

20-432 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD10L3) or Error Code (EA7b)

Fig. 1 : Mounting Positions of Overflow Valve 1, Bypass Valve 2 and Fuel Inlet Joint 3
• Overflow Valve 1 : The spring can be seen through the holes on the both sides.
• Bypass Valve 2 : The spring can be seen through the hole on the nut side.
• Fuel Inlet Joint 3 : The gauze filter can be seen through the holes on the both sides.

Note 2 : Check, clean and replace the filters and strainers according to the following procedures:
1) Gauze filter : Disassemble, check and clean it if clogged.
2) Strainer on upper side of gauze filter : When the gauze filter is clogged, clean the upper strainer.
3) Fuel filter : When any problem still remains even after executing the above 1) and 2), replace the fuel filter.

Note 3 : To check if the fuel injector is defective, ★ Limit of Fuel Spill Flow (Total of six cylinders)
measure the fuel spill from the injector.
k Since the temperature of spilt fuel is high (90°C Stall speed (rpm) Spill limit (cc/min.)
max.), be careful not to get scalded during the 1,600 1,960
work. 1,700 1,020
1) Disconnect the hose connected to the spill tube 1,800 1,080
return assembly (on the rear side of the engine). 1,900 1,140
2) Connect another hose to the end of the spill 2,000 1,200
tube so that spilt fuel enters a container.
3) Start the engine and measure spilt fuel in a
minute after stalling it at each speed.

PC1800-6 20-433
TROUBLESHOOTING AT DISPLAY OF FAILURE Failure Code (AD10MA) or Error Code (E97d)
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD10MA) or Error Code (EA7d)

Failure Code AD10MA or Error Code E97d

Failure Code Error Code Failure F. common rail press. out of control
AD10MA E97d Phenomenon (Front engine controller system)
Failure Content • The fuel pressure of the front engine common rail became abnormal.
Controller
• Operate the machine by controlling it normally.
Reaction
Phenomenon on
• The front engine output drops.
Machine
• The front engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 75
Information
Monitoring screen : Real time monitor (1/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause
and Standard Equipment related to front
value 1 engine common rail is Execute Failure Code (AD10L3).
defective.

Failure Code aD10MA or Error Code EA7d

Failure Code Error Code Failure R. common rail press. out of control
aD10MA EA7d Phenomenon (Rear engine controller system)
Failure Content • The fuel pressure of the rear engine common rail became abnormal.
Controller
• Operate the machine by controlling it normally.
Reaction
Phenomenon on
• The rear engine output drops.
Machine
• The rear engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 95
Information
Monitoring screen : Real time monitor (2/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause
and Standard Equipment related to rear
value 1 engine common rail is Execute Failure Code (aD10L3).
defective.

20-434 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE Failure Code (AD10MB) or Error Code (E97C)
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD10MB) or Error Code (EA7C)

Failure Code AD10MB or Error Code E97C

Failure Code Error Code Failure F. common rail press. too low
AD10MB E97C Phenomenon (Front engine controller system)
Failure Content • Non-pressure feeding (Level 2) occurred to the front engine fuel supply pump.
Controller
• Operate the machine by limiting output and speed of the front engine.
Reaction
Phenomenon on
• The front engine output drops.
Machine
• The front engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 75
Information
Monitoring screen : Real time monitor (1/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause
and Standard Equipment related to front
value 1 engine common rail is Execute Failure Code (AD10L3).
defective.

Failure Code aD10MB or Error Code EA7C

Failure Code Error Code Failure R. common rail press. too low
aD10MB EA7C Phenomenon (Rear engine controller system)
Failure Content • Non-pressure feeding (Level 2) occurred to the rear engine fuel supply pump.
Controller
• Operate the machine by limiting output and speed of the rear engine.
Reaction
Phenomenon on
• The rear engine output drops.
Machine
• The rear engine common rail pressure can be checked on the machine monitor and the CGC monitor.
Related
Monitoring code : 95
Information
Monitoring screen : Real time monitor (2/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause
and Standard Equipment related to rear
value 1 engine common rail is Execute Failure Code (aD10L3).
defective.

PC1800-6 20-435
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (AD11KA) or Error Code (E974)

Failure Code AD11KA or Error Code E974

Failure Code Error Code Failure F. PCV1 line cut

AD11KA E974 Phenomenon (Front engine controller system)
Failure Content • Any disconnection occurred in the F. PCV1 (Front Engine Fuel Supply Pump No.1) circuit.
Controller
• Stop outputting to the F. PCV1 circuit.
Reaction
• F. PCV2 keeps controlling but the engine stops when the following failures occurred at the same time:
Phenomenon on
1 Failure Code (AD51KA) (or) Error Code (E975)
Machine
2 Failure Code (AD51KB) (or) Error Code (E971)
Related
• For troubleshooting F. PVC1, the special adapter (799-601-9430) is necessary.
Information

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
F. PCV1 is defective. PVC1 (Male) Resistance value
1
(Internal disconnection) Between 1 and 2 2.3 – 5.3Ω
Possible Cause and Standard value

Between 1 and ground 1MΩ min.

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Disconnection of wiring harness Wiring harnesses between FE03 (female) B and Resistance
1Ω max.
2 (Disconnection, or defective PCV1 (female) 1 value
contact of connector) Wiring harnesses between FE03 (female) L and Resistance
1Ω max.
PCV1 (female) 2 value
Short circuit with ground in wir- ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 ing harness (Contact with GND Wiring harnesses between FE03 (female) L and Resistance
circuit) 1MΩ min.
PCV1 (female) 2, and ground. value
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
FE03 (Female) Resistance value
4 Defective front engine controller
Between B and L 2.3 – 5.3Ω
Between BL and ground 1MΩ min.

Circuit Diagram related to F. PCV1 (Front Engine Fuel Supply Pump No.1)

20-436 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD11KA) or Error Code (EA74)

Failure Code aD11KA or Error Code EA74

Failure Code Error Code Failure R. PCV1 line cut

aD11KA EA74 Phenomenon (Rear engine controller system)
Failure Content • Any disconnection occurred in the R. PCV1 (Rear Engine Fuel Supply Pump No.1) circuit.
Controller
• Stop outputting to the R. PCV1 circuit.
Reaction
• R. PCV2 keeps controlling but the engine stops when the following failures occurred at the same time:
Phenomenon on
1 Failure Code (aD51KA) (or) Error Code (EA75)
Machine
2 Failure Code (aD51KB) (or) Error Code (EA71)
Related
• For troubleshooting F. PVC1, the special adapter (799-601-9430) is necessary.
Information

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
R. PCV1 is defective. PVC1 (Male) Resistance value
1
(Internal disconnection) Between 1 and 2 2.3 – 5.3Ω
Possible Cause and Standard value

Between 1 and ground 1MΩ min.

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Disconnection of wiring harness Wiring harnesses between RE03 (female) B and Resistance
1Ω max.
2 (Disconnection, or defective PCV1 (female) 1 value
contact of connector) Wiring harnesses between RE03 (female) L and Resistance
1Ω max.
PCV1 (female) 2 value
Short circuit with ground in wir- ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 ing harness (Contact with GND Wiring harnesses between RE03 (female) L and Resistance
circuit) 1MΩ min.
PCV1 (female) 2, and ground. value
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
RE03 (Female) Resistance value
4 Defective rear engine controller
Between B and L 2.3 – 5.3Ω
Between BL and ground 1MΩ min.

Circuit Diagram related to R. PCV1 (Rear Engine Fuel Supply Pump No.1)

PC1800-6 20-437
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (AD11KB) or Error Code (E970)

Failure Code AD11KB or Error Code E970

Failure Code Error Code Failure F. PCV1 over current

AD11KB E970 Phenomenon (Front engine controller system)
Failure Content • Any abnormal current flew through the F. PCV1 (Front Engine Fuel Supply Pump No.1) circuit.
Controller
• Stop outputting to the F. PCV1 circuit.
Reaction
• F. PCV2 keeps controlling but the engine stops when the following failures occurred at the same time:
Phenomenon on
1 Failure Code (AD51KA) (or) Error Code (E975)
Machine
2 Failure Code (AD51KB) (or) Error Code (E971)
Related
• For troubleshooting F. PVC1, the special adapter (799-601-9430) is necessary.
Information

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
F. PCV1 is defective. PVC1 (Male) Resistance value
1
(Internal disconnection) Between 1 and 2 2.3 – 5.3Ω
Possible Cause and Standard value

Between 1 and ground 1MΩ min.

Short circuit with ground in ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
2 wiring harness (Contact with Wiring harnesses between FE03 (female) B and Resistance
GND circuit) 1MΩ min.
PCV1 (female) 1, and ground. value
★Turn off the starting switch for preparation and turn it on for troubleshooting.
Hot short-circuit of wiring Wiring harness between FE03 (female) B and PCV1
Voltage 1V max.
3 harness (female) 1 and ground
(contact with 24V circuit) Wiring harness between FE01 (female) L and PCV1
Voltage 1V max.
(female) 2 and ground
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
FE03 (Female) Resistance value
4 Defective front engine controller
Between B and L 2.3 – 5.3Ω
Between BL and ground 1MΩ min.

Circuit Diagram related to F. PCV1 (Front Engine Fuel Supply Pump No.1)

20-438 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD11KB) or Error Code (EA70)

Failure Code aD11KB or Error Code EA70

Failure Code Error Code Failure R. PCV1 over current

aD11KB EA70 Phenomenon (Rear engine controller system)
Failure Content • Any abnormal current flew through the R. PCV1 (Rear Engine Fuel Supply Pump No.1) circuit.
Controller
• Stop outputting to the R. PCV1 circuit.
Reaction
• R. PCV2 keeps controlling but the engine stops when the following failures occurred at the same time:
Phenomenon on
1 Failure Code (aD51KA) (or) Error Code (EA75)
Machine
2 Failure Code (aD51KB) (or) Error Code (EA71)
Related
• For troubleshooting F. PVC1, the special adapter (799-601-9430) is necessary.
Information

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
R. PCV1 is defective. PVC1 (Male) Resistance value
1
(Internal disconnection) Between 1 and 2 2.3 – 5.3Ω
Possible Cause and Standard value

Between 1 and ground 1MΩ min.

Short circuit with ground in ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
2 wiring harness (Contact with Wiring harnesses between RE03 (female) B and Resistance
GND circuit) 1MΩ min.
PCV1 (female) 1, and ground. value
★Turn off the starting switch for preparation and turn it on for troubleshooting.
Hot short-circuit of wiring Wiring harness between RE03 (female) B and PCV1
Voltage 1V max.
3 harness (female) 1 and ground
(contact with 24V circuit) Wiring harness between RE03 (female) L and PCV1
Voltage 1V max.
(female) 2 and ground
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
RE03 (Female) Resistance value
4 Defective rear engine controller
Between B and L 2.3 – 5.3Ω
Between BL and ground 1MΩ min.

Circuit Diagram related to R. PCV1 (Rear Engine Fuel Supply Pump No.1)

PC1800-6 20-439
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (AD51KA) or Error Code (E975)

Failure Code AD51KA or Error Code E975

Failure Code Error Code Failure F. PCV2 line cut

AD51KA E975 Phenomenon (Front engine controller system)
Failure Content • Any disconnection occurred in the F. PCV2 (Front Engine Fuel Supply Pump No.2) circuit.
Controller
• Stop outputting to the F. PCV2 circuit.
Reaction
• F. PCV1 keeps controlling but the engine stops when the following failures occurred at the same time:
Phenomenon on
1 Failure Code (AD11KA) (or) Error Code (E974)
Machine
2 Failure Code (AD11KB) (or) Error Code (E970)
Related
• For troubleshooting F. PVC2, the special adapter (799-601-9430) is necessary.
Information

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
F. PCV2 is defective. PVC2 (Male) Resistance value
1
(Internal disconnection) Between 1 and 2 2.3 – 5.3Ω
Possible Cause and Standard value

Between 1 and ground 1MΩ min.

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Disconnection of wiring harness Wiring harnesses between FE03 (female) C and Resistance
1Ω max.
2 (Disconnection, or defective PCV2 (female) 1 value
contact of connector) Wiring harnesses between FE03 (female) M and Resistance
1Ω max.
PCV2 (female) 2 value
Short circuit with ground in wir- ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 ing harness (Contact with GND Wiring harnesses between FE03 (female) M and Resistance
circuit) 1MΩ min.
PCV2 (female) 2, and ground. value
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
FE03 (Female) Resistance value
4 Defective front engine controller
Between C and M 2.3 – 5.3Ω
Between CM and ground 1MΩ min.

Circuit Diagram related to F. PCV2 (Front Engine Fuel Supply Pump No.2)

20-440 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD51KA) or Error Code (EA75)

Failure Code aD51KA or Error Code EA75

Failure Code Error Code Failure R. PCV2 line cut

aD51KA EA75 Phenomenon (Rear engine controller system)
Failure Content • Any disconnection occurred in the R. PCV2 (Rear Engine Fuel Supply Pump No.2) circuit.
Controller
• Stop outputting to the R. PCV2 circuit.
Reaction
• R. PCV1 keeps controlling but the engine stops when the following failures occurred at the same time:
Phenomenon on
1 Failure Code (aD11KA) (or) Error Code (EA74)
Machine
2 Failure Code (aD11KB) (or) Error Code (EA70)
Related
• For troubleshooting R. PVC2, the special adapter (799-601-9430) is necessary.
Information

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
R. PCV2 is defective. PVC2 (Male) Resistance value
1
(Internal disconnection) Between 1 and 2 2.3 – 5.3Ω
Possible Cause and Standard value

Between 1 and ground 1MΩ min.

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Disconnection of wiring harness Wiring harnesses between RE03 (female) C and Resistance
1Ω max.
2 (Disconnection, or defective PCV2 (female) 1 value
contact of connector) Wiring harnesses between RE03 (female) M and Resistance
1Ω max.
PCV2 (female) 2 value
Short circuit with ground in wir- ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 ing harness (Contact with GND Wiring harnesses between RE03 (female) M and Resistance
circuit) 1MΩ min.
PCV2 (female) 2, and ground. value
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
RE03 (Female) Resistance value
4 Defective rear engine controller
Between C and M 2.3 – 5.3Ω
Between CM and ground 1MΩ min.

Circuit Diagram related to R. PCV2 (Rear Engine Fuel Supply Pump No.2)

PC1800-6 20-441
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (AD51KB) or Error Code (E971)

Failure Code AD51KB or Error Code E971

Failure Code Error Code Failure F. PCV2 over current

AD51KB E971 Phenomenon (front engine controller system)
Failure Content • Abnormal current flew into F.PCV2 (front engine fuel supply pump No.2) circuit.
Controller
• Stops output to F.PCV2 circuit.
Reaction
• Control is continued with F.PCV1; engine stops, though, if either of the following abnormalities occurs
Phenomenon on additionally:
Machine 1 Failure code (AD11KA) or error code (E974)
2 Failure code (AD11KB) or error code (E970)
Related
• Special adapter (799-601-9430) is required for diagnosing F.PCV2.
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.PCV2 PCV2 (male) Resistance
1
(internal short-circuit) 1-2 2.3 – 5.3Ω
Possible Cause and Standard value

1 - GND 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 grounding (contact with GND Between harness (FE03 (female) C - PCV2 (female)
circuit) Resistance 1MΩ min.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Defective harness caused by
Between harness (FE03 (female) C - PCV2 (female)
3 hot-short-circuit Voltage 1V max.
1) and GND
(contact with 24V circuit)
Between harness (FE03 (female) M - PCV2 (female)
Voltage 1V max.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
FE03(Female) Resistance
4 Defective front engine controller
C-M 2.3 – 5.3Ω
CM - GND 1MΩ min.

Circuit diagram for F.PCV2 (front engine fuel supply pump No.2)

20-442 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aD51KB) or Error Code (EA71)

Failure Code aD51KB or Error Code EA71

Failure Code Error Code Failure R. PCV2 over current

aD51KB EA71 Phenomenon (rear engine controller system)
Failure Content • Abnormal current flew into R.PCV2 (rear engine fuel supply pump No.2) circuit.
Controller
• Stops output to R.PCV2 circuit.
Reaction
• Control is continued with R.PCV1; engine stops, though, if either of the following abnormalities occurs
Phenomenon on additionally:
Machine 1 Failure code (aD11KA) or error code (EA74)
2 Failure code (aD11KB) or error code (EA70)
Related
• Special adapter (799-601-9430) is required for diagnosing R.PCV2.
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.PCV2 PCV2 (male) Resistance
1
(internal short-circuit) 1-2 2.3 – 5.3Ω
Possible Cause and Standard value

1 - GND 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 grounding (contact with GND Between harness (RE03 (female) C - PCV2 (female)
circuit) Resistance 1MΩ min.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Defective harness caused by
Between harness (RE03 (female) C - PCV2 (female)
3 hot-short-circuit Voltage 1V max.
1) and GND
(contact with 24V circuit)
Between harness (RE03 (female) M - PCV2 (female)
Voltage 1V max.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
RE03(Female) Resistance
4 Defective rear engine controller
C-M 2.3 – 5.3Ω
CM - GND 1MΩ min.

Circuit diagram for R.PCV2 (rear engine fuel supply pump No.2)

PC1800-6 20-443
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADA1KA) or Error Code (E981)

Failure Code ADA1KA or Error Code E981

Failure Code Error Code Failure F. TWV#1 line cut

ADA1KA E981 Phenomenon (front engine controller system)
Failure Content • Disconnection occurred in the circuit of F.TWV No.1 (front engine injector No. 1).
Controller
• Stops output to the circuit of F.TWV No.1.
Reaction
Phenomenon on
• Output from front engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No.1 circuit
1 CN1 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FE03 (female) D - CN1 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (FE03 (female) N - CN1 (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective front engine controller FE03 (Female) Resistance
D-N 0.4 – 1.1Ω

Circuit diagram for F.TWV No. 1 (front engine injector No. 1)

20-444 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDA1KA) or Error Code (EA81)

Failure Code aDA1KA or Error Code EA81

Failure Code Error Code Failure R. TWV#1 line cut

aDA1KA EA81 Phenomenon (rear engine controller system)
Failure Content • Disconnection occurred in the circuit of R.TWV No.1 (rear engine injector No. 1).
Controller
• Stops output to the circuit of R.TWV No.1.
Reaction
Phenomenon on
• Output from rear engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No.1 circuit
1 CN1 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (RE03 (female) D - CN1 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (RE03 (female) N - CN1 (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective rear engine controller RE03 (Female) Resistance
D-N 0.4 – 1.1Ω

Circuit diagram for R.TWV No. 1 (rear engine injector No. 1)

PC1800-6 20-445
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADAZKB) or Error Code (E98A)

Failure Code ADAZKB or Error Code E98A

Failure Code Error Code Failure F. TWV#1,2,3 line short

ADAZKB E98A Phenomenon (front engine controller system)
Failure Content • Abnormal current flew into F.TWV No. 1, 2, or 3 (injector No. 1, 2, or 3, respectively) circuit.
Controller
• Stops output to the circuit of F.TWV No. 1, 2, or 3.
Reaction
Phenomenon on
• Output from front engine drops greatly.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No. 1 CN1 (male) Resistance
1
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No. 2 CN2 (male) Resistance
2
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No. 3 CN3 (male) Resistance
3
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Between harness (FE03 (female) D - CN1 (female)

Resistance 1MΩ min.
1) and GND
Between harness (FE03 (female) N - CN1 (female)
Resistance 1MΩ min.
2) and GND
Defective harness caused by Between harness (FE03 (female) 6 - CN2 (female)
Resistance 1MΩ min.
4 grounding (contact with GND 1) and GND
circuit) Between harness (FE03 (female) F - CN2 (female)
Resistance 1MΩ min.
2) and GND
Between harness (FE03 (female) 5 - CN3 (female)
Resistance 1MΩ min.
1) and GND
Between harness (FE03 (female) E - CN3 (female)
Resistance 1MΩ min.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (FE03 (female) D - CN1 (female)
Voltage 1V max.
1) and GND
Between harness (FE03 (female) N - CN1 (female)
Voltage 1V max.
2) and GND
Defective harness caused by
Between harness (FE03 (female) 6 - CN2 (female)
5 hot-short-circuit (contact with Voltage 1V max.
1) and GND
24V circuit)
Between harness (FE03 (female) F - CN2 (female)
Voltage 1V max.
2) and GND
Between harness (FE03 (female) 5 - CN3 (female)
Voltage 1V max.
1) and GND
Between harness (FE03 (female) E - CN3 (female)
Voltage 1V max.
2) and GND

20-446 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADAZKB) or Error Code (E98A)

Circuit diagram for F.TWV No. 1, 2, and 3 (injector No. 1, 2, and 3, respectively)

PC1800-6 20-447
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDAZKB) or Error Code (EA8A)

Failure Code aDAZKB or Error Code EA8A

Failure Code Error Code Failure R. TWV#1,2,3 line short

aDAZKB EA8A Phenomenon (rear engine controller system)
Failure Content • Abnormal current flew into R.TWV No. 1, 2, or 3 (injector No. 1, 2, or 3, respectively) circuit.
Controller
• Stops output to the circuit of R.TWV No. 1, 2, or 3.
Reaction
Phenomenon on
• Output from rear engine drops greatly.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No. 1 CN1 (male) Resistance
1
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No. 2 CN2 (male) Resistance
2
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No. 3 CN3 (male) Resistance
3
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Between harness (RE03 (female) D - CN1 (female)

Resistance 1MΩ min.
1) and GND
Between harness (RE03 (female) N - CN1 (female)
Resistance 1MΩ min.
2) and GND
Defective harness caused by Between harness (RE03 (female) 6 - CN2 (female)
Resistance 1MΩ min.
4 grounding (contact with GND 1) and GND
circuit) Between harness (RE03 (female) F - CN2 (female)
Resistance 1MΩ min.
2) and GND
Between harness (RE03 (female) 5 - CN3 (female)
Resistance 1MΩ min.
1) and GND
Between harness (RE03 (female) E - CN3 (female)
Resistance 1MΩ min.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (RE03 (female) D - CN1 (female)
Voltage 1V max.
1) and GND
Between harness (RE03 (female) N - CN1 (female)
Voltage 1V max.
2) and GND
Defective harness caused by
Between harness (RE03 (female) 6 - CN2 (female)
5 hot-short-circuit (contact with Voltage 1V max.
1) and GND
24V circuit)
Between harness (RE03 (female) F - CN2 (female)
Voltage 1V max.
2) and GND
Between harness (RE03 (female) 5 - CN3 (female)
Voltage 1V max.
1) and GND
Between harness (RE03 (female) E - CN3 (female)
Voltage 1V max.
2) and GND

20-448 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDAZKB) or Error Code (EA8A)

Circuit diagram for R.TWV No. 1, 2, and 3 (injector No. 1, 2, and 3, respectively)

PC1800-6 20-449
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADB1KA) or Error Code (E982)

Failure Code ADB1KA or Error Code E982

Failure Code Error Code Failure F. TWV#2 line cut

ADB1KA E982 Phenomenon (front engine controller system)
Failure Content • Disconnection occurred in the circuit of F.TWV No. 2 (front engine injector No. 2).
Controller
• Stops output to the circuit of F.TWV No. 2.
Reaction
Phenomenon on
• Output from front engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No. 2
1 CN2 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FE03 (female) 6 - CN2 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (FE03 (female) F - CN2 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective front engine controller FE03 (Female) Resistance
6-F 0.4 – 1.1Ω

Circuit diagram for F.TWV No. 2 (front engine injector No. 2)

20-450 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDB1KA) or Error Code (EA82)

Failure Code aDB1KA or Error Code EA82

Failure Code Error Code Failure R. TWV#2 line cut

aDB1KA EA82 Phenomenon (rear engine controller system)
Failure Content • Disconnection occurred in the circuit of R.TWV No. 2 (rear engine injector No. 2).
Controller
• Stops output to the circuit of R.TWV No. 2.
Reaction
Phenomenon on
• Output from rear engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No. 2
1 CN2 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (RE03 (female) 6 - CN2 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (RE03 (female) F - CN2 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective rear engine controller RE03 (Female) Resistance
6-F 0.4 – 1.1Ω

Circuit diagram for R.TWV No. 2 (rear engine injector No. 2)

PC1800-6 20-451
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADC1KA) or Error Code (E983)

Failure Code ADC1KA or Error Code E983

Failure Code Error Code Failure F. TWV#3 line cut

ADC1KA E983 Phenomenon (front engine controller system)
Failure Content • Disconnection occurred in the circuit of F.TWV No. 3 (front engine injector No. 3).
Controller
• Stops output to the circuit of F.TWV No. 3.
Reaction
Phenomenon on
• Output from front engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No. 3
1 CN3 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FE03 (female) 5 - CN3 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (FE03 (female) E - CN3 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective front engine controller FE03 (Female) Resistance
5-E 0.4 – 1.1Ω

Circuit diagram for F.TWV No. 3 (front engine injector No. 3)

20-452 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDC1KA) or Error Code (EA83)

Failure Code aDC1KA or Error Code EA83

Failure Code Error Code Failure R. TWV#3 line cut

aDC1KA EA83 Phenomenon (rear engine controller system)
Failure Content • Disconnection occurred in the circuit of R.TWV No. 3 (rear engine injector No. 3).
Controller
• Stops output to the circuit of R.TWV No. 3.
Reaction
Phenomenon on
• Output from rear engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No. 3
1 CN3 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (RE03 (female) 5 - CN3 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (RE03 (female) E - CN3 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective rear engine controller RE03 (Female) Resistance
5-E 0.4 – 1.1Ω

Circuit diagram for R.TWV No. 3 (rear engine injector No. 3)

PC1800-6 20-453
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADD1KA) or Error Code (E984)

Failure Code ADD1KA or Error Code E984

Failure Code Error Code Failure F. TWV#4 line cut

ADD1KA E984 Phenomenon (front engine controller system)
Failure Content • Disconnection occurred in the circuit of F.TWV No. 4 (front engine injector No. 4).
Controller
• Stops output to the circuit of F.TWV No. 4.
Reaction
Phenomenon on
• Output from front engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No. 4
1 CN4 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FE03 (female) P - CN4 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (FE03 (female) Z - CN4 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective front engine controller FE03 (Female) Resistance
P-Z 0.4 – 1.1Ω

Circuit diagram for F.TWV No. 4 (front engine injector No. 4)

20-454 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDD1KA) or Error Code (EA84)

Failure Code aDD1KA or Error Code EA84

Failure Code Error Code Failure R. TWV#4 line cut

aDD1KA EA84 Phenomenon (rear engine controller system)
Failure Content • Disconnection occurred in the circuit of R.TWV No. 4 (rear engine injector No. 4).
Controller
• Stops output to the circuit of R.TWV No. 4.
Reaction
Phenomenon on
• Output from rear engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No. 4
1 CN4 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (RE03 (female) P - CN4 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (RE03 (female) Z - CN4 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective rear engine controller RE03 (Female) Resistance
P-Z 0.4 – 1.1Ω

Circuit diagram for R.TWV No. 4 (rear engine injector No. 4)

PC1800-6 20-455
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADDZKB) or Error Code (E98b)

Failure Code ADDZKB or Error Code E98b

Failure Code Error Code Failure F. TWV#4,5,6 line short

ADDZKB E98b Phenomenon (front engine controller system)
Failure Content • Abnormal current flew into F.TWV No. 4, 5, or 6 (injector No. 4, 5, or 6, respectively) circuit.
Controller
• Stops output to the circuit of F.TWV No. 4, 5, or 6
Reaction
Phenomenon on
• Output from front engine drops greatly.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No. 4 CN4 (male) Resistance
1
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No. 5 CN5 (male) Resistance
2
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No. 6 CN6 (male) Resistance
3
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Between harness (FE03 (female) P - CN4 (female)

Resistance 1MΩ min.
1) and GND
Between harness (FE03 (female) Z - CN4 (female)
Resistance 1MΩ min.
2) and GND
Defective harness caused by Between harness (FE03 (female) X - CN6 (female)
Resistance 1MΩ min.
4 grounding (contact with GND 1) and GND
circuit) Between harness (FE03 (female) W - CN6 (female)
Resistance 1MΩ min.
2) and GND
Between harness (FE03 (female) O - CN5 (female)
Resistance 1MΩ min.
1) and GND
Between harness (FE03 (female) Y - CN5 (female)
Resistance 1MΩ min.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (FE03 (female) P - CN4 (female)
Voltage 1V max.
1) and GND
Between harness (FE03 (female) Z - CN4 (female)
Voltage 1V max.
2) and GND
Defective harness caused by
Between harness (FE03 (female) X - CN6 (female)
5 hot-short-circuit (contact with Voltage 1V max.
1) and GND
24V circuit)
Between harness (FE03 (female) W - CN6 (female)
Voltage 1V max.
2) and GND
Between harness (FE03 (female) O - CN5 (female)
Voltage 1V max.
1) and GND
Between harness (FE03 (female) Y - CN5 (female)
Voltage 1V max.
2) and GND

20-456 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADDZKB) or Error Code (E98b)

Circuit diagram for F.TWV No. 4, 5, and 6 (front injector No. 4, 5, and 6, respectively)

PC1800-6 20-457
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDDZKB) or Error Code (EA8b)

Failure Code aDDZKB or Error Code EA8b

Failure Code Error Code Failure R. TWV#4,5,6 line short

aDDZKB EA8b Phenomenon (rear engine controller system)
Failure Content • Abnormal current flew into R.TWV No. 4, 5, or 6 (injector No. 4, 5, or 6, respectively) circuit.
Controller
• Stops output to the circuit of R.TWV No. 4, 5, or 6.
Reaction
Phenomenon on
• Output from rear engine drops greatly.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No. 4 CN4 (male) Resistance
1
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No. 5 CN5 (male) Resistance
2
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No. 6 CN6 (male) Resistance
3
(internal short-circuit) 1-2 0.4 – 1.1Ω
12 - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Between harness (RE03 (female) P - CN4 (female)

Resistance 1MΩ min.
1) and GND
Between harness (RE03 (female) Z - CN4 (female)
Resistance 1MΩ min.
2) and GND
Defective harness caused by Between harness (RE03 (female) X - CN6 (female)
Resistance 1MΩ min.
4 grounding (contact with GND 1) and GND
circuit) Between harness (RE03 (female) W - CN6 (female)
Resistance 1MΩ min.
2) and GND
Between harness (RE03 (female) O - CN5 (female)
Resistance 1MΩ min.
1) and GND
Between harness (RE03 (female) Y - CN5 (female)
Resistance 1MΩ min.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (RE03 (female) P - CN4 (female)
Voltage 1V max.
1) and GND
Between harness (RE03 (female) Z - CN4 (female)
Voltage 1V max.
2) and GND
Defective harness caused by
Between harness (RE03 (female) X - CN6 (female)
5 hot-short-circuit (contact with Voltage 1V max.
1) and GND
24V circuit)
Between harness (RE03 (female) W - CN6 (female)
Voltage 1V max.
2) and GND
Between harness (RE03 (female) O - CN5 (female)
Voltage 1V max.
1) and GND
Between harness (RE03 (female) Y - CN5 (female)
Voltage 1V max.
2) and GND

20-458 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDDZKB) or Error Code (EA8b)

Circuit diagram for R.TWV No. 4, 5, and 6 (rear injector No. 4, 5, and 6, respectively)

PC1800-6 20-459
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADE1KA) or Error Code (E985)

Failure Code ADE1KA or Error Code E985

Failure Code Error Code Failure F. TWV#5 line cut

ADE1KA E985 Phenomenon (front engine controller system)
Failure Content • Disconnection occurred in the circuit of F.TWV No.5 (front engine injector No. 5).
Controller
• Stops output to the circuit of F.TWV No.5.
Reaction
Phenomenon on
• Output from front engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No.5 circuit
1 CN5 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FE03 (female) X - CN5 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (FE03 (female) W - CN5 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective front engine controller FE03 (Female) Resistance
X-W 0.4 – 1.1Ω

Circuit diagram for F.TWV No. 5 (front engine injector No. 5)

20-460 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDE1KA) or Error Code (EA85)

Failure Code aDE1KA or Error Code EA85

Failure Code Error Code Failure R. TWV#5 line cut

aDE1KA EA85 Phenomenon (rear engine controller system)
Failure Content • Disconnection occurred in the circuit of R.TWV No.5 (rear engine injector No. 5).
Controller
• Stops output to the circuit of R.TWV No.5.
Reaction
Phenomenon on
• Output from rear engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No.5 circuit
1 CN5 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (RE03 (female) X - CN5 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (RE03 (female) W - CN5 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective rear engine controller RE03 (Female) Resistance
X-W 0.4 – 1.1Ω

Circuit diagram for R.TWV No. 5 (rear engine injector No. 5)

PC1800-6 20-461
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (ADF1KA) or Error Code (E986)

Failure Code ADF1KA or Error Code E986

Failure Code Error Code Failure F. TWV#6 line cut

ADF1KA E986 Phenomenon (front engine controller system)
Failure Content • Disconnection occurred in the circuit of F.TWV No.6 (front engine injector No. 6).
Controller
• Stops output to the circuit of F.TWV No.6.
Reaction
Phenomenon on
• Output from front engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective F.TWV No.6 circuit
1 CN6 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FE03 (female) O - CN6 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (FE03 (female) Y - CN6 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective front engine controller FE03 (Female) Resistance
O-Y 0.4 – 1.1Ω

Circuit diagram for F.TWV No. 6 (front engine injector No. 6)

20-462 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (aDF1KA) or Error Code (EA86)

Failure Code aDF1KA or Error Code EA86

Failure Code Error Code Failure R. TWV#6 line cut

aDF1KA EA86 Phenomenon (rear engine controller system)
Failure Content • Disconnection occurred in the circuit of R.TWV No.6 (rear engine injector No. 6).
Controller
• Stops output to the circuit of R.TWV No.6.
Reaction
Phenomenon on
• Output from rear engine drops.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective R.TWV No.6 circuit
1 CN6 (male) Resistance
(internal disconnection)
1-2 0.4 – 1.1Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (RE03 (female) O - CN6 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (RE03 (female) Y - CN6 (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective rear engine controller RE03 Resistance
O-Y 0.4 – 1.1Ω

Circuit diagram for R.TWV No. 6 (rear engine injector No. 6)

PC1800-6 20-463
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (B@BAZG) or Error Code (E924)

Failure Code B@BAZG or Error Code E924

Failure Code Error Code Failure F. engine oil press. down

B@BAZG E924 Phenomenon (front engine controller system)
• Signal circuits of both low- and high-pressure switches closed (connected to GND) when front engine
is running at 600 rpm or more.
Failure Content
• Signal circuits of low-pressure switch opened (disconnected from GND) and that of high-pressure
switch closed (connected to GND) when front engine is running at 1,300 rpm or more.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, front engine may be damaged.
Machine
Related • Oil-pressure of front engine can be monitored on the machine monitor.
Information Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

Dropped front engine
1 oil-pressure Check engine oil-pressure; if abnormal, correct it.
Possible Cause and Standard value

(when system is normal)

Defective front engine oil-switch
2 Diagnose according to failure code [DDE2L6].
system
★Prepare by turning Starting switch OFF, and diagnose with the switch turned ON
or engine started.
FE01 Front engine Voltage
K - GND (low-pressure Stop 1V max.
3 Defective front engine controller switch signal) Low idling 20 – 30V
E - GND (high-pressure Stop 1V max.
switch signal) 1,300 rpm min. 20 – 30V
If you diagnose while engine is running, do it more than 15 seconds after engine
was started.

Circuit diagram for front engine oil-pressure switch

20-464 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (b@BAZG) or Error Code (EA24)

Failure Code b@BAZG or Error Code EA24

Failure Code Error Code Failure R. engine oil press. down

b@BAZG EA24 Phenomenon (rear engine controller system)
• Signal circuits of both low- and high-pressure switches closed (connected to GND) when rear engine
is running at 600 rpm or more.
Failure Content
• Signal circuits of low-pressure switch opened (disconnected from GND) and that of high-pressure
switch closed (connected to GND) when rear engine is running at 1,300 rpm or more.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, rear engine may be damaged.
Machine
Related • Oil-pressure of rear engine can be monitored on the machine monitor.
Information Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

Dropped rear engine oil-pres-
1 Check engine oil-pressure; if abnormal, correct it.
Possible Cause and Standard value

sure (when system is normal)

Defective rear engine oil-switch
2 Diagnose according to failure code [dDE2L6].
system
★Prepare by turning Starting switch OFF, and diagnose with the switch turned ON
or engine started.
RE01 Rear engine Voltage
K - GND (low-pressure Stop 1V max.
3 Defective rear engine controller switch signal) Low idling 20 – 30V
E - GND (high-pressure Stop 1V max.
switch signal) 1,300 rpm min. 20 – 30V
If you diagnose while engine is running, do it more than 15 seconds after engine
was started.

Circuit diagram for rear engine oil-pressure switch

PC1800-6 20-465
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (B@BAZK)

Failure Code B@BAZK

Failure Code Error Code Failure Low F. engine oil level

B@BAZK — Phenomenon (pump controller system)
• Signal circuit of front engine oil-level switch opened (disconnected from GND) when engine was not
Failure Content
running.
Controller
• Displays Abnormality screen (yellow screen) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, front engine may be damaged.
Machine
Related • Input status of front engine oil-level switch's signals can be monitored on the machine monitor.
Information Monitoring code: 24

Cause Standard value, Remarks for Troubleshooting

Dropped front engine oil-level
1 Check front engine oil-level; supply oil if not sufficient.
(when system is normal)
Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front engine oil-level OL (male) Engine oil level Resistance
2
switch (internal disconnection) If normal level 1Ω max.
1 - GND
If lower than normal level 1MΩ min.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 disconnection (disconnection,
defective contact of connector) Harness (FC02 (female) P - OL (female) 1) Resistance 1Ω max.

★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective pump controller FC02 Engine oil level Voltage
If normal level 1V max.
P - GND
If lower than normal level 20 – 30V

Circuit diagram for front engine oil-level switch

20-466 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (b@BAZK)

Failure Code b@BAZK

Failure Code Error Code Failure Low R. engine oil level

b@BAZK — Phenomenon (pump controller system)
• Signal circuit of rear engine oil-level switch opened (disconnected from GND) when engine was not
Failure Content
running.
Controller
• Displays Abnormality screen (yellow screen) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, rear engine may be damaged.
Machine
Related • Input status of rear engine oil-level switch's signals can be monitored on the machine monitor.
Information Monitoring code: 54

Cause Standard value, Remarks for Troubleshooting

Dropped rear engine oil-level
1 Check rear engine oil-level; supply oil if not sufficient.
(when system is normal)
Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear engine oil-level OL (male) Engine oil level Resistance
2
switch (internal disconnection) If normal level 1Ω max.
1 - GND
If lower than normal level 1MΩ min.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 disconnection (disconnection,
defective contact of connector) Harness (FC01 (female) H - OL (female) 1) Resistance 1Ω max.

★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective pump controller FC01 Engine oil level Voltage
If normal level 1V max.
H - GND
If lower than normal level 20 – 30V

Circuit diagram for rear engine oil-level switch

PC1800-6 20-467
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (B@BCNS) or Error Code (108)

Failure Code B@BCNS or Error Code 108

Failure Code Error Code Failure Abnormal F. coolant temp.

B@BCNS 108 Phenomenon (front engine controller system)
Failure Content • Signal circuit of front engine coolant high-temperature sensor detected 105°C or higher.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, front engine may be damaged.
Machine
• Front engine coolant temperature can be monitored on the machine monitor or CGC monitor.
Related
Monitoring code: 77
Information
Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

Overheated front engine
1 Check front engine cooling system; if abnormal, correct it.
(when system is normal)
Defective front engine coolant
Diagnose according to "Abnormal reading of engine coolant
Possible Cause 2 high-temperature sensor
thermometer displayed on machine monitor" in E mode.
and Standard system
value ★Prepare by turning Starting switch OFF, and diagnose with the
switch OFF.
3 Defective front engine controller F. engine coolant
FE02 (female) Resistance
temperature
Q-] 105°C About 3.28kΩ

Circuit diagram for front engine coolant high-temperature sensor

20-468 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (b@BCNS) or Error Code (111)

Failure Code b@BCNS or Error Code 111

Failure Code Error Code Failure Abnormal R. coolant temp.

b@BCNS 111 Phenomenon (rear engine controller system)
Failure Content • Signal circuit of rear engine coolant high-temperature sensor detected 105°C or higher.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, rear engine may be damaged.
Machine
• Rear engine coolant temperature can be monitored on the machine monitor or CGC monitor.
Related
Monitoring code: 97
Information
Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

Overheated rear engine
1 Check rear engine cooling system; if abnormal, correct it.
(when system is normal)
Defective rear engine coolant
Diagnose according to "Abnormal reading of engine coolant
Possible Cause 2 high-temperature sensor
thermometer displayed on machine monitor" in E mode.
and Standard system
value ★Prepare by turning Starting switch OFF, and diagnose with the
switch OFF.
3 Defective rear engine controller R. engine coolant
RE02 (female) Resistance
temperature
Q-] 105°C About 3.28kΩ

Circuit diagram for rear engine coolant high-temperature sensor

PC1800-6 20-469
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (B@BCZK)

Failure Code B@BCZK

Failure Code Error Code Failure Low F. coolant level

B@BCZK — Phenomenon (pump controller system)
• Signal circuit of front coolant level switch opened (disconnected from GND) when engine was not run-
Failure Content
ning.
Controller
• Displays Abnormality screen (yellow screen) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, front engine may be damaged.
Machine
Related • Input status of front engine coolant-level switch's signals can be monitored on the machine monitor.
Information Monitoring code: 24

Cause Standard value, Remarks for Troubleshooting

Dropped level of coolant in front
Check the coolant level of front engine's sub-tank (including radiator); supply
1 radiator sub-tank
coolant if not sufficient.
(when system is normal)
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front coolant-level P05.1 (male) Sub-tank level Resistance
2 switch 1
Possible Cause and Standard value

(internal disconnection) Within normal levels 1Ω max.

1-2
Lower than LOW level 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front coolant-level P05.2 (male) Coolant level of sub-tank Resistance
3 switch 2
(internal disconnection) Within normal levels 1Ω max.
1-2
Lower than LOW level 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Harness (FC02 (female) Z - P05.1 (female) 1) Resistance 1Ω max.
4 disconnection (disconnection,
defective contact of connector) Harness (P05.1 (female) 2 - P05.2 (female) 1) Resistance 1Ω max.
Harness (P05.2 (female) 2 - GND) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective pump controller FC02 Coolant level of sub-tank Voltage
Within normal levels 1V max.
Z - GND
Lower than LOW level 20 – 30V

20-470 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (B@BCZK)

Related electrical circuit of front coolant level switch

PC1800-6 20-471
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (b@BCZK)

Failure Code b@BCZK

Failure Code Error Code Failure Low R. coolant level

b@BCZK — Phenomenon (pump controller system)
• Signal circuit of rear coolant level switch opened (disconnected from GND) when engine was not run-
Failure Content
ning.
Controller
• Displays Abnormality screen (yellow screen) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, rear engine may be damaged.
Machine
Related • Input status of rear engine coolant-level switch's signals can be monitored on the machine monitor.
Information Monitoring code: 54

Cause Standard value, Remarks for Troubleshooting

Dropped level of coolant in rear
Check the coolant level of rear engine's sub-tank (including radiator); supply
1 radiator sub-tank
coolant if not sufficient.
(when system is normal)
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear coolant-level P06.1 (male) Sub-tank level Resistance
2 switch 1
Possible Cause and Standard value

(internal disconnection) Within normal levels 1Ω max.

1-2
Lower than LOW level 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear coolant-level P06.2 (male) Coolant level of sub-tank Resistance
3 switch 2
(internal disconnection) Within normal levels 1Ω max.
1-2
Lower than LOW level 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Harness (FC01 (female) N - P06.1 (female) 1) Resistance 1Ω max.
4 disconnection (disconnection,
defective contact of connector) Harness (P06.1 (female) 2 - P06.2 (female) 1) Resistance 1Ω max.
Harness (P06.2 (female) 2 - GND) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective pump controller FC01 Coolant level of sub-tank Voltage
Within normal levels 1V max.
N - GND
Lower than LOW level 20 – 30V

20-472 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (b@BCZK)

Related electrical circuit of rear coolant level switch

PC1800-6 20-473
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (B@CBNS)

Failure Code B@CBNS

Failure Code Error Code Failure High F. PTO temp.

B@CBNS — Phenomenon (VHMS controller system)
Failure Content • Signal circuit of front PTO oil sensor detected 125°C or higher.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, front PTO may be damaged.
Machine
Related • Front PTO oil temperature can be monitored on the machine monitor.
Information Monitoring screen: PM Clinic (4/6)

Cause Standard value, Remarks for Troubleshooting

Overheated front PTO oil
1 Check front PTO lubrication system; if abnormal, correct it.
(when system is normal)
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Front PTO oil

P07 (male) Resistance
Defective front PTO temperature
2
oil-temperature sensor system 10 – 100°C About 3.8 - 80kΩ
1-2
125°C About 1.99Ω
1 - GND — 1MΩ min.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 grounding
(contact with GND circuit) Harness (V2A (female) 2 - P07 (female) 1) Resistance 1Ω max.

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Front PTO oil
V2A (female) Resistance
temperature
4 Defective VHMS controller
10 – 100°C About 3.8 - 80kΩ
2 - BC
125°C About 1.99Ω
2 - GND — 1MΩ min.

Circuit diagram for front PTO oil-temperature sensor

20-474 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (b@CBNS)

Failure Code b@CBNS

Failure Code Error Code Failure High R. PTO temp.

b@CBNS — Phenomenon (VHMS controller system)
Failure Content • Signal circuit of rear PTO oil sensor detected 125°C or higher.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, rear PTO may be damaged.
Machine
Related • Rear PTO oil temperature can be monitored on the machine monitor.
Information Monitoring screen: PM Clinic (5/6)

Cause Standard value, Remarks for Troubleshooting

Overheated rear PTO oil
1 Check rear PTO lubrication system; if abnormal, correct it.
(when system is normal)
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Front PTO oil

P08 (male) Resistance
Defective rear PTO temperature
2
oil-temperature sensor system 10 – 100°C About 3.8 - 80kΩ
1-2
125°C About 1.99Ω
1 - GND — 1MΩ min.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 grounding
(contact with GND circuit) Harness (V2A (female) 0 - P08 (female) 1) Resistance 1Ω max.

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Rear PTO oil
V2A (female) Resistance
temperature
4 Defective VHMS controller
10 – 100°C About 3.8 - 80kΩ
0 - BC
125°C About 1.99Ω
0 - GND — 1MΩ min.

Circuit diagram for rear PTO oil-temperature sensor

PC1800-6 20-475
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (B@HANS) or Error Code (115)

Failure Code B@HANS or Error Code 115

Failure Code Error Code Failure Abnormal Hydraulic temp.

B@HANS 115 Phenomenon (pump controller system)
Failure Content • Signal circuit of hydraulic-oil temperature sensor detected 100°C or higher.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, hydraulic equipment may be damaged.
Machine
• Signal status of hydraulic-oil sensor can be monitored on the machine monitor; the temperature of
Related hydraulic-oil can be monitored on the CGC monitor.
Information Monitoring code: 44
Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

Overheated hydraulic-oil
1 Check the temperature of hydraulic-oil; if abnormal, correct it.
(when system is normal)
Defective hydraulic-oil Diagnose according to "Abnormal reading of hydraulic-oil
Possible Cause 2
temperature sensor system thermometer displayed on machine monitor" in E mode.
and Standard
value ★Prepare by turning Starting switch OFF, and diagnose with the
switch OFF.
3 Defective pump controller Hydraulic-oil
FC01 (female) Resistance
temperature
3-K 100°C About 3.75kΩ

Circuit diagram for hydraulic-oil temperature sensor

20-476 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (B@HAZK)

Failure Code B@HAZK

Failure Code Error Code Failure Low Hydraulic oil level

B@HAZK — Phenomenon (pump controller system)
• Signal circuit of hydraulic-oil-level switch opened (disconnected from GND) when engine was not run-
Failure Content
ning.
Controller
• Displays Abnormality screen (yellow screen) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• If the machine is run with the abnormality unfixed, hydraulic equipment may be damaged.
Machine
Related • Signal status of hydraulic-oil level switch can be monitored on the machine monitor.
Information Monitoring code: 24

Cause Standard value, Remarks for Troubleshooting

Dropped hydraulic-oil level
1 Check hydraulic-oil level; supply oil if not sufficient.
(when system is normal)
Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective hydraulic-oil level T10 (male) Hydraulic-oil level Resistance
2
switch (internal disconnection) If normal level 1Ω max.
1-2
If lower than normal level 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 disconnection (disconnection, Harness (FC02 (female) F - T10 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (T10 (female) 2 - GND) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective pump controller FC02 Hydraulic-oil level Voltage
If normal level 1V max.
F - GND
If lower than normal level 20 – 30V

Circuit diagram for hydraulic-oil level switch

PC1800-6 20-477
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (D110KB)

Failure Code D110KB

Failure Code Error Code Failure Short in F. battery relay drive sys.
D110KB — Phenomenon (pump controller system)
• Feedback voltage (controller's source voltage) dropped to 5.7 V or lower during output to battery-relay
Failure Content
drive circuit.
Controller
• Stops output to battery-relay drive circuit.
Reaction
Phenomenon on
• Data may not be written into each controller normally.
Machine
Related • Operational status of battery relay can be monitored on the machine monitor.
Information Monitoring code: 23

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective battery relay (internal Battery relay Continuity, resistance
1
disconnection, short circuit)
Possible Cause and Standard value

Terminal BR - terminal E Continued

Terminal BR - GND 1MΩ min.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FC03 (female) 4 - terminal BR of battery
defective contact of connector) Resistance 1Ω max.
relay)
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 grounding (contact with GND Between harness (FC03 (female) 4 - terminal BR of
circuit) Resistance 1MΩ min.
battery relay) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned ON
or OFF.
FC03 Starting switch Voltage
4 Defective pump controller
When ON 1V max.
4 - GND 20 – 30V
When ON to OFF
(for a few seconds)

Circuit diagram for battery-relay drive

20-478 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (D163KB)

Failure Code D163KB

Failure Code Error Code Failure Short in flash light relay sys.
D163KB — Phenomenon (pump controller system)
Failure Content • Abnormal current flew during output to flash-light relay circuit.
Controller
• Stops output to flash-light relay circuit.
Reaction
Phenomenon on
• Flash-light is not turned ON.
Machine
Related • Operational status of flash-light relay can be monitored on the machine monitor.
Information Monitoring code: 26

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Defective flash-light relay (inter-

1 C57 (male) Resistance
nal short circuit)
1-2 500 – 1,000Ω
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 grounding (contact with GND Between harness (FC03 (female) O - C57 (female)
circuit) Resistance 1MΩ min.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
FC03 Horn switch Voltage
3 Defective pump controller
When OFF 1V max.
O - GND 20 – 30V
When ON
(for 5 seconds)

Circuit diagram for flash-light

PC1800-6 20-479
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (D194KZ)

Failure Code D194KZ

Failure Code Error Code Failure Break in step light power keep
D194KZ — Phenomenon (pump controller system)
Failure Content • Current does not flow during output to step-light relay circuit.
Controller
• No response in particular (Relay does not operate because no current flows.)
Reaction
Phenomenon on
• Step-light is not turned ON.
Machine
Related • Operational status of step-light relay can be monitored on the machine monitor.
Information Monitoring code: 26

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective step-light relay
1 C27 (male) Resistance
(internal short circuit)
1-2
Possible Cause and Standard value

500 – 1,000Ω

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FC03 (female) E - C27 (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (C27 (female) 2 - GND) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
3 hot-short-circuit
(contact with a 24V circuit) Between harness (FE03 (female) E - C27 (female)
Voltage 1V max.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
FC03 Step-light switch Voltage
4 Defective pump controller
When OFF 1V max.
E - GND 20 – 30V
When ON
(for 60 seconds)

Circuit diagram for step-light

20-480 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (D195KB)

Failure Code D195KB

Failure Code Error Code Failure Short in step light relay sys.
D195KB — Phenomenon (pump controller system)
Failure Content • Abnormal current flew during output to step-light relay circuit.
Controller
• Stops output to step-light relay circuit.
Reaction
Phenomenon on
• Step-light is not turned ON.
Machine
Related • Operational status of step-light relay can be monitored on the machine monitor.
Information Monitoring code: 26

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Defective step-light relay

1 C27 (male) Resistance
(internal short circuit)
1-2 500 – 1,000Ω
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 grounding Between harness (FC03 (female) E - C27 (female)
(contact with GND circuit) Resistance 1Ω max.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
FC03 Step-light switch Voltage
3 Defective pump controller
When OFF 1V max.
E - GND 20 – 30V
When ON
(for 60 seconds)

Circuit diagram for step-light

PC1800-6 20-481
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (D1D0KB) or Error Code (E957)

Failure Code D1D0KB or Error Code E957

Failure Code Error Code Failure F. engine power failure (2)

D1D0KB E957 Phenomenon (front engine controller system)
Failure Content • Load source voltage of front engine controller rose to 10 V or higher when Starting switch is OFF.
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

Defective load source relay of ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
1 front engine controller (internal CM12 (male) Resistance
short-circuit) 3-5 1MΩ min.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 hot-short-circuit Between harness (FE03 (female) 12K - CM12
(contact with 24V circuit) Voltage 1V max.
(female) 5) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
OFF or ON.
3 Defective front engine controller FE03 Starting switch Voltage
When OFF 1V max.
12K - GND
When ON 8V max.

20-482 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (D1D0KB) or Error Code (E957)

Circuit diagram for power source of front engine controller

PC1800-6 20-483
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (d1D0KB) or Error Code (EA57)

Failure Code d1D0KB or Error Code EA57

Failure Code Error Code Failure R. engine power failure (2)

d1D0KB EA57 Phenomenon (rear engine controller system)
Failure Content • Load source voltage of rear engine controller rose to 10 V or higher when Starting switch is OFF.
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

Defective load source relay of ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
1 rear engine controller (internal CM13 (male) Resistance
short-circuit) 3-5 1MΩ min.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 hot-short-circuit Between harness (RE03 (female) 12K - CM13
(contact with 24V circuit) Voltage 1V max.
(female) 5) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
OFF or ON.
3 Defective rear engine controller RE03 Starting switch Voltage
When OFF 1V max.
12K - GND
When ON 8V max.

20-484 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (d1D0KB) or Error Code (EA57)

Circuit diagram for power source of rear engine controller

PC1800-6 20-485
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DA20KT) or Error Code (101)

Failure Code DA20KT or Error Code 101

Failure Code Error Code Failure Abnormality in error history data

DA20KT 101 Phenomenon (machine monitor system)
• Abnormality occurred in internal memory or clock function of machine monitor.
Failure Content
• Source voltage of machine monitor rose to 36 V or higher or dropped to 12 V or lower.
Controller
• No response in particular
Reaction
Phenomenon on • Error code on machine monitor can not be erased.
Machine • Clock does not display time correctly (always "00:00" is shown).
Related
Information

Cause Standard value, Remarks for Troubleshooting

If circuit breaker has been shut-down, a circuit is likely to be defective caused by
1 Defective circuit breaker
grounding, etc. (refer to possible cause 3).
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Defective harness caused by Harness (terminal B of battery relay - B62B) Resistance 1Ω max.
2 disconnection (disconnection, Harness (B63A - C81) Resistance 1Ω max.
defective contact of connector) Harness (C80 - P02 (female) 8D) Resistance 1Ω max.
Harness (P02 (female) 19 - GND) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Between harness (terminal B of battery relay - B62B)
Defective harness caused by Resistance 1MΩ min.
and GND
3 grounding
(contact with GND circuit) Between harness (B63A - C81) and GND Resistance 1MΩ min.
Between harness (C80 - P02 (female) 8D) and
Resistance 1MΩ min.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective machine monitor
P02 Voltage
8D - 19 20 – 30V

Circuit diagram for power source of machine monitor

20-486 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DA2SKA)

Failure Code DA2SKA

Failure Code Error Code Failure Network overtime error

DA2SKA — Phenomenon (pump controller system)
Failure Content • Data from pump controller is not updated through communication on S-NET.
Controller
• No response in particular.
Reaction
Phenomenon on
• Machine may not run normally.
Machine
Related • Status of connection for communication on S-NET can be monitored on the machine monitor.
Information Monitoring code: 08

Cause Standard value, Remarks for Troubleshooting

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

1 disconnection (disconnection, Harness (FC02 (female) K - P01 (female) A or FE02

defective contact of connector) Resistance 1Ω max.
(female) K)
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 grounding (contact with GND Between harness (FC02 (female) K - P01 (female)
circuit) Resistance 1MΩ min.
A or FE02 (female) K) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
3 hot-short-circuit (contact with
24V circuit) Between harness (FC02 (female) K - P01 (female)
Voltage 1V max.
A or FE02 (female) K) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective machine monitor
FC02 Voltage
K-U 6 – 9V

20-488 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DA2SKA)

Related electrical circuit of S-NET communication

PC1800-6 20-489
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DA2SKQ)

Failure Code DA2SKQ

Failure Code Error Code Failure Machine model selection error

DA2SKQ — Phenomenon (pump controller system)
• The model-selection signal obtained by pump controller directly does not match with that obtained
Failure Content
from communication.
Controller
• Controls assuming that the model is the defailure one (PC1800-6).
Reaction
Phenomenon on
Machine
Related • Model code of pump controller can be monitored on the machine monitor.
Information Monitoring code: 22

Cause Standard value, Remarks for Troubleshooting

Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective model-selection con- B09 (female) Resistance
1 nector (internal disconnection,
short circuit) 2-6 1Ω max.
134 - 6 1MΩ min.
Possible Cause and Standard value

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FC02 (female) Q - B09 (male) 2) Resistance 1Ω max.
defective contact of connector) Harness (B09 (male) 6 - GND) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Between harness (FC02 (female) [ - B09 (male) 1)
Resistance 1MΩ min.
Defective harness caused by and GND
3 grounding (contact with GND Between harness (FC02 (female) G - B09 (male) 3)
circuit) Resistance 1MΩ min.
and GND
Between harness (FC02 (female) 7 - B09 (male) 4)
Resistance 1MΩ min.
and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective pump controller FC02 Voltage
7G[ - GND 20 – 30V
Q - GND 1V max.

20-490 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DA2SKQ)

Circuit diagram for pump-controller model selection

PC1800-6 20-491
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DA80MA)

Failure Code DA80MA

Failure Code Error Code Failure Auto grease controller error

DA80MA — Phenomenon (pump controller system)
Failure Content • Power-source input signal sent to automaticmatic greasing controller was shut down.
Controller
• No response in particular.
Reaction
Phenomenon on
• Automaticmatic greasing does not function.
Machine
• Status of automaticmatic greasing controller's power-source signal can be monitored on the machine
Related
monitor.
Information
Monitoring code: 25

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the
Defective harness caused by switch OFF.
1 disconnection (disconnection,
Possible Cause defective contact of connector) Harness (FC01 (female) 5 - branched Resis-
1Ω max.
and Standard point of circuit) tance
value ★Prepare by turning Starting switch OFF, and diagnose with the
switch turned ON.
2 Defective pump controller
FC01 Voltage
5 - GND 20 – 30V

Circuit diagram for automaticmatic greasing controller's power source

20-492 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DAB0KR) or Error Code (118)

Failure Code DAB0KR or Error Code 118

Failure Code Error Code Failure Pump controller network overtime error
DAB0KR 118 Phenomenon (pump controller system)
Failure Content • Data from pump controller is not updated through communication on S-NET.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• Machine may not run normally.
Machine
Related • Status of connection for communication on S-NET can be monitored on the machine monitor.
Information Monitoring code: 08

Cause Standard value, Remarks for Troubleshooting

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

1 disconnection (disconnection, Harness (FC02 (female) K - P01 (female) A or FE02

defective contact of connector) Resistance 1Ω max.
(female) K)
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 grounding (contact with GND Between harness (FC02 (female) K - P01 (female)
circuit) Resistance 1MΩ min.
A or FE02 (female) K) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
3 hot-short-circuit (contact with
24V circuit) Between harness (FC02 (female) K - P01 (female)
Voltage 1V max.
A or FE02 (female) K) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective pump controller
FC02 Voltage
K-U 6 – 9V

20-494 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DAB0KR) or Error Code (118)

Related electrical circuit of S-NET communication

PC1800-6 20-495
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DB20KT) or Error Code (E980)

Failure Code DB20KT or Error Code E980

Failure Code Error Code Failure F. engine controller failure

DB20KT E980 Phenomenon (front engine controller system)
Failure Content • Abnormality occurred inside front engine controller.
Controller
• No response in particular
Reaction
Phenomenon on
• Front engine may not run normally.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the
Possible Cause Defective harness caused by switch OFF.
and Standard 1 disconnection (disconnection,
value defective contact of connector) Resis-
Harness (FE03 (female) AUV - GND) 1Ω max.
tance
2 Defective front engine controller You cannot diagnose because of internal defects.

Circuit diagram for power source of front engine controller

20-496 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dB20KT) or Error Code (EA80)

Failure Code dB20KT or Error Code EA80

Failure Code Error Code Failure R. engine controller failure

dB20KT EA80 Phenomenon (rear engine controller system)
Failure Content • Abnormality occurred inside rear engine controller.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear engine may not run normally.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the
Possible Cause Defective harness caused by switch OFF.
and Standard 1 disconnection (disconnection,
value defective contact of connector) Resis-
Harness (RE03 (female) AUV - GND) 1Ω max.
tance
2 Defective rear engine controller You cannot diagnose because of internal defects.

Circuit diagram for power source of rear engine controller

PC1800-6 20-497
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DB22KK) or Error Code (E956)

Failure Code DB22KK or Error Code E956

Failure Code Error Code Failure F. engine power failure (1)

DB22KK E956 Phenomenon (front engine controller system)
Failure Content • Load source voltage of front engine controller dropped to 10 V or lower when Starting switch is ON.
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

If circuit breaker has been shut-down, a circuit is likely to be defective caused by
1 Defective circuit breaker
grounding, etc. (refer to possible cause 4).
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective load power-source
2 Try to replace the right-side relay with another; if engine becomes
relay of front engine controller CM12
normal, load power-source relay of engine controller is defective.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (FE03 (female) 12K - CM12 (female) 5)
Possible Cause and Standard value

Resistance 1Ω max.
Defective harness caused by Harness (CM12 (female) 3 - CM21) Resistance 1Ω max.
3 disconnection (disconnection, Harness (CM12 (female) 1 - branched point of
defective contact of connector) Resistance 1Ω max.
circuit)
Harness (CM12 (female) 2 - branched point of
Resistance 1Ω max.
circuit)
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Between harness (FE03 (female) 12K - CM12
Resistance 1MΩ min.
Defective harness caused by (female) 5) and GND
4 grounding Between harness (CM12 (female) 3 - CM21) and
(contact with GND circuit) Resistance 1MΩ min.
GND
Between harness (CM12 (female) 1 - branched point
Resistance 1MΩ min.
of circuit) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
OFF or ON.
5 Defective front engine controller FE03 Starting switch Voltage
When OFF 1V max.
12K - GND
When ON 20 – 30V

20-498 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DB22KK) or Error Code (E956)

Related electrical circuit of front engine controller power source

PC1800-6 20-499
TROUBLESHOOTING AT DISPLAY OF FAILURE Failure Code (dB22KK) or Error Code (EA56)
CODE OR ERROR CODE [CODE DISPLAY MODE]

Failure Code dB22KK or Error Code EA56

Failure Code Error Code Failure R. engine power failure (1)

dB22KK EA56 Phenomenon (rear engine controller system)
Failure Content • Load source voltage of rear engine controller dropped to 10 V or lower when Starting switch is ON.
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

If circuit breaker has been shut-down, a circuit is likely to be defective caused by
1 Defective circuit breaker
grounding, etc. (refer to possible cause 4).
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective load power-source
2 Try to replace the right-side relay with another; if engine becomes
relay of rear engine controller CM12
normal, load power-source relay of engine controller is defective.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (RE03 (female) 12K - CM13 (female) 5)
Possible Cause and Standard value

Resistance 1Ω max.
Defective harness caused by Harness (CM13 (female) 3 - CM21) Resistance 1Ω max.
3 disconnection (disconnection, Harness (CM13 (female) 1 - branched point of
defective contact of connector) Resistance 1Ω max.
circuit)
Harness (CM13 (female) 2 - branched point of
Resistance 1Ω max.
circuit)
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Between harness (RE03 (female) 12K - CM13
Resistance 1MΩ min.
Defective harness caused by (female) 5) and GND
4 grounding Between harness (CM13 (female) 3 - CM21) and
(contact with GND circuit) Resistance 1MΩ min.
GND
Between harness (CM13 (female) 1 - branched point
Resistance 1MΩ min.
of circuit) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
OFF or ON.
5 Defective rear engine controller RE03 Starting switch Voltage
When OFF 1V max.
12K - GND
When ON 20 – 30V

20-500 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dB22KK) or Error Code (EA56)

Related electrical circuit of rear engine controller power source

PC1800-6 20-501
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DB29KQ) or Error Code (E920)

Failure Code DB29KQ or Error Code E920

Failure Code Error Code Failure F. engine type selection error

DB29KQ E920 Phenomenon (front engine controller system)
• The model-selection signal obtained by front engine controller directly does not match with that ob-
Failure Content
tained from communication.
Controller
• Controls assuming that the model is the defailure one.
Reaction
Phenomenon on
• Engine's output does not reach at normal level.
Machine
Related • Model code of front engine controller can be monitored on the machine monitor.
Information Monitoring code: 85

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front-engine model- CM14 (female) Resistance
1 selection connector (internal
disconnection, short circuit) 2-6 1Ω max.
Possible Cause and Standard value

34 - 6 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FE01 (female) 3 - CM14 (male) 2) Resistance 1Ω max.
defective contact of connector) Harness (FE02 (female) 1 - CM14 (male) 6) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (FE01 (female) M - CM14 (male)
Resistance 1MΩ min.
3 grounding (contact with GND 3) and GND
circuit) Between harness (FE01 (female) G - CM14 (male)
Resistance 1MΩ min.
4) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective front engine controller FE01, FE02 Voltage
FE01 GM - FE02 1 20 – 30V
FE01 3 - FE02 1 1V max.

Circuit diagram for model selection of front engine controller

20-502 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dB29KQ) or Error Code (EA20)

Failure Code dB29KQ or Error Code EA20

Failure Code Error Code Failure R. engine type selection error

dB29KQ EA20 Phenomenon (rear engine controller system)
• The model-selection signal obtained by rear engine controller directly does not match with that ob-
Failure Content
tained from communication.
Controller
• Controls assuming that the model is the defailure one.
Reaction
Phenomenon on
• Engine's output does not reach at normal level.
Machine
Related • Model code of rear engine controller can be monitored on the machine monitor.
Information Monitoring code: A5

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear-engine model- CM15 (female) Resistance
1 selection connector (internal
disconnection, short circuit) 2-6 1Ω max.
Possible Cause and Standard value

34 - 6 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (RE01 (female) M - CM15 (male) 2) Resistance 1Ω max.
defective contact of connector) Harness (RE02 (female) 1 - CM15 (male) 6) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (RE01 (female) 3 - CM15 (male)
Resistance 1MΩ min.
3 grounding (contact with GND 1) and GND
circuit) Between harness (RE01 (female) G - CM15 (male)
Resistance 1MΩ min.
4) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective rear engine controller RE01, RE02 Voltage
RE01 3G - RE02 1 20 – 30V
RE01 M - RE02 1 1V max.

Circuit diagram for model selection of rear engine controller

PC1800-6 20-503
TROUBLESHOOTING AT DISPLAY OF FAILURE Failure Code (DB2AMA) or Error Code (E95A)
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (bB2AMA) or Error Code (EA5A)

Failure Code DB2AMA or Error Code E95A

Failure Code Error Code Failure F. engine Q-adjust sw. signal error
DB2AMA E95A Phenomenon (front engine controller system)
Failure Content • Q-setting switch of front engine controller is not set at a correct position.
Controller
• No response in particular
Reaction
Phenomenon on
• Q setting of front engine controller cannot be changed.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause Wrong setting of Q switch of The setting of Q switch is wrong, if both Q switches 1 and 2 are
1
and Standard front engine controller set to [F].
value If possible cause 1 above does not apply, engine controller may
2 Defective front engine controller
be defective.

Failure Code bB2AMA or Error Code EA5A

Failure Code Error Code Failure R. engine Q-adjust sw. signal error
bB2AMA EA5A Phenomenon (rear engine controller system)
Failure Content • Q-setting switch of rear engine controller is not set at a correct position.
Controller
• No response in particular
Reaction
Phenomenon on
• Q setting of rear engine controller cannot be changed.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Possible Cause Wrong setting of Q switch of The setting of Q switch is wrong, if both Q switches 1 and 2 are
1
and Standard rear engine controller set to [F].
value If possible cause 1 above does not apply, engine controller may
2 Defective rear engine controller
be defective.

20-504 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DB2RMC) or Error Code (E935)

Failure Code DB2RMC or Error Code E935

Failure Code Error Code Failure F. KOM-NET/c error

DB2RMC E935 Phenomenon (front engine controller system)
• Front engine controller cannot recognize rear engine controller or VHMS controller on CAN communi-
Failure Content
cation circuit.
Controller
• No response in particular
Reaction
Phenomenon on
• Front engine may not run normally.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (FE02 (female) L - RE02 (female) L, V4A
(female) B, or C96 (female) B)
Defective harness caused by
Resistance 1Ω max.
1 disconnection (disconnection,
defective contact of connector) Harness (FE02 (female) V - RE02 (female) V, V4A
(female) 4, or C96 (female) A)
Resistance 1Ω max.

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Between harness (FE02 (female) L - RE02 (female)
L, V4A (female) B, C96 (female) B, CM31 (male)
Resistance 1MΩ min.
0, CM32 (male) 0, FC02 (female) L, or C94
(female) B) and GND
Defective harness caused by
Possible Cause and Standard value

2 grounding (contact with GND

circuit) Between harness (FE02 (female) V - RE02 (female)
V, V4A (female) 4, C96 (female) A, CM31 (male)
Resistance 1MΩ min.
3, CM32 (male) 3, FC02 (female) V, or C94
(female) A) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (FE02 (female) L - RE02 (female)
L, V4A (female) B, C96 (female) B, CM31 (male)
Defective harness caused by Voltage 1V max.
0, CM32 (male) 0, FC02 (female) L, or C94
(female) B) and GND
3 hot-short-circuit (contact with
24V circuit)
Between harness (FE02 (female) V - RE02 (female)
V, V4A (female) 4, C96 (female) A, CM31 (male)
Voltage 1V max.
3, CM32 (male) 3, FC02 (female) V, or C94
(female) A) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective CAN termination
4 C94 (male), C96 (male) Resistance
A-B
resistance
40 – 80Ω
If any possible cause in 1 though 4 above does not apply, rear engine controller
Defective rear engine controller
5 or VHMS controller may be defective. (You cannot diagnose because of internal
or VHMS controller
defects.)

20-506 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DB2RMC) or Error Code (E935)

Related electrical circuit of CAN communication

PC1800-6 20-507
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dB2RMC) or Error Code (EA35)

Failure Code dB2RMC or Error Code EA35

Failure Code Error Code Failure R. KOM-NET/c error

dB2RMC EA35 Phenomenon (rear engine controller system)
• Rear engine controller cannot recognize front engine controller or VHMS controller on CAN commu-
Failure Content
nication circuit.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear engine may not run normally.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (RE02 (female) L - FE02 (female) L, V4A
(female) B, or C96 (female) B)
Defective harness caused by
Resistance 1Ω max.
1 disconnection (disconnection,
defective contact of connector) Harness (RE02 (female) V - FE02 (female) V, V4A
(female) 4, or C96 (female) A)
Resistance 1Ω max.

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Between harness (RE02 (female) L - FE02 (female)
L, V4A (female) B, C96 (female) B, CM31 (male)
Resistance 1MΩ min.
0, CM32 (male) 0, FC02 (female) L, or C94
(female) B) and GND
Defective harness caused by
Possible Cause and Standard value

2 grounding (contact with GND

circuit) Between harness (RE02 (female) V - FE02 (female)
V, V4A (female) 4, C96 (female) A, CM31 (male)
Resistance 1MΩ min.
3, CM32 (male) 3, FC02 (female) V, or C94
(female) A) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (RE02 (female) L - FE02 (female)
L, V4A (female) B, C96 (female) B, CM31 (male)
Defective harness caused by Voltage 1V max.
0, CM32 (male) 0, FC02 (female) L, or C94
(female) B) and GND
3 hot-short-circuit (contact with
24V circuit)
Between harness (RE02 (female) V - FE02 (female)
V, V4A (female) 4, C96 (female) A, CM31 (male)
Voltage 1V max.
3, CM32 (male) 3, FC02 (female) V, or C94
(female) A) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective CAN termination
4 C94 (male), C96 (male) Resistance
A-B
resistance
40 – 80Ω
If any possible cause in 1 though 4 above does not apply, front engine controller
Defective front engine controller
5 or VHMS controller may be defective. (You cannot diagnose because of internal
or VHMS controller
defects.)

20-508 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dB2RMC) or Error Code (EA35)

Related electrical circuit of CAN communication

PC1800-6 20-509
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DB2SMC) or Error Code (E955)

Failure Code DB2SMC or Error Code E955

Failure Code Error Code Failure F. S-NET error

DB2SMC E955 Phenomenon (front engine controller system)
Failure Content • Data from front controller is not updated through communication on S-NET.
Controller
• No response in particular
Reaction
Phenomenon on
• Front engine may not run normally.
Machine
Related • Status of connection for communication on S-NET can be monitored on the machine monitor.
Information Monitoring code: 08

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by
Harness (FE02 (female) K - P01 (female) A or FC02
1 disconnection (disconnection, Resistance 1Ω max.
(female) K)
defective contact of connector)
Harness (FE02 (female) U - RE02 (female) U) Resistance 1Ω max.
Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (FE02 (female) K - P01 (female)
Resistance 1MΩ min.
2 grounding (contact with GND A, FC02 (female) K, or C02 (female) 2) and GND
circuit) Harness (FE02 (female) U - RE02 (female) U) and
Resistance 1MΩ min.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Defective harness caused by
Between harness (FE02 (female) K - P01 (female)
3 hot-short-circuit (contact with Voltage 1V max.
A, FC02 (female) K, or C02 (female) 2) and GND
24V circuit)
Harness (FE02 (female) U - RE02 (female) U) and
Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective front engine controller FE01, FE02 Voltage
FE02 K - A 6 – 9V
FE02 U - FE02 A 6 – 9V

20-510 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DB2SMC) or Error Code (E955)

Related electrical circuit of S-NET communication

PC1800-6 20-511
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dB2SMC) or Error Code (EA55)

Failure Code dB2SMC or Error Code EA55

Failure Code Error Code Failure R. S-NET error

dB2SMC EA55 Phenomenon (rear engine controller system)
Failure Content • Data from rear controller is not updated through communication on S-NET.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear engine may not run normally.
Machine
Related • Status of connection for communication on S-NET can be monitored on the machine monitor.
Information Monitoring code: 08

Cause Standard value, Remarks for Troubleshooting

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
1 disconnection (disconnection, Harness (RE02 (female) K - V3A (female) 8) Resistance 1Ω max.
defective contact of connector) Harness (RE02 (female) U - FE02 (female) U) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Defective harness caused by Between harness (RE02 (female) K - V3A (female)

Resistance 1MΩ min.
2 grounding (contact with GND 8, CM31 (male) 4, or CM32 (male) 4) and GND
circuit) Harness (RE02 (female) U - FE02 (female) U) and
Resistance 1MΩ min.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Defective harness caused by
Between harness (RE02 (female) K - V3A (female)
3 hot-short-circuit (contact with Voltage 1V max.
8, CM31 (male) 4, or CM32 (male) 4) and GND
24V circuit)
Harness (RE02 (female) U - FE02 (female) U) and
Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective rear engine controller RE01, RE02 Voltage
RE02 K - A 6 – 9V
RE02 U - RE02 A 6 – 9V

20-512 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dB2SMC) or Error Code (EA55)

Related electrical circuit of S-NET communication

PC1800-6 20-513
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBB0KK)

Failure Code DBB0KK

Failure Code Error Code Failure VHMS controller power source voltage error
DBB0KK — Phenomenon (VHMS controller system)
Failure Content • Switch source voltage of VHMS controller became below 9.5 (±2.5) V or above 42.4 (±6) V.
Controller
• No response in particular
Reaction
Phenomenon on
• System may not operate normally.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

If circuit breaker has been shut-down, a circuit is likely to be defective caused by
1 Defective circuit breaker
Possible Cause and Standard value

grounding, etc. (refer to possible cause 3).

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Harness (V1 (female) 89 - C84) Resistance 1Ω max.
2 disconnection (disconnection,
defective contact of connector) Harness (V1 (female) AB or V2B (female) 9 - GND) Resistance 1Ω max.
Harness (V1 (female) IJ - GND) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 grounding (contact with GND Between harness (V1 (female) 89 - C84, or other
circuit) Resistance 1MΩ min.
related circuit) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective VHMS controller
V1 Voltage
89 - AB 20 – 30V

Circuit diagram for power source of VHMS controller

20-514 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBB0KM)

Failure Code DBB0KM

Failure Code Error Code Failure Connector mismatch

DBB0KM — Phenomenon (VHMS controller system)
Failure Content • Signal circuit which checks the connection of connectors detected abnormal connection of connector.
Controller
• No response in particular
Reaction
Phenomenon on
• System may not operate normally.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Wrong connection of
Check if V2A and V3A connectors, as well as V2B and V3B connectors, are con-
Possible Cause and Standard value

1 connectors of VHMS controller

nected correctly; if wrong, correct them.
(when system is normal)

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (V2A (female) 9 - GND) Resistance 1Ω max.
defective contact of connector) Harness (V2B (female) B - GND) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
V2A, V2B, V3A, V3B Voltage
3 Defective VHMS controller V2A 9 - GND 1V max.
V2B B - GND 1V max.
V3A 9 - GND 20 – 30V
V3B B - GND 20 – 30V

Circuit diagram for connection of connectors of VHMS controller

PC1800-6 20-515
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBB0KP)

Failure Code DBB0KP

Failure Code Error Code Failure Voltage source sys. error

DBB0KP — Phenomenon (VHMS controller system)
• Source voltage (5 V) of VHMS controller's sensor is out of normal range (4.5 - 5.5 V).
Failure Content • Source voltage (12 V) of VHMS controller's sensor is out of normal range (10 - 15 V).
• Source voltage (24 V) of VHMS controller's sensor is out of normal range (20 - 30 V).
Controller
• No response in particular
Reaction
Phenomenon on • System may not operate normally.
Machine • Normal monitoring may become impossible on CGC monitor.
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Between harness (V1 (female) 4 - front ENGP
(female) B, rear ENGP (female) B, V01 (female) B,
V02 (female) B, V03 (female) B, V04 (female) B, or
V05 (female) B) and GND (in the case of a 5 V cir-
Resistance 1MΩ min.

cuit)
Between harness (V1 (female) 5 - front ENGP
(female) B, rear ENGP (female) B, or CM37 2) and
Defective harness caused by
1 grounding Resistance 1MΩ min.
(contact with GND circuit) GND (in the case of a 5 V circuit)
Between harness (V1 (female) 3 - B50 (female) A)
Resistance 1MΩ min.
and GND (in the case of a 12 V circuit)
Possible Cause and Standard value

Between harness (V1 (female) 2 - B58.1 (female)

A, B59.1 (female) A, B58.2 (female) A, B59.2
(female) A, P15 (female) B, H21 (male) B, or H22
Resistance 1MΩ min.
(male) B) and GND (in the case of a 24 V circuit)
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (V1 (female) 4 - front ENGP
(female) B, rear ENGP (female) B, V01 (female) B,
V02 (female) B, V03 (female) B, V04 (female) B, or
V05 (female) B) and GND (in the case of a 5 V cir-
Voltage 1V max.
Defective harness caused by
2 hot-short-circuit cuit)
(contact with 24V circuit)
Between harness (V1 (female) 5 - front ENGP
(female) B, rear ENGP (female) B, or CM37 2) and Voltage 1V max.
GND (in the case of a 5 V circuit)
Between harness (V1 (female) 3 - B50 (female) A)
Voltage 1V max.
and GND (in the case of a 12 V circuit)
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
V1 Voltage
3 Defective VHMS controller 4 - AB 4.5 – 5.5V
5 - AB 4.5 – 5.5V
3 - AB 10 – 15V
2 - AB 20 – 30V

20-516 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBB0KP)

Related electrical circuit of VHMS controller sensor power source (5V, 12V, 24V)

PC1800-6 20-517
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBB0KQ)

Failure Code DBB0KQ

Failure Code Error Code Failure VHMS machine model selection error
DBB0KQ — Phenomenon (VHMS controller system)
• The model-selection signal obtained by VHMS controller directly does not match with that obtained
Failure Content
from communication.
Controller
• Controls assuming that the model is the defailure one.
Reaction
Phenomenon on
• System may not operate normally.
Machine
Related • Model code of VHMS controller can be monitored on the machine monitor.
Information Monitoring code: 05

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective model-selection
connector B12 (female) Resistance
1
(internal disconnection, short 2-6 1Ω max.
circuit)
1345 - 6 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

2 disconnection (disconnection, Harness (V3A (female) 5 - B12 (male) 2) Resistance 1Ω max.

defective contact of connector) Harness (V2A (female) BC - B12 (male) 6) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Between harness (V3A (female) F - B12 (male) 1)
Resistance 1MΩ min.
and GND
Defective harness caused by Between harness (V3A (female) E - B12 (male) 3)
Resistance 1MΩ min.
3 grounding and GND
(contact with GND circuit) Between harness (V3A (female) D - B12 (male) 4)
Resistance 1MΩ min.
and GND
Between harness (V3A (female) 3 - B12 (male) 5)
Resistance 1MΩ min.
and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective VHMS controller V2A, V3A Voltage
V3A 3DEF - V2A BC 20 – 30V
V3A 5 - V2A BC 1V max.

20-518 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBB0KQ)

Circuit diagram for VHMS controller model selection

PC1800-6 20-519
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBB0KR) or Error Code (116)

Failure Code DBB0KR or Error Code 116

Failure Code Error Code Failure VHMS network overtime error

DBB0KR 116 Phenomenon (VHMS controller system)
Failure Content • Data from VHMS controller is not updated through communication on S-NET.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• System may not operate normally.
Machine
Related • Status of connection for communication on S-NET can be monitored on the machine monitor.
Information Monitoring code: 08

Cause Standard value, Remarks for Troubleshooting

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
1 disconnection (disconnection, Harness (V3A (female) H - P01 (female) 4) Resistance 1Ω max.
defective contact of connector) Harness (V3A (female) 8 - RE02 (female) K) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Defective harness caused by Between harness (V3A (female) H - P01 (female) 4

Resistance 1MΩ min.
2 grounding or CM25 (female) 4) and GND
(contact with GND circuit) Harness (V3A (female) 8 - RE02 (female) K, CM31
Resistance 1MΩ min.
(female) 4, or CM32 (female) 4)
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Defective harness caused by
Between harness (V3A (female) H - P01 (female) 4
3 hot-short-circuit Voltage 1V max.
or CM25 (female) 4) and GND
(contact with 24V circuit)
Harness (V3A (female) 8 - RE02 (female) K, CM31
Voltage 1V max.
(female) 4, or CM32 (female) 4)
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
4 Defective VHMS controller V3A Voltage
8-C 6 – 9V
H-G 6 – 9V

20-520 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBB0KR) or Error Code (116)

Related electrical circuit of S-NET communication

PC1800-6 20-521
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBB0KT)

Failure Code DBB0KT

Failure Code Error Code Failure VHMS sys. error

DBB0KT — Phenomenon (VHMS controller system)
• Abnormality occurred in the memory inside VHMS controller.
Failure Content
• Abnormality occurred in VHMS controller.
Controller
• Continues control in G mode.
Reaction
Phenomenon on
• Dropped output in DH and H modes
Machine
Related
Information

Possible Cause Cause Standard value, Remarks for Troubleshooting

and Standard
value 1 Defective VHMS controller You cannot diagnose because of internal defects.

20-522 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBBQKR)

Failure Code DBBQKR

Failure Code Error Code Failure KOM-NET/c error

DBBQKR — Phenomenon (VHMS controller system)
Failure Content • VHMS controller cannot recognize front or rear engine controller on CAN communication circuit.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• Front engine may not run normally.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (V4A (female) B - FE02 (female) L, RE02
(female) L, or C96 (female) B)
Defective harness caused by
Resistance 1Ω max.
1 disconnection (disconnection,
defective contact of connector) Harness (V4A (female) 4 - FE02 (female) V, RE02
(female) V, or C96 (female) A)
Resistance 1Ω max.

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Between harness (V4A (female) B - FE02 (female)
L, RE02 (female) L, C96 (female) B, CM31 (male)
Resistance 1MΩ min.
Possible Cause and Standard value

0, CM32 (male) 0, FC02 (female) L, C94 (female)

B) and GND
Defective harness caused by
2 grounding
(contact with GND circuit) Between harness (V4A (female) 4 - FE02 (female)
V, RE02 (female) V, C96 (female) A, CM31 (male)
Resistance 1MΩ min.
3, CM32 (male) 3, FC02 (female) V, C94 (female)
A) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (V4A (female) B - FE02 (female)
L, RE02 (female) L, C96 (female) B, CM31 (male)
Defective harness caused by Voltage 1V max.
0, CM32 (male) 0, FC02 (female) L, C94 (female)
B) and GND
3 hot-short-circuit
(contact with 24V circuit)
Between harness (V4A (female) 4 - FE02 (female)
V, RE02 (female) V, C96 (female) A, CM31 (male)
Voltage 1V max.
3, CM32 (male) 3, FC02 (female) V, C94 (female)
A) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective CAN termination
4 C94 (male), C96 (male) Resistance
A-B
resistance
40 – 80Ω
Defective front or rear engine If any possible cause in 1 though 4 above does not apply, front or rear engine
5
controller controller may be defective. (You cannot diagnose because of internal defects.)

20-524 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DBBQKR)

Related electrical circuit of CAN communication

PC1800-6 20-525
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DD11KB) or Error Code (E954)

Failure Code DD11KB or Error Code E954

Failure Code Error Code Failure Short F. engine starter sw.

DD11KB E954 Phenomenon (front engine controller system)
Failure Content • Starting switch C signal was detected when front engine is running (at 500 rpm or more).
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF or at
START.
Defective Starting switch C04 Starting switch Resistance
1
(internal short-circuit)
Possible Cause and Standard value

When OFF 1MΩ min.

Terminal B - C
When at START 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (Terminal C of C04 - C63 (female)
Voltage 1V max.
Defective harness caused by 3, or C61 (female) 1) and GND
2 hot-short-circuit Between harness (C63 (female) 6 - C59 (female) 5,
(contact with 24V circuit) Voltage 1V max.
or P01 (female) I) and GND
Between harness (C59 (female) 1 - FC01 (female)
G, FE01 (female) J, or front starter's terminal S) and Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the engine started.
FE01 Starting switch Voltage
3 Defective front engine controller
When ON
J - GND 1V max.
(engine running)

20-526 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DD11KB) or Error Code (E954)

Related electrical circuit of engine preheat, start, charge

PC1800-6 20-527
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dD11KB) or Error Code (EA54)

Failure Code dD11KB or Error Code EA54

Failure Code Error Code Failure Short R. engine starter sw.

dD11KB EA54 Phenomenon (rear engine controller system)
Failure Content • Starting switch C signal was detected when rear engine is running (at 500 rpm or more).
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF or at
START.
Defective Starting switch C04 Starting switch Resistance
1
(internal short-circuit)
Possible Cause and Standard value

When OFF 1MΩ min.

Terminal B - C
When at START 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Between harness (Terminal C of C04 - C63 (female)
Voltage 1V max.
Defective harness caused by 3, or C61 (female) 1) and GND
2 hot-short-circuit Between harness (C63 (female) 6 - C59 (female) 5,
(contact with 24V circuit) Voltage 1V max.
or P01 (female) I) and GND
Between harness (C59 (female) 3 - RC01 (female)
A, RE01 (female) J, or rear starter's terminal S) and Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the engine started.
RE01 Starting switch Voltage
3 Defective rear engine controller
When ON
J - GND 1V max.
(engine running)

20-528 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dD11KB) or Error Code (EA54)

Related electrical circuit of engine preheat, start, charge

PC1800-6 20-529
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DDE2L6) or Error Code (E936)

Failure Code DDE2L6 or Error Code E936

Failure Code Error Code Failure F. engine oil press. sw. error
DDE2L6 E936 Phenomenon (front engine controller system)
• Signal circuit of low-pressure switch closed (connected to GND) and that of high-pressure switch
opened (disconnected from GND) when front engine is running at 600 rpm or more.
• Signal circuit of low-pressure switch opened (disconnected from GND) when front engine was stopped
Failure Content
(start signal = OFF).
• Signal circuit of high-pressure switch opened (disconnected from GND) when front engine was
stopped (start signal = OFF).
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related • Oil-pressure of front engine can be monitored on the machine monitor.
Information Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF or
engine started.
Defective front-engine oil PSL Engine Resistance
1
low-pressure switch
Stop 1Ω max.
Terminal - GND
Low idling 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF or
engine started.
Defective front-engine oil PSH Engine Resistance
Possible Cause and Standard value

2
high-pressure switch
Stop 1Ω max.
Terminal - GND
1,300 rpm min. 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 disconnection (disconnection, Harness (FE01 (female) K - PSL) Resistance 1Ω max.
defective contact of connector) Harness (FE01 (female) E - PSH) Resistance 1Ω max.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
4 grounding Between harness (FE01 (female) K - PSL) and GND Resistance 1MΩ min.
(contact with GND circuit) Between harness (FE01 (female) E - PSH) and GND Resistance 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
FE01 Engine Voltage
K - GND (low-pressure Stop 1V max.
5 Defective front engine controller switch signal) Low idling 20 – 30V
E - GND (high-pressure Stop 1V max.
switch signal) 1,300 rpm min. 20 – 30V
If you diagnose while engine is running, do it more than 15 seconds after engine
was started.

20-530 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DDE2L6) or Error Code (E936)

Related electrical circuit of front engine oil pressure switch

PC1800-6 20-531
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dDE2L6) or Error Code (EA36)

Failure Code dDE2L6 or Error Code EA36

Failure Code Error Code Failure R. engine oil press. sw. error
dDE2L6 EA36 Phenomenon (rear engine controller system)
• Signal circuit of low-pressure switch closed (connected to GND) and that of high-pressure switch
opened (disconnected from GND) when rear engine is running at 600 rpm or more.
• Signal circuit of low-pressure switch opened (disconnected from GND) when rear engine was stopped
Failure Content
(start signal = OFF).
• Signal circuit of high-pressure switch opened (disconnected from GND) when rear engine was
stopped (start signal = OFF).
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related • Oil-pressure of rear engine can be monitored on the machine monitor.
Information Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF or
engine started.
Defective rear-engine oil PSL Engine Resistance
1
low-pressure switch
Stop 1Ω max.
Terminal - GND
Low idling 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF or
engine started.
Defective rear-engine oil PSH Engine Resistance
2
Possible Cause and Standard value

high-pressure switch
Stop 1Ω max.
Terminal - GND
1,300 rpm min. 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 disconnection (disconnection, Harness (RE01 (female) K - PSL) Resistance 1Ω max.
defective contact of connector) Harness (RE01 (female) E - PSH) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by
Between harness (RE01 (female) K - PSL) and GND Resistance 1MΩ min.
4 grounding
(contact with GND circuit) Between harness (RE01 (female) E - PSH) and
Resistance 1MΩ min.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
RE01 Engine Voltage
K - GND (low-pressure Stop 1V max.
5 Defective rear engine controller switch signal) Low idling 20 – 30V
E - GND (high-pressure Stop 1V max.
switch signal) 1,300 rpm min. 20 – 30V
If you diagnose while engine is running, do it more than 15 seconds after engine
was started.

20-532 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dDE2L6) or Error Code (EA36)

Related electrical circuit of rear engine oil pressure switch

PC1800-6 20-533
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DGE4KX) or Error Code (E93d)

Failure Code DGE4KX or Error Code E93d

Failure Code Error Code Failure F. engine fuel temp. sensor error
DGE4KX E93d Phenomenon (front engine controller system)
Failure Content • Signal voltage of front engine fuel-temperature sensor rose to 4.5 V or higher.
Controller
• Operates with normal control.
Reaction
Phenomenon on
• Output drops somewhat at a low temperature.
Machine
• Front engine fuel temperature can be monitored on the machine monitor or CGC monitor.
Related
Monitoring code: 79
Information
Monitoring screen: Real-time monitor (1/6)

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front engine fuel-tem- THL (male) Resistance
A-B
Possible Cause and Standard value

1 perature sensor (internal dis-

connection, short-circuit) 0.3 - 9kΩ
AB - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (FE02 (female) G - THL (female) A)
Defective harness caused by
2 disconnection (disconnection, Resistance 1Ω max.
defective contact of connector) Harness (FE02 (female) S - THL (female) B) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 grounding Between harness (FE02 (female) G - THL (female)
A) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
FE02 (female) Resistance
4 Defective front engine controller
G-S 0.3 - 9kΩ
GS - GND 1MΩ min.

Circuit diagram for front engine fuel-temperature sensor

20-534 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dGE4KX) or Error Code (EA3d)

Failure Code dGE4KX or Error Code EA3d

Failure Code Error Code Failure R. engine fuel temp. sensor error
dGE4KX EA3d Phenomenon (rear engine controller system)
Failure Content • Signal voltage of rear engine fuel-temperature sensor rose to 4.5 V or higher.
Controller
• Operates with normal control.
Reaction
Phenomenon on
• Output drops somewhat at a low temperature.
Machine
• Rear engine fuel temperature can be monitored on the machine monitor or CGC monitor.
Related
Monitoring code: 99
Information
Monitoring screen: Real-time monitor (2/6)

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear engine fuel-tem- THL (male) Resistance
A-B
Possible Cause and Standard value

1 perature sensor (internal dis-

connection, short-circuit) 0.3 - 9kΩ
AB - GND 1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (RE02 (female) G - THL (female) A)
Defective harness caused by
2 disconnection (disconnection, Resistance 1Ω max.
defective contact of connector) Harness (RE02 (female) S - THL (female) B) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 grounding Between harness (RE02 (female) G - THL (female)
A) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
RE02 (female) Resistance
4 Defective rear engine controller
G-S 0.3 - 9kΩ
GS - GND 1MΩ min.

Circuit diagram for rear engine fuel-temperature sensor

PC1800-6 20-535
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DGT4KA)

Failure Code DGT4KA

Failure Code Error Code Failure Exhaust temp. sensor F-F failure
DGT4KA — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of front exhaust temperature sensor of front engine dropped to 0.3 V or lower.
Controller
• No response in particular
Reaction
Phenomenon on
• Front exhaust temperature of front engine cannot be monitored on CGC monitor.
Machine
Related • Front exhaust temperature of front engine can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Defective 24 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.

Defective front exhaust temper- ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 ature sensor of front engine P29.1 (male) Resistance
(internal disconnection) 1-2
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
Possible Cause and Standard value

gine started.
Defective amplifier for front
3 exhaust temperature sensor of B58.1 Voltage
front engine (internal defect) A-C 20 – 30V
B-C 0.3 – 4.7V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.

Defective harness caused by Harness (P27.1 (female) 1 - P29.1 (female) 1) Resistance 1Ω max.
4 disconnection (disconnection, Harness (P27.1 (female) 2 - P29.1 (female) 2) Resistance 1Ω max.
defective contact of connector) Harness (V1 (female) 2 - B58.1 (female) A) Resistance 1Ω max.
Harness (V2A (female) 7 - B58.1 (female) B) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
5 grounding Between harness (V2A (female) 7 - B58.1 (female)
B) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
7 - BC 0.3 – 4.7V

20-536 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DGT4KA)

Related electrical circuit of front engine exhaust temperature sensor (front, rear)

PC1800-6 20-537
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dGT4KA)

Failure Code dGT4KA

Failure Code Error Code Failure Exhaust temp. sensor R-F failure
dGT4KA — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of rear exhaust temperature sensor of front engine dropped to 0.3 V or lower.
Controller
• No response in particular
Reaction
Phenomenon on
• Front exhaust temperature of rear engine cannot be monitored on CGC monitor.
Machine
Related • Front exhaust temperature of rear engine can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Defective 24 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.

Defective front exhaust temper- ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 ature sensor of rear engine P30.1 (male) Resistance
(internal disconnection) 1-2
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
Possible Cause and Standard value

gine started.
Defective amplifier for front
3 exhaust temperature sensor of B59.1 Voltage
rear engine (internal defect) A-C 20 – 30V
B-C 0.3 – 4.7V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.

Defective harness caused by Harness (P28.1 (female) 1 - P30.1 (female) 1) Resistance 1Ω max.
4 disconnection (disconnection, Harness (P28.1 (female) 2 - P30.1 (female) 2) Resistance 1Ω max.
defective contact of connector) Harness (V1 (female) 2 - B59.1 (female) A) Resistance 1Ω max.
Harness (V2A (female) F - B59.1 (female) B) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
5 grounding Between harness (V2A (female) F - B59.1 (female)
B) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
F - BC 0.3 – 4.7V

20-538 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dGT4KA)

Related electrical circuit of rear engine exhaust temperature sensor (front, rear)

PC1800-6 20-539
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DGT4KB)

Failure Code DGT4KB

Failure Code Error Code Failure Exhaust temp. sensor F-F failure
DGT4KB — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of front exhaust temperature sensor of front engine rose to 4.9 V or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Front exhaust temperature of front engine cannot be monitored on CGC monitor.
Machine
Related • Front exhaust temperature of front engine can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Defective 24 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front exhaust temper- P29.1 (male) Resistance
2 ature sensor of front engine
(internal short-circuit) 1-2
12 - GND
Possible Cause and Standard value

1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective amplifier for front-side
3 exhaust temperature sensor of B58.1 Voltage
front engine (internal defect) A-C 20 – 30V
B-C 0.3 – 4.7V
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
4 grounding Between harness (P27.1 (female) 1 - P29.1 (female)
(contact with GND circuit) Resistance 1MΩ min.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
Harness (V2A (female) 7 - B58.1 (female) B) and
5 hot-short-circuit
(contact with 24V circuit) Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
7 - BC 0.3 – 4.7V

20-540 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DGT4KB)

Related electrical circuit of front engine exhaust temperature sensor (front, rear)

PC1800-6 20-541
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dGT4KB)

Failure Code dGT4KB

Failure Code Error Code Failure Exhaust temp. sensor R-F failure
dGT4KB — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of front exhaust temperature sensor of rear engine rose to 4.9 V or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Front exhaust temperature of rear engine cannot be monitored on CGC monitor.
Machine
Related • Rear exhaust temperature of front engine can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Defective 24 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front exhaust temper- P30.1 (male) Resistance
2 ature sensor of rear engine
(internal short-circuit) 1-2
12 - GND
Possible Cause and Standard value

1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective amplifier for front-side
3 exhaust temperature sensor of B59.1 Voltage
rear engine (internal defect) A-C 20 – 30V
B-C 0.3 – 4.7V
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
4 grounding Between harness (P28.1 (female) 1 - P30.1 (female)
(contact with GND circuit) Resistance 1MΩ min.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
Harness (V2A (female) F - B59.1 (female) B) and
5 hot-short-circuit
(contact with 24V circuit) Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
F - BC 0.3 – 4.7V

20-542 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dGT4KB)

Related electrical circuit of rear engine exhaust temperature sensor (front, rear)

PC1800-6 20-543
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DGT5KA)

Failure Code DGT5KA

Failure Code Error Code Failure Exhaust temp. sensor F-R failure
DGT5KA — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of rear exhaust temperature sensor of front engine dropped to 0.3 V or lower.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear exhaust temperature of front engine cannot be monitored on CGC monitor.
Machine
Related • Rear exhaust temperature of front engine can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Defective 24 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.

Defective rear exhaust temper- ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 ature sensor of front engine P29.2 (male) Resistance
(internal disconnection) 1-2
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
Possible Cause and Standard value

gine started.
Defective amplifier for rear
3 exhaust temperature sensor of B58.2 Voltage
front engine (internal defect) A-C 20 – 30V
B-C 0.3 – 4.7V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.

Defective harness caused by Harness (P27.2 (female) 1 - P29.2 (female) 1) Resistance 1Ω max.
4 disconnection (disconnection, Harness (P27.2 (female) 2 - P29.2 (female) 2) Resistance 1Ω max.
defective contact of connector) Harness (V1 (female) 2 - B58.2 (female) A) Resistance 1Ω max.
Harness (V2A (female) 6 - B58.2 (female) B) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
5 grounding Between harness (V2A (female) 6 - B58.1 (female)
B) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
6 - BC 0.3 – 4.7V

20-544 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DGT5KA)

Related electrical circuit of front engine exhaust temperature sensor (front, rear)

PC1800-6 20-545
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dGT5KA)

Failure Code dGT5KA

Failure Code Error Code Failure Exhaust temp. sensor R-R failure
dGT5KA — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of rear exhaust temperature sensor of rear engine dropped to 0.3 V or lower.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear exhaust temperature of front engine cannot be monitored on CGC monitor.
Machine
Related • Rear exhaust temperature of rear engine can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Defective 24 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.

Defective rear exhaust temper- ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 ature sensor of rear engine P30.2 (male) Resistance
(internal disconnection) 1-2
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
Possible Cause and Standard value

gine started.
Defective amplifier for rear
3 exhaust temperature sensor of B59.2 Voltage
rear engine (internal defect) A-C 20 – 30V
B-C 0.3 – 4.7V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.

Defective harness caused by Harness (P28.2 (female) 1 - P30.2 (female) 1) Resistance 1Ω max.
4 disconnection (disconnection, Harness (P28.2 (female) 2 - P30.2 (female) 2) Resistance 1Ω max.
defective contact of connector) Harness (V1 (female) 2 - B59.2 (female) A) Resistance 1Ω max.
Harness (V2A (female) 5 - B59.2 (female) B) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
5 grounding Between harness (V2A (female) 5 - B59.2 (female)
B) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
5 - BC 0.3 – 4.7V

20-546 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dGT5KA)

Related electrical circuit of rear engine exhaust temperature sensor (front, rear)

PC1800-6 20-547
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DGT5KB)

Failure Code DGT5KB

Failure Code Error Code Failure Exhaust temp. sensor F-R failure
DGT5KB — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of rear exhaust temperature sensor of front engine rose to 4.9 V or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear exhaust temperature of front engine cannot be monitored on CGC monitor.
Machine
Related • Rear exhaust temperature of front engine can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Defective 24 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear exhaust temper- P29.2 (male) Resistance
2 ature sensor of front engine
(internal short-circuit) 1-2
12 - GND
Possible Cause and Standard value

1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective amplifier for rear
3 exhaust temperature sensor of B58.2 Voltage
front engine (internal defect) A-C 20 – 30V
B-C 0.3 – 4.7V
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
4 grounding Between harness (P27.2 (female) 1 - P29.2 (female)
(contact with GND circuit) Resistance 1MΩ min.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
Harness (V2A (female) 6 - B58.2 (female) B) and
5 hot-short-circuit
(contact with 24V circuit) Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
6 - BC 0.3 – 4.7V

20-548 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DGT5KB)

Related electrical circuit of front engine exhaust temperature sensor (front, rear)

PC1800-6 20-549
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dGT5KB)

Failure Code dGT5KB

Failure Code Error Code Failure Exhaust temp. sensor R-R failure
dGT5KB — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of rear exhaust temperature sensor of rear engine rose to 4.9 V or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear exhaust temperature of rear engine cannot be monitored on CGC monitor.
Machine
Related • Rear exhaust temperature of rear engine can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Defective 24 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear exhaust temper- P30.2 (male) Resistance
2 ature sensor of rear engine
(internal short-circuit) 1-2
12 - GND
Possible Cause and Standard value

1MΩ min.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective amplifier for rear
3 exhaust temperature sensor of B59.2 Voltage
rear engine (internal defect) A-C 20 – 30V
B-C 0.3 – 4.7V
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
4 grounding Between harness (P28.2 (female) 1 - P30.2 (female)
(contact with GND circuit) Resistance 1MΩ min.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
Harness (V2A (female) 5 - B59.2 (female) B) and
5 hot-short-circuit
(contact with 24V circuit) Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
5 - BC 0.3 – 4.7V

20-550 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dGT5KB)

Related electrical circuit of rear engine exhaust temperature sensor (front, rear)

PC1800-6 20-551
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DH30KX) or Error Code (E93C)

Failure Code DH30KX or Error Code E93C

Failure Code Error Code Failure F. engine boost press. sensor error
DH30KX E93C Phenomenon (front engine controller system)
• Signal voltage of front engine boost-pressure sensor dropped to 0.5 V or lower or rose to 4.5 V or
Failure Content
higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Front engine boost-pressure cannot be monitored on machine monitor or CGC monitor.
Machine
• Diagnosing boost-pressure sensor requires a special adapter (799-601-9420).
Related • Front engine boost-pressure can be monitored on machine monitor or CGC monitor.
Information Monitoring code: 76
Monitoring screen: PM Clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch ON.
Defective front engine PIM Resistance
1 boost-pressure sensor
(internal defect) 3-1 4.6 – 5.4V
2-1 0.5 – 4.5V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by
Possible Cause and Standard value

Harness (FE02 (female) 9 - PIM (female) 3) Resistance 1Ω max.

2 disconnection (disconnection,
defective contact of connector) Harness (FE02 (female) J - PIM (female) 2) Resistance 1Ω max.
Harness (FE02 (female) ] - PIM (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (FE02 (female) 9 - PIM (female)
Resistance 1MΩ min.
3 grounding 3) and GND
(contact with GND circuit) Between harness (FE02 (female) J - PIM (female)
Resistance 1MΩ min.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
4 hot-short-circuit
(contact with 24V circuit) Harness (FE02 (female) J - PIM (female) 2) and
Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective front engine controller FE02 Voltage
9-] 4.6 – 5.4V
J-] 0.5 – 4.5V

Related electrical circuit of front engine boost pressure sensor

20-552 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dH30KX) or Error Code (EA3C)

Failure Code dH30KX or Error Code EA3C

Failure Code Error Code Failure R. engine boost press. sensor error
dH30KX EA3C Phenomenon (rear engine controller system)
• Signal voltage of rear engine boost-pressure sensor dropped to 0.5 V or lower or rose to 4.5 V or
Failure Content
higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear engine boost-pressure cannot be monitored on machine monitor or CGC monitor.
Machine
• Diagnosing boost-pressure sensor requires a special adapter (799-601-9420).
Related • Rear engine boost-pressure can be monitored on machine monitor or CGC monitor.
Information Monitoring code: 96
Monitoring screen: PM Clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch ON.
Defective rear engine PIM Resistance
1 boost-pressure sensor
(internal defect) 3-1 4.6 – 5.4V
2-1 0.5 – 4.5V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by
Possible Cause and Standard value

Harness (RE02 (female) 9 - PIM (female) 3) Resistance 1Ω max.

2 disconnection (disconnection,
defective contact of connector) Harness (RE02 (female) J - PIM (female) 2) Resistance 1Ω max.
Harness (RE02 (female) ] - PIM (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (RE02 (female) 9 - PIM (female)
Resistance 1MΩ min.
3 grounding 1) and GND
(contact with GND circuit) Between harness (RE02 (female) J - PIM (female)
Resistance 1MΩ min.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
4 hot-short-circuit
(contact with 24V circuit) Harness (RE02 (female) J - PIM (female) 2) and
Voltage 1V max.
GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective rear engine controller RE02 Voltage
9-] 4.6 – 5.4V
J-] 0.5 – 4.5V

Related electrical circuit of rear engine boost pressure sensor

PC1800-6 20-553
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DH40KX) or Error Code (E977)

Failure Code DH40KX or Error Code E977

Failure Code Error Code Failure F. engine common rail press. sensor error
DH40KX E997 Phenomenon (front engine controller system)
• Signal voltage of front engine common-rail pressure sensor dropped to 0.7 V or lower or rose to 4.5 V
Failure Content
or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Front engine common-rail pressure cannot be monitored on machine monitor or CGC monitor.
Machine
• Front engine common-rail pressure can be monitored on machine monitor and CGC monitor.
Related
Monitoring code: 75
Information
Monitoring screen: Real-time monitor (1/6)

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Defective front engine
1 common-rail pressure sensor PFUEL Voltage
(internal defect) 3-1 4.6 – 5.4V
2-1 0.7 – 4.5V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Defective harness caused by Harness (FE02 (female) 9 - PFUEL (female) 3 Resistance 1Ω max.
2 disconnection (disconnection,
defective contact of connector) Harness (FE02 (female) ` - PFUEL (female) 2) Resistance 1Ω max.
Harness (FE02 (female) ] - PFUEL (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (FE02 (female) 9 - PFUEL
Resistance 1MΩ min.
3 grounding (female) 3) and GND
(contact with GND circuit) Between harness (FE02 (female) ` - PFUEL
Resistance 1MΩ min.
(female) 2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
4 hot-short-circuit
(contact with 24V circuit) Between harness (FE02 (female) ` - PFUEL
Voltage 1V max.
(female) 2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective front engine controller FE02 Voltage
9-] 4.6 – 5.4V
`-] 0.7 – 4.5V

Related electrical circuit of front engine common rail pressure sensor

20-554 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dH40KX) or Error Code (EA77)

Failure Code dH40KX or Error Code EA77

Failure Code Error Code Failure R. engine common rail press. sensor error
dH40KX EA97 Phenomenon (rear engine controller system)
• Signal voltage of rear engine common-rail pressure sensor dropped to 0.7 V or lower or rose to 4.5 V
Failure Content
or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear engine common-rail pressure cannot be monitored on machine monitor or CGC monitor.
Machine
• Rear engine common-rail pressure can be monitored on machine monitor and CGC monitor.
Related
Monitoring code: 95
Information
Monitoring screen: Real-time monitor (2/6)

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Defective rear engine
1 common-rail pressure sensor PFUEL Voltage
(internal defect) 3-1 4.6 – 5.4V
2-1 0.7 – 4.5V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Defective harness caused by Harness (RE02 (female) 9 - PFUEL (female) 3) Resistance 1Ω max.
2 disconnection (disconnection,
defective contact of connector) Harness (RE02 (female) ` - PFUEL (female) 2) Resistance 1Ω max.
Harness (RE02 (female) ] - PFUEL (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (RE02 (female) 9 - PFUEL
Resistance 1MΩ min.
3 grounding (female) 3) and GND
(contact with GND circuit) Between harness (RE02 (female) ` - PFUEL
Resistance 1MΩ min.
(female) 2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
4 hot-short-circuit
(contact with 24V circuit) Between harness (RE02 (female) ` - PFUEL
Voltage 1V max.
(female) 2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective rear engine controller RE02 Voltage
9-] 4.6 – 5.4V
`-] 0.7 – 4.5V

Related electrical circuit of rear engine common rail pressure sensor

PC1800-6 20-555
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DHE4KB)

Failure Code DHE4KB

Failure Code Error Code Failure F. engine oil Press. sensor failure
DHE4KB — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of front engine oil-pressure sensor dropped to 0.3 V or lower.
Controller
• No response in particular
Reaction
Phenomenon on
• Front engine oil-pressure cannot be monitored on CGC monitor.
Machine
Related • Front engine oil-pressure can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

Defective 5 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Possible Cause and Standard value

Defective front engine oil-pres- ENGP Voltage

2
B-A
sure sensor (internal defect)
4.5 – 5.5V
C-A 0.3 – 4.7V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (V1 (female) 4 - ENGP (female) B)
Defective harness caused by
3 disconnection (disconnection, Resistance 1Ω max.
defective contact of connector) Harness (V2A (female) 8 - ENGP (female) C) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
4 grounding Between harness (V2A (female) 8 - ENGP (female)
C) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
5 Defective VHMS controller
V2A Voltage
8 - BC 0.3 – 4.7V

Circuit diagram for front engine oil-pressure sensor

20-556 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dHE4KB)

Failure Code dHE4KB

Failure Code Error Code Failure R. engine oil Press. sensor failure
dHE4KB — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of rear engine oil-pressure sensor dropped to 0.3 V or lower.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear engine oil-pressure cannot be monitored on CGC monitor.
Machine
Related • Rear engine oil-pressure can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

Defective 5 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Possible Cause and Standard value

Defective rear engine oil-pres- ENGP Voltage

2
B-A
sure sensor (internal defect)
4.5 – 5.5V
C-A 0.3 – 4.7V
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (V1 (female) 4 - ENGP (female) B)
Defective harness caused by
3 disconnection (disconnection, Resistance 1Ω max.
defective contact of connector) Harness (V2A (female) E - ENGP (female) C) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
4 grounding Between harness (V2A (female) E - ENGP (female)
C) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
5 Defective VHMS controller
V2A Voltage
E - BC 0.3 – 4.7V

Circuit diagram for rear engine oil-pressure sensor

PC1800-6 20-557
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DHE4KY)

Failure Code DHE4KY

Failure Code Error Code Failure F. engine oil Press. sensor failure
DHE4KY — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of front engine oil-pressure sensor rose to 4.7 V or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Front engine oil-pressure cannot be monitored on CGC monitor.
Machine
Related • Front engine oil-pressure can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

Defective 5 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective front engine oil-pres- ENGP Voltage
2
B-A
sure sensor (internal defect)
4.5 – 5.5V
C-A 0.3 – 4.7V
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
3 hot-short-circuit
Between harness (V2A (female) 8 - ENGP (female)
C) and GND
(contact with 24V circuit) Voltage 1V max.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
4 Defective VHMS controller
V2A Voltage
8 - BC 0.3 – 4.7V

Circuit diagram for front engine oil-pressure sensor

20-558 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dHE4KY)

Failure Code dHE4KY

Failure Code Error Code Failure R. engine oil Press. sensor failure
dHE4KY — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of rear engine oil-pressure sensor rose to 4.7 V or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear engine oil-pressure cannot be monitored on CGC monitor.
Machine
Related • Rear engine oil-pressure can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (1/6)

Cause Standard value, Remarks for Troubleshooting

Defective 5 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective rear engine oil-pres- ENGP Voltage
2
B-A
sure sensor (internal defect)
4.5 – 5.5V
C-A 0.3 – 4.7V
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
3 hot-short-circuit
Between harness (V2A (female) E - ENGP (female)
C) and GND
(contact with 24V circuit) Voltage 1V max.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
4 Defective VHMS controller
V2A Voltage
E - BC 0.3 – 4.7V

Circuit diagram for rear engine oil-pressure sensor

PC1800-6 20-559
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DHE5KB)

Failure Code DHE5KB

Failure Code Error Code Failure F. engine blowby Press. sensor failure
DHE5KB — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of front engine blow-by pressure sensor dropped to 0.1 V or lower.
Controller
• No response in particular
Reaction
Phenomenon on
• Front engine blow-by pressure cannot be monitored on CGC monitor.
Machine
Related • Front engine blow-by pressure can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Defective 5 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective front engine blow-by
2 pressure sensor ENBP Voltage
(internal defect) B-C 4.5 – 5.5V
A-C
Possible Cause and Standard value

0.1 – 4.7V
Defective front engine blow-by
Since oil, dust, water, etc. may be sticking to the sensor, check and clean the
3 pressure sensor (external
sensor. For details, see TESTING AND ADJUSTING.
defect)
Defective front engine blow-by
Since installation of the sensor may be defective, check and correct it.
4 pressure sensor (defect instal-
For details, see TESTING AND ADJUSTING.
lation)
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (V1 (female) 5 - ENBP (female) B)
Defective harness caused by
5 disconnection (disconnection, Resistance 1Ω max.
defective contact of connector) Harness (V2A (female) E - ENBP (female) A) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
6 grounding Between harness (V2A (female) D - ENBP (female)
A) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
7 Defective VHMS controller
V2A Voltage
D - BC 0.1 – 4.7V

Circuit diagram for front engine blow-by pressure sensor

20-560 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dHE5KB)

Failure Code dHE5KB

Failure Code Error Code Failure R. engine blowby Press. sensor failure
dHE5KB — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of rear engine blow-by pressure sensor dropped to 0.1 V or lower.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear engine blow-by pressure cannot be monitored on CGC monitor.
Machine
Related • Rear engine blow-by pressure can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Defective 5 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective rear engine blow-by
2 pressure sensor ENBP Voltage
(internal defect) B-C 4.5 – 5.5V
A-C
Possible Cause and Standard value

0.1 – 4.7V
Defective rear engine blow-by
Since oil, dust, water, etc. may be sticking to the sensor, check and clean the
3 pressure sensor (external
sensor. For details, see TESTING AND ADJUSTING.
defect)
Defective rear engine blow-by
Since installation of the sensor may be defective, check and correct it.
4 pressure sensor (defect instal-
For details, see TESTING AND ADJUSTING.
lation)
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Harness (V1 (female) 5 - ENBP (female) B)
Defective harness caused by
5 disconnection (disconnection, Resistance 1Ω max.
defective contact of connector) Harness (V2A (female) H - ENBP (female) A) Resistance 1Ω max.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
6 grounding Between harness (V2A (female) H - ENBP (female)
A) and GND
(contact with GND circuit) Resistance 1MΩ min.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
7 Defective VHMS controller
V2A Voltage
H - BC 0.1 – 4.7V

Circuit diagram for rear engine blow-by pressure sensor

PC1800-6 20-561
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DHE5KY)

Failure Code DHE5KY

Failure Code Error Code Failure F. engine blowby Press. sensor failure
DHE5KY — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of front engine blow-by pressure sensor rose to 4.7 V or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Front engine blow-by pressure cannot be monitored on CGC monitor.
Machine
Related • Front engine blow-by pressure can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Defective 5 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective front engine blow-by
2 pressure sensor ENBP Voltage
B-C
Possible Cause and Standard value

(internal defect) 4.5 – 5.5V

A-C 0.1 – 4.7V
Defective front engine blow-by
Since oil, dust, water, etc. may be sticking to the sensor, check and clean the
3 pressure sensor (external
sensor. For details, see TESTING AND ADJUSTING.
defect)
Defective front engine blow-by
Since installation of the sensor may be defective, check and correct it.
4 pressure sensor (defect instal-
For details, see TESTING AND ADJUSTING.
lation)
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
5 hot-short-circuit
Between harness (V2A (female) D - ENBP (female)
A) and GND
(contact with 24V circuit) Voltage 1V max.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
D - BC 0.1 – 4.7V

Circuit diagram for front engine blow-by pressure sensor

20-562 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dHE5KY)

Failure Code dHE5KY

Failure Code Error Code Failure R. engine blowby Press. sensor failure
dHE5KY — Phenomenon (VHMS controller system)
Failure Content • Signal voltage of rear engine blow-by pressure sensor rose to 4.7 V or higher.
Controller
• No response in particular
Reaction
Phenomenon on
• Rear engine blow-by pressure cannot be monitored on CGC monitor.
Machine
Related • Rear engine blow-by pressure can be monitored on CGC monitor.
Information Monitoring screen: PM Clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Defective 5 V power-source Check if a failure code [DBB0KP] is displayed; if either is, diagnose according to
1
system of sensor it.
★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
Defective rear engine blow-by
2 pressure sensor ENBP Voltage
B-C
Possible Cause and Standard value

(internal defect) 4.5 – 5.5V

A-C 0.1 – 4.7V
Defective rear engine blow-by
Since oil, dust, water, etc. may be sticking to the sensor, check and clean the
3 pressure sensor (external
sensor. For details, see TESTING AND ADJUSTING.
defect)
Defective rear engine blow-by
Since installation of the sensor may be defective, check and correct it.
4 pressure sensor (defect instal-
For details, see TESTING AND ADJUSTING.
lation)
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
5 hot-short-circuit
Between harness (V2A (female) H - ENBP (female)
A) and GND
(contact with 24V circuit) Voltage 1V max.

★Prepare by turning Starting switch OFF, and diagnose with the switch ON or en-
gine started.
6 Defective VHMS controller
V2A Voltage
H - BC 0.1 – 4.7V

Circuit diagram for rear engine blow-by pressure sensor

PC1800-6 20-563
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DK10KX) or Error Code (E931)

Failure Code DK10KX or Error Code E931

Failure Code Error Code Failure F. fuel dial sys. error

DK10KX E931 Phenomenon (front engine controller system)
Failure Content
• Signal voltage of front engine fuel-dial dropped to 0.5 V or lower or rose to 4.5 V or higher.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
• Keeps engine's rpm with the last signal of fuel-dial before the abnormality occurred.
• Engine's rpm cannot be controlled.
Phenomenon on
• High idling cannot be reached occasionally, causing insufficient output.
Machine
• Hunting may occur.
Related • Status of input from front engine fuel-dial can be monitored on machine monitor.
Information Monitoring code: 82

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.

Defective front engine fuel dial C03 (male) Voltage

1 (internal disconnection, short- 1-3 4.0 – 6.0kΩ
circuit) 1-2 0.25 – 7.0kΩ
3-2 0.25 – 7.0kΩ
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Harness (FE02 (female) I - C03 (female) 1) Resistance 1Ω max.
Possible Cause and Standard value

2 disconnection (disconnection,
defective contact of connector) Harness (FE02 (female) 0 - C03 (female) 2) Resistance 1Ω max.
Harness (FE02 (female) S - C03 (female) 3) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (FE02 (female) I - C03 (female)
Resistance 1MΩ min.
3 grounding 1) and GND
(contact with GND circuit) Between harness (FE02 (female) 0 - C03 (female)
Resistance 1MΩ min.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Defective harness caused by
Between harness (FE02 (female) I - C03 (female)
4 hot-short-circuit Voltage 1V max.
1) and GND
(contact with 24V circuit)
Between harness (FE02 (female) 0 - C03 (female)
Voltage 1V max.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective front engine controller FE02 Voltage
I-S 4.6 – 5.6V
0-S 0.5 – 4.5V

Related electrical circuit of front engine fuel dial

20-564 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dK10KX) or Error Code (EA31)

Failure Code dK10KX or Error Code EA31

Failure Code Error Code Failure R. fuel dial sys. error

dK10KX EA31 Phenomenon (rear engine controller system)
Failure Content • Signal voltage of rear engine fuel-dial dropped to 0.5 V or lower or rose to 4.5 V or higher.
Controller • Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction • Keeps engine's rpm with the last signal of fuel-dial before the abnormality occurred.
• Engine's rpm cannot be controlled.
Phenomenon on
• High idling cannot be reached occasionally, causing insufficient output.
Machine
• Hunting may occur.
Related • Status of input from rear engine fuel-dial can be monitored on machine monitor.
Information Monitoring code: A2

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.

Defective rear engine fuel dial C06 (male) Voltage

1 (internal disconnection, short- 1-3 4.0 – 6.0kΩ
circuit) 1-2 0.25 – 7.0kΩ
3-2 0.25 – 7.0kΩ
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Harness (RE02 (female) I - C06 (female) 1) Resistance 1Ω max.
Possible Cause and Standard value

2 disconnection (disconnection,
defective contact of connector) Harness (RE02 (female) 0 - C06 (female) 2) Resistance 1Ω max.
Harness (RE02 (female) S - C06 (female) 3) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (RE02 (female) I - C06 (female)
Resistance 1MΩ min.
3 grounding 1) and GND
(contact with GND circuit) Between harness (RE02 (female) 0 - C06 (female)
Resistance 1MΩ min.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
Defective harness caused by
Between harness (RE02 (female) I - C06 (female)
4 hot-short-circuit Voltage 1V max.
1) and GND
(contact with 24V circuit)
Between harness (RE02 (female) 0 - C06 (female)
Voltage 1V max.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective rear engine controller RE02 Voltage
I-S 4.6 – 5.6V
0-S 0.5 – 4.5V

Related electrical circuit of rear engine fuel dial

PC1800-6 20-565
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DLE2MA)

Failure Code DLE2MA

Failure Code Error Code Failure F. engine speed sensor sys. error
DLE2MA — Phenomenon (pump controller system)
Failure Content • Normal pulse signals are not input into the signal circuit of front engine speed sensor.
Controller
• Continues control in a mode substantially same as G mode.
Reaction
Phenomenon on • Output drops somewhat due to the control kept substantially same as G mode.
Machine • Front engine's rpm cannot be monitored on machine monitor.
Related • Front engine's rpm (signals of engine speed sensor) can be monitored on machine monitor.
Information Monitoring code: 10

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front engine speed ENE (male) Resistance
1 sensor (internal disconnection,
short-circuit) 1-2 500 – 1,000Ω
1 - GND
Possible Cause and Standard value

1MΩ min.
Defective adjustment of front
2 Refer to "Check and Adjustment: Adjustment of engine speed sensor".
engine speed sensor

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 disconnection (disconnection, Harness (FC02 (female) _ - ENE (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (FC02 (female) ] - ENE (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
4 hot-short-circuit
(contact with 24V circuit) Between harness (FC02 (female) _ - ENE (female)
Voltage 1V max.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective pump controller FC02 (female) Resistance
_-] 500 – 1,000Ω
_ - GND 1MΩ min.

Circuit diagram for front engine speed sensor

20-566 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dLE2MA)

Failure Code dLE2MA

Failure Code Error Code Failure R. engine speed sensor sys. error
dLE2MA — Phenomenon (pump controller system)
Failure Content • Normal pulse signals are not input into the signal circuit of rear engine speed sensor.
Controller
• Continues control in a mode substantially same as G mode.
Reaction
Phenomenon on • Output drops somewhat due to the control kept substantially same as G mode.
Machine • Rear engine's rpm cannot be monitored on machine monitor.
Related • Rear engine's rpm (signals of engine speed sensor) can be monitored on machine monitor.
Information Monitoring code: 11

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear engine speed ENE (male) Resistance
1 sensor (internal disconnection,
short-circuit) 1-2 500 – 1,000Ω
1 - GND
Possible Cause and Standard value

1MΩ min.
Defective adjustment of rear
2 Refer to "Check and Adjustment: Adjustment of engine speed sensor".
engine speed sensor

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 disconnection (disconnection, Harness (FC02 (female) T - ENE (female) 1) Resistance 1Ω max.
defective contact of connector) Harness (FC02 (female) S - ENE (female) 2) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
4 hot-short-circuit
(contact with 24V circuit) Between harness (FC02 (female) T - ENE (female)
Voltage 1V max.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
5 Defective pump controller FC02 (female) Resistance
T-S 500 – 1,000Ω
T - GND 1MΩ min.

Circuit diagram for rear engine speed sensor

PC1800-6 20-567
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DLE3LE) or Error Code (E91b)

Failure Code DLE3LE or Error Code E91b

Failure Code Error Code Failure F. engine Ne sensor problem

DLE3LE E91b Phenomenon (front engine controller system)
Failure Content • Signals of front engine Ne speed sensor do not help to distinguish crank angle.
Controller
• No response in particular
Reaction
Phenomenon on • Engine speed becomes unstable or engine may stop occasionally.
Machine • Front engine's rpm cannot be monitored on machine monitor.
• Front engine's rpm (signals of Ne sensor) can be monitored on machine monitor.
Related
Monitoring code: 70
Information
• Diagnosing front engine Ne sensor requires a special adapter (799-601-9410).

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front engine Ne sen- NE (male) Resistance
1 sor (internal disconnection,
short-circuit) 1-2 85 – 210Ω
Possible Cause and Standard value

12 - GND 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FE02 (female) Z - NE (female) 2) Resistance 1Ω max.
defective contact of connector) Harness (FE02 (female) P - NE (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (FE02 (female) Z - NE (female)
Resistance 1MΩ min.
3 grounding 2) and GND
(contact with GND circuit) Between harness (FE02 (female) P - NE (female)
Resistance 1MΩ min.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
FE02 (female) Resistance
4 Defective front engine controller
Z-P 85 – 210Ω
ZP - GND 1MΩ min.

Circuit diagram for front engine Ne sensor

20-568 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dLE3LE) or Error Code (EA1b)

Failure Code dLE3LE or Error Code EA1b

Failure Code Error Code Failure R. engine Ne sensor problem

dLE3LE EA1b Phenomenon (rear engine controller system)
Failure Content • Signals of rear engine Ne speed sensor do not help to distinguish crank angle.
Controller
• No response in particular
Reaction
Phenomenon on • Engine speed becomes unstable or engine may stop occasionally.
Machine • Rear engine's rpm cannot be monitored on machine monitor.
• Rear engine's rpm (signals of Ne sensor) can be monitored on machine monitor.
Related
Monitoring code: 70
Information
• Diagnosing rear engine Ne sensor requires a special adapter (799-601-9410).

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear engine Ne sen- NE (male) Resistance
1 sor (internal disconnection,
short-circuit) 1-2 85 – 210Ω
Possible Cause and Standard value

12 - GND 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (RE02 (female) Z - NE (female) 2) Resistance 1Ω max.
defective contact of connector) Harness (RE02 (female) P - NE (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (RE02 (female) Z - NE (female)
Resistance 1MΩ min.
3 grounding 2) and GND
(contact with GND circuit) Between harness (RE02 (female) P - NE (female)
Resistance 1MΩ min.
1) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
RE02 (female) Resistance
4 Defective rear engine controller
Z-P 85 – 210Ω
ZP - GND 1MΩ min.

Circuit diagram for rear engine Ne sensor

PC1800-6 20-569
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DLH1LC) or Error Code (E91C)

Failure Code DLH1LC or Error Code E91C

Failure Code Error Code Failure F. engine G sensor problem

DLH1LC E91C Phenomenon (front engine controller system)
Failure Content • Signals from front engine G sensor do not match with those from Ne sensor.
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related
• Diagnosing front engine G sensor requires a special adapter (799-601-9410).
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective front engine G sensor G (male) Resistance
1 (internal disconnection, short-
1-2 1.4k – 3.5kΩ
Possible Cause and Standard value

circuit)
12 - GND 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (FE02 (female) Y - G (female) 2) Resistance 1Ω max.
defective contact of connector) Harness (FE02 (female) O - G (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (FE02 (female) Y - G (female) 2)
Resistance 1MΩ min.
3 grounding and GND
(contact with GND circuit) Between harness (FE02 (female) O - G (female) 1)
Resistance 1MΩ min.
and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
FE02 (female) Resistance
4 Defective front engine controller
Y-O 1.4k – 3.5kΩ
YO - GND 1MΩ min.

Circuit diagram for front engine G sensor

20-570 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dLH1LC) or Error Code (EA1C)

Failure Code dLH1LC or Error Code EA1C

Failure Code Error Code Failure R. engine G sensor problem

dLH1LC EA1C Phenomenon (rear engine controller system)
Failure Content • Signals from rear engine G sensor do not match with those from Ne sensor.
Controller
• No response in particular
Reaction
Phenomenon on
Machine
Related
• Diagnosing rear engine G sensor requires a special adapter (799-601-9410).
Information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective rear engine G sensor G (male) Resistance
1 (internal disconnection, short-
circuit) 1-2 1.4k – 3.5kΩ
Possible Cause and Standard value

12 - GND 1MΩ min.

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 disconnection (disconnection, Harness (RE02 (female) Y - G (female) 2) Resistance 1Ω max.
defective contact of connector) Harness (RE02 (female) O - G (female) 1) Resistance 1Ω max.
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective harness caused by Between harness (RE02 (female) Y - G (female) 2)
Resistance 1MΩ min.
3 grounding and GND
(contact with GND circuit) Between harness (RE02 (female) O - G (female) 1)
Resistance 1MΩ min.
and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
RE02 (female) Resistance
4 Defective rear engine controller
Y-O 1.4k – 3.5kΩ
YO - GND 1MΩ min.

Circuit diagram for rear engine G sensor

PC1800-6 20-571
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DPA0KR)

Failure Code DPA0KR

Failure Code Error Code Failure Monitor network overtime error

DPA0KR — Phenomenon (entire S-NET communication system)
Failure Content • Abnormality occurred in the entire S-NET communication system.
Controller
• Displays Abnormality screen (red) on the CGC monitor, warning operator of abnormality.
Reaction
Phenomenon on
• Machine may not run normally.
Machine
Related • Status of connection for communication on S-NET can be monitored on the machine monitor.
Information Monitoring code: 08

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

Defective communication on S-
1 Diagnose according to "Failure code [DA2SKA]".
NET of pump controller system
Defective communication on S-
2 Diagnose according to "Failure code [DAB0KR] or error code [118]".
NET of pump controller system
Defective communication on S-
3 NET of front engine controller Diagnose according to "Failure code [DB2SMC] or error code [E955]".
system
Defective communication on S-
4 NET of rear engine controller Diagnose according to "Failure code [dB2SMC] or error code [EA55]".
system
Defective communication on S-
5 Diagnose according to "Failure code [DBB0KR] or error code [116]".
NET of VHMS controller system

20-572 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DV00KY) or Error Code (102)

Failure Code DV00KY or Error Code 102

Failure Code Error Code Failure Short circuit in buzzer output

DV00KY 102 Phenomenon (machine monitor system)
Failure Content • Abnormal current flew through alarm-buzzer circuit during output to GND.
Controller
• Stops alarm-buzzer circuit's output to GND.
Reaction
Phenomenon on
• Alarm-buzzer does not sound.
Machine
Related • Status of operation of alarm-buzzer can be monitored on the machine monitor.
Information Monitoring code: 47

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Possible Cause and Standard value

Defective alarm-buzzer
1 C01 (male) Resistance
(internal short-circuit)
1-2 200Ω
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
2 hot-short-circuit
(contact with 24V circuit) Between harness (P01 (female) 7 - C01 (female) 1)
Voltage 1V max.
and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
ON.
P01 Alarm buzzer Voltage
3 Defective machine monitor
When stopped 20 – 30V
7 - GND When operating
1V max.
(sounding)

Circuit diagram for alarm buzzer

PC1800-6 20-573
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DV20KB)

Failure Code DV20KB

Failure Code Error Code Failure Short in travel alarm sys.

DV20KB — Phenomenon (pump controller system)
Failure Content • Abnormal current flew into travel-alarm circuit during output to it.
Controller
• Stops output to travel-alarm circuit.
Reaction
Phenomenon on
• Travel alarm does not sound.
Machine
Related • Status of operation of travel-alarm can be monitored on the machine monitor.
Information Monitoring code: 23

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
Defective travel-alarm T11 (male) Resistance
1
(internal short-circuit) 1-2 5 – 25Ω
2 - GND 1MΩ min.
Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 grounding Between harness (FC03 (female) 8 - T11 (female)
(contact with GND circuit) Resistance 1Ω max.
2) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
3 Defective pump controller FC03 (female) Resistance
8 - GND 5 – 25Ω

Circuit diagram for travel alarm

20-574 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DW42KZ)

Failure Code DW42KZ

Failure Code Error Code Failure Auto decel output sys. error
DW42KZ — Phenomenon (pump controller system)
• Circuit voltage rose to 5.7 V or higher when automatic-deceleration signal is ON.
Failure Content
• Circuit voltage dropped to 5.5 V or lower when automatic-deceleration signal is OFF.
Controller
• No response in particular
Reaction
Phenomenon on
• Automatic-deceleration does not operate or is not released.
Machine
Related • Status of automatic-deceleration signals can be monitored on the machine monitor.
Information Monitoring code: 26

Cause Standard value, Remarks for Troubleshooting

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
1 disconnection (disconnection, Harness (FC02 (female) 9 - FE01 (female) L or
defective contact of connector) Resistance 1Ω max.
RE01 (female) L)
Possible Cause and Standard value

Defective harness caused by ★Prepare by turning Starting switch OFF, and diagnose with the switch OFF.
2 grounding Between harness (FC02 (female) 9 - FE01 (female)
(contact with GND circuit) Resistance 1MΩ min.
L or RE01 (female) L) and GND
★Prepare by turning Starting switch OFF, and diagnose with the switch turned
Defective harness caused by ON.
3 hot-short-circuit
(contact with 24V circuit) Between harness (FC02 (female) 9 - FE01 (female)
Voltage 1V max.
L or RE01 (female) L) and GND
★Prepare by turning Starting switch OFF, and diagnose with engine started.
FC02 Automatic-deceleration Voltage
4 Defective pump controller
Operating (decelerated) 1V max.
9 - GND
Released (full) 20 – 30V
Defective front or rear engine
5 You cannot diagnose because of internal defects.
controller

Circuit diagram for automatic-deceleration signals

PC1800-6 20-575
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DW45KA)

Failure Code DW45KA

Failure Code Error Code Failure Break in swing brake sys.

DW45KA — Phenomenon (Pump controller system)
Failure Content • Current does not flow at the time of output to swing holding brake solenoid circuit.
Controller • Abnormality (red) is displayed on the CGC monitor to warn the operator of abnormality.
Reaction • No action is taken.
Phenomenon on
• Since the swing holding brake is not released, the machine cannot swing.
Machine
Related • The operating state of the swing holding brake solenoid can be monitored on the machine monitor.
Information Monitoring code : 23

Cause Standard value, Remarks for Troubleshooting

Defective swing holding brake ★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
1 solenoid B16(Male), B18 (Male) Resistance value
(Internal disconnection) Between 1 and 2 20 – 60Ω
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective swing lock switch
2 C17 (female) Swing lock switch Resistance value
(Internal disconnection)
Between 3 and 5 OFF 1Ω max.
★Turn off the starting switch for preparation, and start the engine for
Defective swing safety relay troubleshooting.
3
(Internal disconnection) Replace the right relay with another relay. If the machine returns to
Possible Cause and Standard value

C99
normal, the swing safety relay is defective.
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective diode
4 C55 Continuity check
(Internal disconnection)
Between 2 and 1 Continue
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between FC03 (female) [ and
Resistance 1Ω max.
C55 (female) 2
Wiring harnesses between C55 (female) 1 and C17
Resistance 1Ω max.
Disconnection of wiring harness (male) 3
5 (Disconnection, or defective Wiring harness between C17 (male) 5 and
contact of connector) Resistance 1Ω max.
C99(female) 3
Wiring harnesses between C99 (female) 6 and B16
Resistance 1Ω max.
(female) 1, and B18 (female) 1
Wiring harnesses between B16 (female) 2, B18
Resistance 1Ω max.
(female) 2 and ground
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
FC03 (female) Resistance value
6 Defective pump controller Between [ and ground 10 – 30Ω
When measuring the solenoid resistance value at the pump controller section,
disconnect the diode C55 and connect 1, 2 pins on the female side directly.

20-576 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DW45KA)

Related electrical circuit of swing brake solenoid

PC1800-6 20-577
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DW45KB)

Failure Code DW45KB

Failure Code Error Code Failure Short in swing brake sys.

DW45KB — Phenomenon (Pump controller system)
Failure Content • Some abnormal current flew at the time of output to swing holding brake solenoid circuit.
Controller • Abnormality (red) is displayed on the CGC monitor to warn the operator of abnormality.
Reaction • Stop outputting to the swing holding brake solenoid circuit.
Phenomenon on
• Since the swing holding brake is not released, the machine cannot swing.
Machine
Related • The operating state of the swing holding brake solenoid can be monitored on the machine monitor.
Information Monitoring code : 23

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective swing holding brake B16 (Male), B18 (Male) Resistance value
1 solenoid
(Internal disconnection) Between 1 and 2 20 – 60Ω
Between 1 and ground 1MΩ min.
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective diode
2 B17 (male) Resistance value
(Internal short-circuit)
Between 1 and 2 1MΩ min.
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective swing lock switch
3 C17 (female) Swing lock switch Resistance value
(Internal short-circuit)
Possible Cause and Standard value

Between 3 and 2 OFF 1MΩ min.

★Turn off the starting switch for preparation, and start the engine for
Defective swing safety relay troubleshooting.
4
(Internal short-circuit) Replace the right relay with another relay. If the machine returns to
C99
normal, the swing safety relay is defective.

Defective swing holding brake ★Turn off the starting switch and troubleshoot while keeping it off.
5 release switch in an emergency B08 (male) Swing release switch Resistance value
(Internal short-circuit) Between 5 and 4 OFF 1MΩ min.
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between FC03 (female) [ – C55 – Continuity No
C17 (male) 3 and B08 (female) 5, and ground. check continuity
Short circuit with ground in wir-
6 ing harness Wiring harness between C17 (male) 5 and (female) Resistance
1MΩ min.
(Contact with GND circuit) 3, and ground value
Wiring harness between C99 (female) 6 – B16
Resistance
(female) 1, B18 (female) 1, and B17 (female) 1 1MΩ min.
value
and ground
★Turn off the starting switch for preparation, and start the engine for
troubleshooting.
FC03 Swing lever Voltage
7 Defective pump controller
9 seconds later from
1V max.
Between [ and ground neutral time
Operating time 20 – 30V

20-578 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DW45KB)

Related electrical circuit of swing brake solenoid

PC1800-6 20-579
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DW48KA)

Failure Code DW48KA

Failure Code Error Code Failure Break in CO cancel sol. sys.

DW48KA — Phenomenon (Pump Controller System)
Failure Content • No current flows at the time of output to the CO cancel solenoid circuit.
Controller
• No action is taken. (No current flows and the solenoid does not work.)
Reaction
Phenomenon on
• The power is weak in the DH Mode and in the Heavy Lift Mode.
Machine
Related • The operating state of the CO cancel solenoid can be monitored on the machine monitor.
Information Monitoring code : 23

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Defective CO cancel solenoid
1 B24 (Male) Resistance value
(Internal disconnection)
Between 1 and 2 20 – 60Ω
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Disconnection of wiring harness Wiring harnesses between FC03 (female) G and B24 Resistance
1Ω max.
2 (Disconnection, defective con- (female) 1 value
tact of connector) Wiring harnesses between B24 (female) 2 and Resistance
1Ω max.
ground value
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 Defective pump controller FC03 (female) Resistance value
Between G and ground 20 – 60Ω

Circuit Diagram related to CO Cancel Solenoid

20-580 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DW48KB)

Failure Code DW48KB

Failure Code Error Code Failure Short in CO cancel sol. sys.

DW48KB — Phenomenon (Pump Controller System)
Failure Content • Some abnormal current flew at the time of output to the CO cancel solenoid circuit.
Controller
• Stop outputting to the CO cancel solenoid circuit.
Reaction
Phenomenon on
• The power is weak in the DH Mode and in the Heavy Lift Mode.
Machine
Related • The operating state of the CO cancel solenoid can be monitored on the machine monitor.
Information Monitoring code : 23

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Defective CO cancel solenoid B24 (Male) Resistance value
Possible Cause and Standard value

1
(Internal short-circuit) Between 1 and 2 20 – 60Ω
Between 1 and ground 1MΩ min.
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective diode
2 B25 (male) Resistance value
(Internal short-circuit)
Between 1 and 2 1MΩ min.
Short circuit with ground in wir- ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 ing harness Wiring harnesses between FC03 (female) G, B24 Resistance
(Contact with GND circuit) 1MΩ min.
(female) 1 and B25 (female) 1, and ground value
★Turn off the starting switch for preparation and turn it on for troubleshooting.
FC03 Working mode switch Voltage
4 Defective pump controller
H or G 1V max.
Between G and ground
DH 20 – 30V

Circuit Diagram related to CO Cancel Solenoid

PC1800-6 20-581
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DW91KA)

Failure Code DW91KA

Failure Code Error Code Failure Break in straight travel sol. sys.
DW91KA — Phenomenon (Pump Controller System)
Failure Content • No current flows at the time of output to the straight-travel solenoid circuit.
Controller
• No action is taken. (No current flows and the solenoid does not work.)
Reaction
Phenomenon on • Some travel deviation may occur when travel and work equipment or swing are operated at the same
Machine time.
Related • The operating state of the straight-travel solenoid can be monitored on the machine monitor.
Information Monitoring code : 23

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Defective straight-travel sole-
1 B26 (Male) Resistance value
noid (Internal disconnection)
Between 1 and 2 20 – 60Ω
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Disconnection of wiring harness Wiring harnesses between FC03 (female) 7 and B26 Resistance
1Ω max.
2 (Disconnection, defective con- (female) 1 value
tact of connector) Wiring harnesses between B26 (female) 2 and Resistance
1Ω max.
ground value
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 Defective pump controller FC03 (female) Resistance value
Between 7 and ground 20 – 60Ω

Circuit Diagram related to Straight-travel Solenoid

20-582 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DW91KB)

Failure Code DW91KB

Failure Code Error Code Failure Short in straight travel sol. sys.
DW91KB — Phenomenon (Pump Controller System)
Failure Content • Some abnormal current flew at the time of output to the straight-travel solenoid circuit.
Controller
• Stop outputting to the straight-travel solenoid circuit.
Reaction
Phenomenon on • Some travel deviation may occur when travel and work equipment or swing are operated at the same
Machine time.
Related • The operating state of the straight-travel solenoid can be monitored on the machine monitor.
Information Monitoring code : 23

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Defective straight-travel sole- B26 (Male) Resistance value
1
noid (Internal short-circuit) Between 1 and 2 20 – 60Ω
Possible Cause and Standard value

Between 1 and ground 1MΩ min.

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective diode
2 B27 (male) Resistance value
(Internal short-circuit)
Between 1 and 2 1MΩ min.
Short circuit with ground in wir- ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 ing harness Wiring harnesses between FC03 (female) 7, B26 Resistance
(Contact with GND circuit) 1MΩ min.
(female) 1 and B27 (female) 1, and ground value
★Turn off the starting switch for preparation and start the engine for troubleshoot-
ing.
FC03 Control lever Voltage
4 Defective pump controller
At neutral time 1V max.
Between 7 and ground Left-and-right travel +
20 – 30V
work equipment

Circuit Diagram related to Straight-travel Solenoid

PC1800-6 20-583
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DWK0KA)

Failure Code DWK0KA

Failure Code Error Code Failure Break in 2-stage relief sol. sys.
DWK0KA — Phenomenon (Pump Controller System)
Failure Content • No current flows at the time of output to the 2-stage relief solenoid circuit.
Controller
• No action is taken. (No current flows and the solenoid does not work.)
Reaction
Phenomenon on • The power is weak when the heavy lift is operated.
Machine The power is weak when travel is operated.
Related • The operating state of the 2-stage relief solenoid can be monitored on the machine monitor.
Information Monitoring code : 23

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Defective 2-stage relief sole-
1 B28 (Male) Resistance value
noid (Internal disconnection)
Between 1 and 2 20 – 60Ω
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Disconnection of wiring harness Wiring harnesses between FC03 (female) R and B28 Resistance
1Ω max.
2 (Disconnection, defective con- (female) 1 value
tact of connector) Wiring harnesses between B28 (female) 2 and Resistance
1Ω max.
ground value
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 Defective pump controller FC03 (female) Resistance value
Between R and ground 20 – 60Ω

Circuit Diagram related to 2-stage Relief Solenoid

20-584 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DWK0KB)

Failure Code DWK0KB

Failure Code Error Code Failure Short in 2-stage relief sol. sys.
DWK0KB — Phenomenon (Pump Controller System)
Failure Content • Some abnormal current flew at the time of output to the 2-stage relief solenoid circuit.
Controller
• Stop outputting to the 2-stage relief solenoid circuit.
Reaction
Phenomenon on • The power is weak when the heavy lift is operated.
Machine • The power is weak when travel is operated.
Related • The operating state of the 2-stage relief solenoid can be monitored on the machine monitor.
Information Monitoring code : 23

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Defective 2-stage relief sole- B28 (Male) Resistance value
1
Possible Cause and Standard value

noid (Internal short-circuit) Between 1 and 2 20 – 60Ω

Between 1 and ground 1MΩ min.
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective diode
2 B29 (male) Resistance value
(Internal short-circuit)
Between 1 and 2 1MΩ min.
Short circuit with ground in wir- ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
3 ing harness Wiring harnesses between FC03 (female) R, B28 Resistance
(Contact with GND circuit) 1MΩ min.
(female) 1 and B29 (female) 1, and ground value
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
4 Defective pump controller FC03 Control lever Voltage
At neutral time 1V max.
Between R and ground
At travel operation 20 – 30V

Circuit Diagram related to 2-stage Relief Solenoid

PC1800-6 20-585
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DXA0KA)

Failure Code DXA0KA

Failure Code Error Code Failure Break in F. TVC sol. sys.

DXA0KA — Phenomenon (Pump controller system)
Failure Content • No current flows to the front TVC solenoid circuit.
Controller
• No action is taken. (No current flows and the solenoid does not work.)
Reaction
• Abnormality (red) is displayed on the CGC monitor to warn the operator of abnormality.
Phenomenon on
• The engine speed drops as the load increases, and the engine comes to stop some times or the over-
Machine
all speed may drop.
• The output state of the front TVC solenoid can be monitored on the machine monitor.
Related
Monitoring code : 13
Information
Monitoring screen : Real time monitor (1/6) & (3/6)

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective front TVC solenoid
1 P03 (Male) Resistance value
(Internal disconnection)
Between 1 and 2 10 – 22Ω
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective pump drive switch in B07 (male) Pump drive switch Resistance value
2 an emergency
(Internal disconnection) Between 1 and 3 1Ω max.
OFF
Possible Cause and Standard value

Between 2 and 4 1Ω max.

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between FC03 (female) 6 and B07 Resistance
1Ω max.
(female) 1 value
Disconnection of wiring harness Wiring harnesses between B07 (female) 3 and P03 Resistance
1Ω max.
3 (Disconnection, defective con- (female) 1 value
tact of connector) Wiring harnesses between FC03 (female) 3 and B07 Resistance
1Ω max.
(female) 2 value
Wiring harnesses between B07 (female) 4 and P03 Resistance
1Ω max.
(female) 2 value
★Turn off the starting switch and turn it on for troubleshooting
Wiring harnesses between FC03 (female) 6 and B07
Hot short-circuit of wiring har- Voltage 1V max.
4 (female) 1, and ground
ness (Contact with 24V circuit)
Wiring harnesses between B07 (female) 3 and P03
Voltage 1V max.
(female) 1, and ground
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
5 Defective pump controller FC03 (female) Resistance value
Between 6 and 3 10 – 22Ω

20-586 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DXA0KA)

Related electrical circuit of TVC solenoid

PC1800-6 20-587
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dXA0KA)

Failure Code dXA0KA

Failure Code Error Code Failure Break in R. TVC sol. sys.

dXA0KA — Phenomenon (Pump controller system)
Failure Content • No current flows to the rear TVC solenoid circuit.
Controller
• No action is taken. (No current flows and the solenoid does not work.)
Reaction
• Abnormality (red) is displayed on the CGC monitor to warn the operator of abnormality.
Phenomenon on
• The engine speed drops as the load increases, and the engine comes to stop some times or the over-
Machine
all speed may drop.
• The output state of the rear TVC solenoid can be monitored on the machine monitor.
Related
Monitoring code : 14
Information
Monitoring screen : Real time monitor (2/6) & (4/6)

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective rear TVC solenoid
1 P04 (Male) Resistance value
(Internal disconnection)
Between 1 and 2 10 – 22Ω
★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective pump drive switch in B07 (male) Pump drive switch Resistance value
2 an emergency
(Internal disconnection) Between 7 and 9 1Ω max.
OFF
Possible Cause and Standard value

Between 6 and 8 1Ω max.

★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between FC03 (female) F and B07 Resistance
1Ω max.
(female) 7 value
Disconnection of wiring harness Wiring harnesses between B07 (female) 9 and P04 Resistance
1Ω max.
3 (Disconnection, defective con- (female) 1 value
tact of connector) Wiring harnesses between FC03 (female) C and B07 Resistance
1Ω max.
(female) 6 value
Wiring harnesses between B07 (female) 8 and P04 Resistance
1Ω max.
(female) 2 value
★Turn off the starting switch and turn it on for troubleshooting
Wiring harnesses between FC03 (female) F and B07
Hot short-circuit of wiring har- Voltage 1V max.
4 (female) 7, and ground
ness (Contact with 24V circuit)
Wiring harnesses between B07 (female) 9 and P04
Voltage 1V max.
(female) 1, and ground
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
5 Defective pump controller FC03 (female) Resistance value
Between F and C 10 – 22Ω

20-588 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dXA0KA)

Related electrical circuit of TVC solenoid

PC1800-6 20-589
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DXA0KB)

Failure Code DXA0KB

Failure Code Error Code Failure Short in F. TVC sol. sys.

DXA0KB — Phenomenon (Pump controller system)
Failure Content • Some abnormal current flew to the front TVC solenoid circuit.
Controller
• Stop outputting to the front TVC solenoid circuit.
Reaction
Phenomenon on • Abnormality (red) is displayed on the CGC monitor to warn the operator of abnormality.
Machine • The engine speed drops as the load increases, and the engine comes to stop some times.
• The output state of the front TVC solenoid can be monitored on the machine monitor and the CGC
Related monitor.
Information Monitoring code : 13
Monitoring screen : Real time monitor (1/6) & (3/6)

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective front TVC solenoid P03 (Male) Resistance value
1 (Internal short-circuit, ground
failure) Between 1 and 2 10 – 22Ω
Possible Cause and Standard value

Between 1 and ground 1MΩ min.

Defective pump drive switch in ★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
2 an emergency B07 (male) Pump drive switch Resistance value
(Internal short-circuit) Between 1 and 0 OFF 1MΩ min.
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Short circuit with ground in Wiring harnesses between FC03 (female) 6 and B07 Resistance
1MΩ min.
3 wiring harness (female) 1, and ground value
(Contact with GND circuit) Wiring harnesses between B07 (female) 3 and P03 Resistance
1MΩ min.
(female) 1, and ground value
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
FC03 (female) Resistance value
4 Defective pump controller
Between 6 and 3 10 – 22Ω
Between 6 and ground 1MΩ min.

20-590 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (DXA0KB)

Related electrical circuit of TVC solenoid

PC1800-6 20-591
TROUBLESHOOTING AT DISPLAY OF FAILURE Failure Code (dXA0KB)
CODE OR ERROR CODE [CODE DISPLAY MODE]

Failure Code dXA0KB

Failure Code Error Code Failure Short in R. TVC sol. sys.

dXA0KB — Phenomenon (Pump controller system)
Failure Content • Some abnormal current flew to the rear TVC solenoid circuit.
Controller
• Stop outputting to the rear TVC solenoid circuit.
Reaction
Phenomenon on • Abnormality (red) is displayed on the CGC monitor to warn the operator of abnormality.
Machine • The engine speed drops as the load increases, and the engine comes to stop some times.
• The output state of the rear TVC solenoid can be monitored on the machine monitor and the CGC
Related monitor.
Information Monitoring code : 14
Monitoring screen : Real time monitor (2/6) & (4/6)

Cause Standard value, Remarks for Troubleshooting

★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
Defective rear TVC solenoid P04 (Male) Resistance value
1 (Internal short-circuit, ground
failure) Between 1 and 2 10 – 22Ω
Possible Cause and Standard value

Between 1 and ground 1MΩ min.

Defective pump drive switch in ★Turn off the starting switch for preparation, and troubleshoot while keeping it off.
2 an emergency B07 (male) Pump drive switch Resistance value
(Internal short-circuit) Between 7 and 0 OFF 1MΩ min.
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Short circuit with ground in Wiring harnesses between FC03 (female) F and B07 Resistance
1MΩ min.
3 wiring harness (female) 7, and ground value
(Contact with GND circuit) Wiring harnesses between B07 (female) 9 and P04 Resistance
1MΩ min.
(female) 1, and ground value
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
FC03 (female) Resistance value
4 Defective pump controller
Between F and C 10 – 22Ω
Between F and ground 1MΩ min.

20-592 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (dXA0KB)

Related electrical circuit of TVC solenoid

PC1800-6 20-593
TROUBLESHOOTING AT DISPLAY OF FAILURE Failure Code (F@BBZL)
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (f@BBZL)

Failure Code F@BBZL

Failure Code Error Code Failure High blowby Press. F. engine

F@BBZL — Phenomenon (VHMS Controller System)
Failure Content • The signal circuit of the front engine blow-by pressure sensor detected more than 8.83kPa {900H2O}.
Controller
• No action is taken.
Reaction
Phenomenon on
• The front engine will probably be damaged if used continuously as it is.
Machine
Related • The front engine blow-by pressure can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Front engine blow-by pressure
1 rises abnormally Check the front engine, and repair it if it is out of order.
(when the system is normal).
Possible Cause
Check if the failure code (DHE5KB) is displayed.
and Standard
Defective front engine blow-by Troubleshoot it if displayed.
value 2
pressure sensor system Check if the failure code (DHE5KY) is displayed.
Troubleshoot it if displayed.
When Cases 1 and 2 are normal, the VHMS controller is consid-
3 Defective VHMS controller
ered to be defective.

Failure Code f@BBZL

Failure Code Error Code Failure High blowby Press. R. engine

f@BBZL — Phenomenon (VHMS Controller System)
Failure Content • The signal circuit of the rear engine blow-by pressure sensor detected more than 8.83kPa {900H2O}.
Controller
• No action is taken.
Reaction
Phenomenon on
• The rear engine will probably be damaged if used continuously as it is.
Machine
Related • The rear engine blow-by pressure can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Rear engine blow-by pressure
1 rises abnormally Check the rear engine, and repair it if it is out of order.
(when the system is normal).
Possible Cause
Check if the failure code (dHE5KB) is displayed.
and Standard
Defective rear engine blow-by Troubleshoot it if displayed.
value 2
pressure sensor system Check if the failure code (dHE5KY) is displayed.
Troubleshoot it if displayed.
When Cases 1 and 2 are normal, the VHMS controller is consid-
3 Defective VHMS controller
ered to be defective.

20-594 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE Failure Code (F@BVL6)
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (f@BVL6)

Failure Code F@BVL6

Failure Code Error Code Failure F. engine stop

F@BVL6 — Phenomenon (Front Engine Controller System)
Failure Content • While the starting switch is ON, the engine stopped more than 2 minutes later the front engine started.
Controller
• No action is taken.
Reaction
Phenomenon on
• The front engine will probably be damaged if used continuously as it is.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

The front engine stops
Check the front engine (including fuel level), and repair it if it is
1 abnormally
Possible Cause out of order.
(when the system is normal).
and Standard
value Defective front engine controller
2 Troubleshoot Failure Code (DB22KK).
power system
When Causes 1 and 2 are normal, keep operating the machine
3 Defective front engine controller
as it is to check the situations.

Failure Code f@BVL6

Failure Code Error Code Failure R. engine stop

f@BVL6 — Phenomenon (Rear Engine Controller System)
Failure Content • While the starting switch is ON, the engine stopped more than 2 minutes later the rear engine started.
Controller
• No action is taken.
Reaction
Phenomenon on
• The rear engine will probably be damaged if used continuously as it is.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

The rear engine stops
Check the rear engine (including fuel level), and repair it if it is
1 abnormally
Possible Cause out of order.
(when the system is normal).
and Standard
value Defective rear engine controller
2 Troubleshoot Failure Code (dB22KK).
power system
When Causes 1 and 2 are normal, keep operating the machine
3 Defective rear engine controller
as it is to check the situations.

PC1800-6 20-595
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (F@BYNR)

Failure Code F@BYNR

Failure Code Error Code Failure High F-F cyl. exhaust temp. 2
F@BYNR — Phenomenon (VHMS Controller System)
• The signal circuit of the exhaust gas temperature sensor in front of the front engine detected exhaust
gas temperatures over the limit line 2 for more than 10 seconds.
Failure Content
(Exhaust gas temperature limit line 2 : A straight line between 750°C at the rated output speed or more
and 800°C at the maximum torque speed or more)
Controller
• No action is taken.
Reaction
Phenomenon on
• The front engine will probably be damaged if used continuously as it is.
Machine
Related • Front engine exhaust gas temperatures can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

The font engine exhaust gas

1 temperature rises abnormally Check the front engine, and repair it if it is out of order.
(when the system is normal).
Check if the failure code (DGT4KA) is displayed.
Defective exhaust gas tempera- Troubleshoot it if displayed.
2 ture sensor system in front of
front engine Check if the failure code (DHT4KB) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
3 Defective VHMS controller
V2A Exhaust gas temperature Voltage
Between 7 and BC 700 – 800°C 3.89 – 4.31V

Circuit Diagram related to Front Engine Exhaust Gas Temperature Sensor (Front Side, Rear Side)

20-596 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (f@BYNR)

Failure Code f@BYNR

Failure Code Error Code Failure High R-F cyl. exhaust temp. 2
f@BYNR — Phenomenon (VHMS Controller System)
• The signal circuit of the exhaust gas temperature sensor in front of the rear engine detected exhaust
gas temperatures over the limit line 2 for more than 10 seconds.
Failure Content
(Exhaust gas temperature limit line 2 : A straight line between 750°C at the rated output speed or more
and 800°C at the maximum torque speed or more)
Controller
• No action is taken.
Reaction
Phenomenon on
• The rear engine will probably be damaged if used continuously as it is.
Machine
Related • Rear engine exhaust gas temperatures can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

The rear engine exhaust gas

1 temperature rises abnormally Check the rear engine, and repair it if it is out of order.
(when the system is normal).
Check if the failure code (dGT4KA) is displayed.
Defective exhaust gas tempera- Troubleshoot it if displayed.
2 ture sensor system in front of
rear engine Check if the failure code (dHT4KB) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
3 Defective VHMS controller
V2A Exhaust gas temperature Voltage
Between F and BC 700 – 800°C 3.89 – 4.31V

Circuit Diagram related to Rear Engine Exhaust Gas Temperature Sensor (Front Side, Rear Side)

PC1800-6 20-597
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (F@BYNS)

Failure Code F@BYNS

Failure Code Error Code Failure High F-F cyl. exhaust temp. 1
F@BYNS — Phenomenon (VHMS Controller System)
• The signal circuit of the exhaust gas temperature sensor in front of the front engine detected exhaust
gas temperatures over the limit line 1 for more than 10 seconds.
Failure Content
(Exhaust gas temperature limit line 1 : A straight line between 700°C at the rated output speed or more
and 750°C at the maximum torque speed or more)
Controller
• No action is taken.
Reaction
Phenomenon on
• The front engine will probably be damaged if used continuously as it is.
Machine
Related • Front engine exhaust gas temperatures can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

The font engine exhaust gas

1 temperature rises abnormally Check the front engine, and repair it if it is out of order.
(when the system is normal).
Check if the failure code (DGT4KA) is displayed.
Defective exhaust gas tempera- Troubleshoot it if displayed.
2 ture sensor system in front of
front engine Check if the failure code (DHT4KB) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
3 Defective VHMS controller
V2A Exhaust gas temperature Voltage
Between 7 and BC 700 – 800°C 3.89 – 4.31V

Circuit Diagram related to Front Engine Exhaust Gas Temperature Sensor (Front Side, Rear Side)

20-598 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (f@BYNS)

Failure Code f@BYNS

Failure Code Error Code Failure High R-F cyl. exhaust temp. 1
f@BYNS — Phenomenon (VHMS Controller System)
• The signal circuit of the exhaust gas temperature sensor in front of the rear engine detected exhaust
gas temperatures over the limit line 1 for more than 10 seconds.
Failure Content
(Exhaust gas temperature limit line 1 : A straight line between 700°C at the rated output speed or more
and 750°C at the maximum torque speed or more)
Controller
• No action is taken.
Reaction
Phenomenon on
• The rear engine will probably be damaged if used continuously as it is.
Machine
Related • Rear engine exhaust gas temperatures can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

The rear engine exhaust gas

1 temperature rises abnormally Check the rear engine, and repair it if it is out of order.
(when the system is normal).
Check if the failure code (dGT4KA) is displayed.
Defective exhaust gas tempera- Troubleshoot it if displayed.
2 ture sensor system in front of
rear engine Check if the failure code (dHT4KB) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
3 Defective VHMS controller
V2A Exhaust gas temperature Voltage
Between F and BC 700 – 800°C 3.89 – 4.31V

Circuit Diagram related to Rear Engine Exhaust Gas Temperature Sensor (Front Side, Rear Side)

PC1800-6 20-599
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (F@BZNR)

Failure Code F@BZNR

Failure Code Error Code Failure High F-R cyl. exhaust temp. 2
F@BZNR — Phenomenon (VHMS Controller System)
• The signal circuit of the exhaust gas temperature sensor in rear of the front engine detected exhaust
gas temperatures over the limit line 2 for more than 10 seconds.
Failure Content
(Exhaust gas temperature limit line 2 : A straight line between 750°C at the rated output speed or more
and 800°C at the maximum torque speed or more)
Controller
• No action is taken.
Reaction
Phenomenon on
• The front engine will probably be damaged if used continuously as it is.
Machine
Related • Front engine exhaust gas temperatures can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

The font engine exhaust gas

1 temperature rises abnormally Check the front engine, and repair it if it is out of order.
(when the system is normal).
Check if the failure code (DGT5KA) is displayed.
Defective exhaust gas tempera- Troubleshoot it if displayed.
2 ture sensor system in rear of
front engine Check if the failure code (DHT5KB) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
3 Defective VHMS controller
V2A Exhaust gas temperature Voltage
Between 6 and BC 700 – 800°C 3.89 – 4.31V

Circuit Diagram related to Front Engine Exhaust Gas Temperature Sensor (Front Side, Rear Side)

20-600 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (f@BZNR)

Failure Code f@BZNR

Failure Code Error Code Failure High R-R cyl. exhaust temp. 2
f@BZNR — Phenomenon (VHMS Controller System)
• The signal circuit of the exhaust gas temperature sensor in rear of the rear engine detected exhaust
gas temperatures over the limit line 2 for more than 10 seconds.
Failure Content
(Exhaust gas temperature limit line 2 : A straight line between 750°C at the rated output speed or more
and 800°C at the maximum torque speed or more)
Controller
• No action is taken.
Reaction
Phenomenon on
• The rear engine will probably be damaged if used continuously as it is.
Machine
Related • Rear engine exhaust gas temperatures can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

The rear engine exhaust gas

1 temperature rises abnormally Check the rear engine, and repair it if it is out of order.
(when the system is normal).
Check if the failure code (dGT5KA) is displayed.
Defective exhaust gas tempera- Troubleshoot it if displayed.
2 ture sensor system in rear of
rear engine Check if the failure code (dHT5KB) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
3 Defective VHMS controller
V2A Exhaust gas temperature Voltage
Between 5 and BC 700 – 800°C 3.89 – 4.31V

Circuit Diagram related to Rear Engine Exhaust Gas Temperature Sensor (Front Side, Rear Side)

PC1800-6 20-601
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (F@BZNS)

Failure Code F@BZNS

Failure Code Error Code Failure High F-R cyl. exhaust temp. 1
F@BZNS — Phenomenon (VHMS Controller System)
• The signal circuit of the exhaust gas temperature sensor in rear of the front engine detected exhaust
gas temperatures over the limit line 1 for more than 10 seconds.
Failure Content
(Exhaust gas temperature limit line 1 : A straight line between 700°C at the rated output speed or more
and 750°C at the maximum torque speed or more)
Controller
• No action is taken.
Reaction
Phenomenon on
• The front engine will probably be damaged if used continuously as it is.
Machine
Related • Front engine rear exhaust gas temperatures can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (2/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

The font engine exhaust gas

1 temperature rises abnormally Check the front engine, and repair it if it is out of order.
(when the system is normal).
Check if the failure code (DGT5KA) is displayed.
Defective exhaust gas tempera- Troubleshoot it if displayed.
2 ture sensor system in rear of
front engine Check if the failure code (DHT5KB) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
3 Defective VHMS controller
V2A Exhaust gas temperature Voltage
Between 6 and BC 700 – 800°C 3.89 – 4.31V

Circuit Diagram related to Front Engine Exhaust Gas Temperature Sensor (Front Side, Rear Side)

20-602 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (f@BZNS)

Failure Code f@BZNS

Failure Code Error Code Failure High R-R cyl. exhaust temp. 1
f@BZNS — Phenomenon (VHMS Controller System)
• The signal circuit of the exhaust gas temperature sensor in rear of the rear engine detected exhaust
gas temperatures over the limit line 1 for more than 10 seconds.
Failure Content
(Exhaust gas temperature limit line 1 : A straight line between 700°C at the rated output speed or more
and 750°C at the maximum torque speed or more)
Controller
• No action is taken.
Reaction
Phenomenon on
• The rear engine will probably be damaged if used continuously as it is.
Machine
Related • Rear engine rear exhaust gas temperatures can be monitored on the CGC monitor.
Information Monitoring screen : PM clinic (3/6)

Cause Standard value, Remarks for Troubleshooting

Possible Cause and Standard value

The rear engine exhaust gas

1 temperature rises abnormally Check the rear engine, and repair it if it is out of order.
(when the system is normal).
Check if the failure code (dGT5KA) is displayed.
Defective exhaust gas tempera- Troubleshoot it if displayed.
2 ture sensor system in rear of
rear engine Check if the failure code (dHT5KB) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
3 Defective VHMS controller
V2A Exhaust gas temperature Voltage
Between 5 and BC 700 – 800°C 3.89 – 4.31V

Circuit Diagram related to Rear Engine Exhaust Gas Temperature Sensor (Front Side, Rear Side)

PC1800-6 20-603
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (F@HCKA)

Failure Code F@HCKA

Failure Code Error Code Failure Break swing press. sensor failure
F@HCKA — Phenomenon (VHMS Controller System)
Failure Content • The signal voltage of the swing pump pressure sensor dropped below 0.3V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Swing pump pressures cannot be monitored on the CGC monitor.
Machine
Related • Swing pump pressures can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (3/6) & (4/6), PM clinic (4/6) & (5/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power Check if the failure code (DBB0KB) is displayed.
1
system Troubleshoot it if displayed.
★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Possible Cause and Standard value

Defective swing pump pres- V05 Voltage

2
Between B and A
sure sensor (Internal defect)
4.5 – 5.5V
Between C and A 0.3 – 4.7V
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between V1 (female) 4 and V05
(female) B
Disconnection of wiring harness Resistance
1Ω max.
3 (Disconnection, defective con- value
tact of connector) Wiring harnesses between V1 (female) 0 and V05
(female) C
Resistance
1Ω max.
value
Short circuit with ground in wir- ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
4 ing harness Wiring harnesses between V1 (female) 0 and V05
(female) C, and ground
Resistance
(Contact with GND circuit) 1MΩ min.
value
★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
5 Defective VHMS controller
V1, V2A Voltage
Between V1 0 and V2A BC 0.3 – 4.7V

Circuit Diagram related to Swing Pump Pressure Sensor

20-604 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (F@HCKB)

Failure Code F@HCKB

Failure Code Error Code Failure Short swing press. sensor failure
F@HCKB — Phenomenon (VHMS Controller System)
Failure Content • The signal voltage of the swing pump pressure sensor up-to over 4.7V.
Controller
• No action is taken.
Reaction
Phenomenon on
• Swing pump pressures cannot be monitored on the CGC monitor.
Machine
Related • Swing pump pressures can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (3/6) & (4/6), PM clinic (4/6) & (5/6)

Cause Standard value, Remarks for Troubleshooting

Defective sensor 5V power Check if the failure code (DBB0KB) is displayed.
1
system Troubleshoot it if displayed.
Possible Cause and Standard value

★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
Defective swing pump pres- V05 Voltage
2
Between B and A
sure sensor (Internal defect)
4.5 – 5.5V
Between C and A 0.3 – 4.7V
Short circuit with ground in wir- ★Turn off the starting switch for preparation and turn it on for troubleshooting.
3 ing harness Wiring harnesses between V1 (female) 0 and V05
(female) C
(Contact with 24V circuit) Voltage 1 V max.

★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
4 Defective VHMS controller
V1, V2A Voltage
Between V1 0 and V2A BC 0.3 – 4.7V

Circuit Diagram related to Swing Pump Pressure Sensor

PC1800-6 20-605
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (F@HCZL)

Failure Code F@HCZL

Failure Code Error Code Failure High relief press. swing pump
F@HCZL — Phenomenon (VHMS Controller System)
Failure Content • The signal circuit of the swing pump pressure sensor detected 37.3MPa {380kg/cm2} or more.
Controller
• Abnormality (red) is displayed on the CGC monitor to warn the operator of abnormality.
Reaction
Phenomenon on
• The hydraulic equipment will probably be damaged if used continuously as it is.
Machine
Related • Swing pump pressures can be monitored on the CGC monitor.
Information Monitoring screen : Real time monitor (3/6) & (4/6), PM clinic (4/6) & (5/6)

Cause Standard value, Remarks for Troubleshooting

The swing pump oil pressure
Possible Cause and Standard value

1 rises abnormally (when the sys- Check the swing pump relief pressure, and repair it if it is out of order.
tem is normal).
Check if the failure code (F@HCKA) is displayed.
Troubleshoot it if displayed.
Defective swing pump Check if the failure code (F@HCKB) is displayed.
2
pressure sensor system Troubleshoot it if displayed.
Check if the failure code (DBB0KP) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.
3 Defective VHMS controller V1, V2A Swing oil pressure Voltage
Between V1 0 and 37.3MPa
3.42 – 3.54V
V2A BC {380kg/cm2}

Circuit Diagram related to Swing Pump Pressure Sensor

20-606 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (J100KA)

Failure Code J100KA

Failure Code Error Code Failure Break gear pump Press. sensor failure
J100KA — Phenomenon (VHMS Controller System)
Failure Content • The signal voltage of the swing pump pressure sensor dropped below 0.3V.
Controller
• No action is taken.
Reaction
Phenomenon on
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Defective sensor 24V power Check if Failure Code (DBB0KP) is displayed.
1
system Troubleshoot it if displayed.
★Turn off the starting switch and turn it on or start the engine for troubleshooting.
P15 Voltage
Possible Cause and Standard value

Defective gear pump pressure

Between B and A
2
sensor (Internal defect) 20 – 30V
Between C and A 0.3 – 4.7V
★Turn off the starting switch for preparation and troubleshoot while keeping it off.
Wiring harnesses between V1 (female) 2 and P15
(female) B
Disconnection of wiring harness Resistance
1Ω max.
3 (Disconnection, defective con- value
tact of connector) Wiring harnesses between V1 (female) 1 and P15
(female) C
Resistance
1Ω max.
value
Short circuit with ground in wir- ★Turn off the starting switch for preparation and troubleshoot while keeping it off.
4 ing harness Wiring harness between V1 (female) 1 and P15
(female) C, and ground
Resistance
(Contact with GND circuit) 1MΩ min.
value
★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
5 Defective VHMS controller
V1, V2A Voltage
Between V1 1 and V2A BC 0.3 – 4.7V

Circuit Diagram related to Gear Pump Pressure Sensor

PC1800-6 20-607
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (J100KB)

Failure Code J100KB

Failure Code Error Code Failure Short gear pump Press. sensor failure
J100KB — Phenomenon (VHMS Controller System)
Failure Content • The signal voltage of the swing pump pressure sensor up-to over 4.7V.
Controller
• No action is taken.
Reaction
Phenomenon on
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

Defective sensor 24V power Check if Failure Code (DBB0KP) is displayed.
1
Possible Cause and Standard value

system Troubleshoot it if displayed.

★Turn off the starting switch and turn it on or start the engine for troubleshooting.
Defective gear pump pressure P15 Voltage
Between B and A
2
sensor (Internal defect) 20 – 30V
Between C and A 0.3 – 4.7V
★Turn off the starting switch for preparation and turn it on for troubleshooting.
Hot short-circuit of wiring har-
3 Wiring harnesses between V1 (female) 1 and P15
(female) C
ness (Contact with 24V circuit) Voltage 1V max.

★Turn off the starting switch for preparation, and turn it on or start the engine for
troubleshooting.
4 Defective VHMS controller
V1, V2A Voltage
Between V1 1 and V2A BC 0.3 – 4.7V

Circuit Diagram related to Gear Pump Pressure Sensor

20-608 PC1800-6
TROUBLESHOOTING AT DISPLAY OF FAILURE
CODE OR ERROR CODE [CODE DISPLAY MODE] Failure Code (J100L6)

Failure Code J100L6

Failure Code Error Code Failure Abnomality gear pump press.

J100L6 — Phenomenon (VHMS Controller System)
• The signal circuit of the gear pump pressure sensor detected 2.55MPa {26kg/cm2} or less or 3.73MPa
Failure Content {38kg/cm2} or more (when the hydraulic oil temperature was over 50°C and both the front engine and
the rear engine were more than 1,750rpm).
Controller
• Abnormality (red) is displayed on the CGC monitor to warn the operator of abnormality.
Reaction
Phenomenon on
• The hydraulic equipment will probably be damaged if used continuously as it is.
Machine
Related
Information

Cause Standard value, Remarks for Troubleshooting

The gear pump pressure rises
1 abnormally Check the gear pump pressure and repair it if it is out of order.
Possible Cause and Standard value

(when the system is normal).

Check if the failure code (J100KA) is displayed.
Troubleshoot it if displayed.
Defective gear pump pressure Check if the failure code (J100KB) is displayed.
2
sensor system Troubleshoot it if displayed.
Check if the failure code (DBB0KP) is displayed.
Troubleshoot it if displayed.
★Turn off the starting switch for preparation and start the engine for
troubleshooting.

3 Defective VHMS controller V1, V2A Swing oil pressure Voltage

2
Between V1 1 and 2.55MPa {26kg/cm } 3.08V approx.
V2A BC 3.73MPa {38kg/cm } 2
4.04V approx.

Circuit Diagram related to Gear Pump Pressure Sensor

PC1800-6 20-609
 TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)

INFORMATION CONTAINED IN THE TROUBLESHOOTING LIST .......................................................... 20-702

E-1 Engine doesn't start up......................................................................................................................... 20-703
E-2 Preheating does not work..................................................................................................................... 20-708
E-3 Automatic-decelerator does not work ................................................................................................... 20- 711
E-4 Boom shock-less function does not operate normally .......................................................................... 20-712
E-5 Machine pushup function does not work normally ............................................................................... 20-715
E-6 Travel alarm is not sounded ................................................................................................................. 20-717
E-7 All the machine monitor lamps do not come on for 3 seconds after the starting switch is turned ON.. 20-718
E-8 When the starting switch is turned ON, machine monitor lamps all stayed lighted up and
do not go out.................................................................................................................................. 20-720
E-9 Machine monitor lamps which is lighted up when the starting switch is turned ON,
do not exactly represent the machine operating status ................................................................. 20-720
E-10 A basic check item flashes on the machine monitor while the starting switch is turned ON .............. 20-721
E-11 While the engine is in operation, a caution item flashes on the machine monitor .............................. 20-722
E-12 While the engine is in operation, an emergency stop item flashes on the machine monitor .............. 20-724
E-13 Warm-up monitor unintended comes on or flashes on the machine monitor
though the warm-up operation is not turned ON............................................................................ 20-726
E-14 Swing lock monitor does not come on................................................................................................ 20-728
E-15 Engine water temperature gauge is not correct. ................................................................................ 20-730
E-16 Display of the machine monitor's hydraulic oil temperature gauge is not correct............................... 20-732
E-17 Display of fuel gauge is not correct .................................................................................................... 20-733
E-18 Alarm buzzer of the machine monitor does not work normally........................................................... 20-734
E-19 Clock and service meter are not correctly displayed .......................................................................... 20-736
E-20 Bit display for boom RAISE is not correctly displayed........................................................................ 20-737
E-21 Bit display for boom LOWER is not correctly displayed ..................................................................... 20-738
E-22 Bit display for arm IN is not correctly displayed.................................................................................. 20-739
E-23 Bit display for arm OUT is not correctly displayed.............................................................................. 20-740
E-24 Bit display for bucket CURL is not correctly displayed ....................................................................... 20-741
E-25 Bit display for bucket DUMP is not correctly displayed ...................................................................... 20-742
E-26 Bit display for swing is not correctly displayed ................................................................................... 20-744
E-27 Bit display for LH travel is not correctly displayed .............................................................................. 20-746
E-28 Bit display for RH travel is not correctly displayed ............................................................................. 20-748
E-29 Bit display for the service is not correctly displayed ........................................................................... 20-750
E-30 Bit display for the bottom OPEN, CLOSE is not correctly displayed .................................................. 20-752
E-31 Air conditioner does not work ............................................................................................................. 20-754

PC1800-6 20-701
TROUBLESHOOTING INFORMATION CONTAINED IN THE TROUBLESHOOTING LIST

INFORMATION CONTAINED IN THE TROUBLESHOOTING LIST

★ The Troubleshooting List and related circuit diagrams contain the following information.
You are advised to understand the information well before starting your troubleshooting work.

Nature of
Trouble recognized on the machine
trouble
Relevant
Information relevant to the subject trouble or troubleshooting
information

Cause Standard value, Remarks for Troubleshooting

<Information described>
• The reference value to be used for determining validity of the estimated potential
cause(s).
1 • Remarks to be referenced when determining validity of the potential cause(s).

<Trouble on harness>
• Disconnection
Possible cause and Standard value

Improper connector connection or disconnection in wiring harness is present.

• Ground failure
A wiring harness not to be connected to the GND (ground) is somehow contacted with
2 the ground.
Potential cause of
• Hot short
trouble
The ground not to be connected to the power supply (24V) circuit is somehow contact-
(the numbers used here
ed with the power supply (24V) circuit.
are only for itemizing the
possible causes and do
<Points to be considered in troubleshooting>
not represent the
1) Display on the connector number and handling of T-adapter
degrees of importance)
3 Except where otherwise specified, connect T-adapter as shown below in the trouble-
shooting.
• When the male or female is not indicated on the connector number, separate the
connectors and then insert T-adapter to both the male and female sides.
• When the male or female is indicated on the connector number, connect T-branch
to the female side alone.
2) Pin number display order and handling of tester lead
4 Except where otherwise specified, connect the tester lead as described below in the
troubleshooting.
• Connect (+) lead to the pin number or harness indicated in the front side position.
• Connect (–) lead to the pin number or harness indicated in the rear side position.

Relevant circuit diagram

The portion of the circuit related to the subject trouble is extracted in this space.

• Connector No.: Indicates (Model – Number of pins) (Color)

• Arrow (↔): Indicates the approximate installing position on the machine

20-702 PC1800-6
TROUBLESHOOTING E-1

E-1 Engine doesn't start up

Nature of
• Both the front and rear engines don't start up
trouble (1)
Relevant • When the "Machine monitor doesn't come on" or "MDC (multiple display and control) does not display"
information as the starting switch is turned ON, failure in the main power system is suspected. Check this system.

Cause Standard value, Remarks for Troubleshooting

Failure on the fuse/ When the fuse is burnt out or the circuit breaker is shut down, troubles such as ground fail-
1
circuit breaker ure must be present on the circuit (see the cause 10).
★Prepare by turning the starting switch off and then start troubleshooting with the switch
been turned off.
2 Low battery
Battery voltage Specific gravity of battery
24 V min. 1.26 min.
★Prepare by turning the starting switch off and then start troubleshooting with the switch
Failure on starting been turned off or engine started.
switch C04 Starting switch Resistance value
3
(internal disconnec-
tion) When turned off 1 MΩ min.
Across pin B and pin C
When turned START 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
Possible cause and Standard value

Failure on engine- gine.

4
stop relay If you can start up the engine by swapping the right side relay with another C62
one, a failure exists on the engine stop relay. C63
Failure on the start- ★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
ing switch R1 signal gine.
5 canceling relay
(internal disconnec- If you can start up the engine by swapping the right side relay with another
C60
tion) one, a failure exists on the starting switch R1 signal canceling relay.

★Prepare by turning the starting switch off and then start troubleshooting with the switch
been turned off.
Failure on the
engine-stop switch P22 (male) Stop switch Resistance value
6
of the catwalk When turned off
(internal short circuit) 1 MΩ min.
Across 1 and 2 (in operation)
When turned ON (stopped) 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch
been turned off.
Failure on the
engine-stop switch in P22 (male) Stop switch Resistance value
7
the engine room When turned off
(internal short circuit) 1 MΩ min.
Across 1 and 2 (in operation)
When turned ON (stopped) 1 Ω max.
Failure on the ★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
engine-selection gine.
8 relay
(internal disconnec- If you can start up the engine by swapping the right side relay with another
C59
tion) one, a failure exists on the engine-selection relay.

PC1800-6 20-703
TROUBLESHOOTING E-1

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch
been turned off.
Resistance 1Ω
Across wiring harnesses of C78 and C04 B pin
value max.
Disconnection in the Resistance 1Ω
wiring harness Across wiring harnesses of C04 C pin and C63 (female) 3
value max.
9 (disconnection/
improper harness Across wiring harnesses of C63 (female) 6 and C59 Resistance 1Ω
contact) (female) 5 value max.
Across wiring harnesses of C04 a BR pin and C60 (female) Resistance 1Ω
5 value max.
Possible cause and Standard value

Across wiring harnesses of C60 (male) 1 and C62 (female) Resistance 1Ω

5 value max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch
been turned off.
Across the wiring harness and ground between C78 and C04
Resistance 1 MΩ
B pin as well as wring and harness and ground between rele-
value min.
vant circuits.
Across the wiring harness and ground between C04 C pin
Ground failure on Resistance 1 MΩ
and C61 (female) 1 as well as C04 C pin and C63 (female)
wiring harness value min.
10 3.
(contact with GND
circuit) Across wiring harness and ground between C63 (female) 6
Resistance 1 MΩ
and C59 (female) 5 as well as C63 (male) 5 and P01
value min.
(female) I.
Across the wiring harness and ground between C04 BR pin Resistance 1 MΩ
and C60 (female) 5. value min.
Across the wring harness and ground between C60 (female) Resistance 1 MΩ
1 and C62 (female) 5. value min.
★Prepare by turning the starting switch off and then start troubleshooting with the switch
Hot short on the wir- been turned ON.
11 ing harness (contact Across the wiring harness and ground between C62 (female)
with 24V circuit) 1V
8, C63 (female) 1 and C67 (female) as well as that and P22 Voltage
max.
(female) 2, P22 (female) 2 and P24 (female).

20-704 PC1800-6
TROUBLESHOOTING E-1

Nature of
• Font engine alone does not start up
trouble (2)
Relevant
information

Cause Standard value, Remarks for Troubleshooting

Failure on the fuse/ When the fuse is burnt out or the circuit breaker is shut down, troubles such as ground fail-
1
circuit breaker ure must be present on the circuit (see the causes).
★Prepare by turning the starting switch off and then start troubleshooting with the switch
Failure on the been turned off.
engine-selector C05 (male) Selector switch Resistance value
2
switch
(internal short circuit) Front engine 1 MΩ min.
Across 1 and 2
Rear engine 1 Ω max.
Failure on the ★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
engine-selection gine.
3
relay (internal dis- If you can start up the front engine by swapping the right side relay with
connection) C59
another one, a failure exists on the engine-selection relay.
★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
gine.
Possible cause and Standard value

Starter Voltage
Failure on the front Power supply: Across B pin and ground 20 – 30 V
4 engine starter
(internal failure) Charge: Across R pin and ground 1 V max.
Start: Across S pin and ground 20 – 30 V
If the power supply, charging and starting voltage is normal and still the starter can't be
turned ON, a failure exists on the starter.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Failure on the front switch on.
5 engine alternator
Alternator Voltage
(internal short circuit)
Across R pin and ground 1 V max.
Disconnection in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch
wiring harness (dis- been turned off.
6
connection/improper Across the wiring harnesses between C59 (female) 1 and Resistance 1Ω
contact) starter S pin value max.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Ground failure on switch on.
the wiring harness
7 Across the wiring harness and ground between C59 (female)
(contact with GND Resistance 1 MΩ
circuit) 1 and starter S pin as well as C59 (female) 1 and FC01
value min.
(female) G and FE01 (female) J.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short on the wir- switch on.
8 ing harness (contact Across the wiring harness and ground between starter R pin
with 24V circuit) 1V
and alternator R pin as well as starter R pin and B04 (female) Voltage
max.
2 and FC01 E.

PC1800-6 20-705
TROUBLESHOOTING E-1

Nature of
• Rear engine alone does not start up
trouble (3)
Relevant
information

Cause Standard value, Remarks for Troubleshooting

Failure on the fuse/ When the fuse is burnt out or the circuit breaker is shut down, troubles such as ground fail-
1
circuit breaker ure must be present on the circuit (see the causes).
★Prepare by turning the starting switch off and then start troubleshooting with the switch
Failure on the been turned off.
engine-selector C05 (male) Selector switch Resistance value
2
switch
(internal short circuit) Front engine 1 MΩ min.
Across 1 and 2
Rear engine 1 Ω max.
Failure on the ★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
engine-selection gine.
3
relay (internal dis- If you can start up the rear engine by swapping the right side relay with
connection) C59
another one, a failure exists on the engine-selection relay.
★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
gine.
Possible cause and Standard value

Starter Voltage
Failure on the rear Power supply: Across B pin and ground 20 – 30 V
4 engine starter
(internal failure) Charge: Across R pin and ground 1 V max.
Start: Across S pin and ground 20 – 30 V
If the power supply, charging and starting voltage is normal and still the starter can't be
turned ON, a failure exists on the starter.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Failure on the rear switch on.
5 engine alternator
Alternator Voltage
(internal short circuit)
Across R pin and ground 1 V max.
Disconnection in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch
wiring harness (dis- been turned off.
6
connection/improper Across the wiring harnesses between C59 (female) 3 and Resistance 1Ω
contact) starter S pin value max.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Ground failure on switch on.
the wiring harness
7 Across the wiring harness and ground between C59 (female)
(contact with GND Resistance 1 MΩ
circuit) 3 and starter S pin as well as C59 (female) 3 and FC01
value min.
(female) A and RE01 (female) J.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short on the wir- switch on.
8 ing harness (contact Across the wiring harness and ground between starter R pin
with 24V circuit) 1V
and alternator R pin as well as starter R pin and B03 (female) Voltage
max.
2 and V2A 4.

20-706 PC1800-6
TROUBLESHOOTING E-1

Related electrical circuit of engine preheat, start, charging

PC1800-6 20-707
TROUBLESHOOTING E-2

E-2 Preheating does not work

Nature of
• Preheating does not work for both the front and rear engines
trouble (1)
Relative • Make sure cranking of the starter works (When the starter is not operable, apply the troubleshooting pro-
information cedures described in the "Engine does not start up")

Cause Standard value, Remarks for Troubleshooting

Failure on the fuse/ When the fuse is burnt out or the circuit breaker is shut down, troubles such as ground fail-
1
circuit breaker ure must be present on the circuit (see the causes).
★Prepare by turning the starting switch off and then start troubleshooting with the switch
been turned off.
Failure on the pre-
2 heating switch (inter- C82 (male) Preheating switch Resistance value
nal disconnection) When turned off 1 MΩ min.
Across 1 and 2
When turned ON 1 Ω max.
Failure on the warm- ★Prepare by turning the starting switch off and then start troubleshooting by turning the
up signal cut relay switch on.
3
(internal disconnec- If you can warm up by swapping the right side relay with another one, a fail-
tion) C61
ure exists on the warm-up signal cut relay.
Failure on the ★Prepare by turning the starting switch off and then start troubleshooting by turning the
engine warm-up switch on.
4
relay (internal dis- If you can warm up by swapping the right side relay with another one, a fail-
connection) C98
ure exists on the engine warm-up relay.
Failure on the ★Prepare by turning the starting switch off and then start troubleshooting by turning the
engine-selection switch on.
5
Possible cause and Standard value

relay (internal dis- If the warm-up becomes available by swapping the right side relay with
connection) C59
another one, a failure exists on the engine-selection relay.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the diode ing turned off.
6
(internal short circuit) C52 (male) Conducted
Across 1 and 2 Not conducted
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Across the wiring harnesses between C70 and C82 (female) Resistance 1Ω
1 as well as C70 value max.
Disconnection in the Across the wiring harnesses between C82 (female) 2 and Resistance 1Ω
wiring harness (dis- C61 (female) 3 value max.
7
connection/improper Across the wiring harnesses between C61 (female) 6 and Resistance 1Ω
harness contact) C98 (female) 1 value max.
Across the wiring harnesses between C98 (female) 2 and Resistance 1Ω
ground value max.
Across the wiring harnesses between C98 (female) 5 and Resistance 1Ω
C59 (female) 6 value max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Across the wiring harness and ground between C70 and C82 Resistance 1 MΩ
(female) 1 as well as relevant circuits. value min.
Ground failure on
Across the wiring harness and ground between C82 (female) Resistance 1 MΩ
the wiring harness
8 2 and C61 (female) 3 value min.
(contact with GND
circuit) Across the wiring harness and ground between C61 (female)
Resistance 1 MΩ
6 and C98 (female) 1 as well as C52 (female) 1 and P01
value min.
(female) H.
Across the wiring harness and ground between C98 (female) Resistance 1 MΩ
5 and C59 (female) 6 value min.

20-708 PC1800-6
TROUBLESHOOTING E-2

Nature of
• Only one of the front or rear engine can be warmed up
trouble (2)
Relevant
information

Cause Standard value, Remarks for Troubleshooting

Failure on the fuse/ When the fuse is burnt out or the circuit breaker is shut down, troubles such as ground fail-
1
circuit breaker ure must be present on the circuit (see the causes).
Failure on the ★Prepare by turning the starting switch off and then start troubleshooting by turning the
engine selection switch on.
2
relay (internal dis- If you can warm up by swapping the right side relay with another one, a fail-
connection) C59
ure exists on the engine-selection relay.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
switch on.

Failure on the front Heater relay Preheating switch Voltage

engine heater relay Across HT terminal
20 – 30 V
3 or rear engine heater and ground
relay (internal dis- ON
Across power terminal
Possible cause and Standard value

connection) 20 – 30 V
and ground
If above voltages are normal and still operating sounds are not generated, a failure exists
on the heater relay.
Failure on the front ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
engine electrical ing turned off.
intake air heater or Electrical intake air heater Conducted
4 the rear engine elec-
trical intake air
heater (internal dis- Across terminals Not conducted
connection)
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Disconnection in the Across the wiring harnesses between C59 (female) 2 and Resistance 1Ω
wiring harness (dis- HT terminal (front engine circuit) value max.
5
connection/improper Across the wiring harnesses between C59 (female) 4 and Resistance 1Ω
connector contact) HT terminal (rear engine circuit) value max.
Across the wiring harnesses between the starter B pin and Resistance 1Ω
heater relay (front and rear engine circuits) value max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Ground failure on ing turned off.
the wiring harness Across the wiring harness - between C59 (female) 2 and HT Resistance 1 MΩ
6
(contact with GND terminal - and ground (front engine circuit) value min.
circuit) Across the wiring harness - between C59 (female) 4 and HT Resistance 1 MΩ
terminal - and ground (rear engine circuit) value min.

PC1800-6 20-709
TROUBLESHOOTING E-2

Related electrical circuit of engine preheat, start, charging

20-710 PC1800-6
TROUBLESHOOTING E-3

E-3 Automatic-decelerator does not work

Nature of
• The automatic-decelerator does not work
trouble
• Revolution of the automatic-decelerator is set to 1,400 rpm. Thus, it does not work if the fuel dial is set
above that.
Relevant
• When referencing displays on the monitor, make sure that the engine is run.
information
• When normal displays are not available from the monitor, check the monitor according to the procedures
described in the "The machine monitor does not normally display bits ***"(shown below).

Cause Standard value, Remarks for Troubleshooting

Machine monitor Boom lever Bit display
1 Boom RAISE signal At neutral Goes off
Monitoring code 20 – [4]
In RAISE operation Comes on
Machine monitor Boom lever Bit display
Boom LOWER sig-
2 At neutral Goes off
nal Monitoring code 20 – [3]
In LOWER operation Comes on
Machine monitor Arm lever Bit display
3 Arm IN signal At neutral Goes off
Monitoring code 20 – [5]
In digging operation Comes on
Machine monitor Arm lever Bit display
4 Arm OUT signal At neutral Goes off
Possible cause and Standard value

Monitoring code 20 – [6]

In dump operation Comes on
Machine monitor Bucket lever Bit display
5 Bucket CURL signal At neutral Goes off
Monitoring code 21 – [1]
In digging operation Comes on
Machine monitor Bucket lever Bit display
6 Bucket DUMP signal At neutral Goes off
Monitoring code 21 – [2]
In dump operation Comes on
Machine monitor Bottom dump switch Bit display
Bottom dump signal
7 When turned off Goes off
(Loading shovel) Monitoring code 21 – [4]
When turned ON Comes on
Machine monitor Swing lever Bit display
8 Swing signal At neutral Goes off
Monitoring code 20 – [1]
In left/right swing operation Comes on
Machine monitor Left travel lever Bit display
9 Left travel signal At neutral Goes off
Monitoring code 21 – [5]
In forward/reverse operation Comes on
Machine monitor Right travel lever Bit display
10 Right travel signal At neutral Goes off
Monitoring code 20 – [2]
In forward/reverse operation Comes on
Failure on pump When above potential causes 1 to 10 are found innocent, a failure exists on the pump con-
11
controller troller.

PC1800-6 20-711
TROUBLESHOOTING E-4

E-4 Boom shock-less function does not operate normally

Nature of
• The boom shock-less function is not operable
trouble (1)
Relevant
information

Cause Standard value, Remarks for Troubleshooting

Failure on the fuse/ • When the fuse is burnt out or the circuit breaker is shut down, troubles such as ground fail-
1
circuit breaker ure must be present on the circuit (see the cause 7).
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the boom ing turned off.
shock-less switch C22 (male) Switch Resistance value
2
(internal disconnec-
tion) When turned OFF 1 MΩ min.
Across 1 and 3
When turned ON 1 Ω max.
Failure on the boom ★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
shock-less relay gine.
3
(internal disconnec- If you can restore the normal operation by swapping the right side relay with
tion) C51
another one, a failure exists on the boom shock-less relay.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the diode ing turned off.
4
(internal short circuit) B14 (male) Resistance
Across 1 and 2 1MΩ min.
Possible cause and Standard value

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the boom ing turned off.
shock-less solenoid B13 (male), B15 (male) Resistance value
5
(internal disconnec-
tion/short circuit) Across 1 and 2 20 – 30 Ω
Across 1 and ground 1 MΩ min.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Across the wiring harnesses between fuse 6 outlet and C22 Resistance 1Ω
(female) 1 as well as C51 (female) 3 value max.
Disconnection in the Across the wiring harnesses between C51 (female) 5 and Resistance 1Ω
wiring harness (dis- B13 (female) 1 as well as B15 (female) 1 value max.
6
connection/improper Across the wiring harnesses between the ground and B13 Resistance 1Ω
connector contact) (female) 2 as well as B15 (female) 2 value max.
Across the wiring harnesses between C22 (female) 3 and Resistance 1Ω
C51 (female) 1 value max.
Across the wiring harnesses between C51 (female) 2 and Resistance 1Ω
ground value max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Across the wiring harness and ground between fuse 6 outlet
Ground failure on Resistance 1 MΩ
and C22 (female) 1 and C51 (female) 3 as well as other rel-
the wiring harness value min.
7 evant circuits.
(contact with GND
circuit) Across the wiring harness and ground between C51 (female) Resistance 1 MΩ
5 and B13 (female) 1, B15 (female) 1 and B14 (female) 1 value min.
Across the wiring harness and ground between C22 (female) Resistance 1 MΩ
3 and B15 (female) 1 value min.

20-712 PC1800-6
TROUBLESHOOTING E-4

Nature of
• Cancellation of the boom shock-less function is not available
trouble (2)
Relevant
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Failure on the boom
1 shock-less switch C22 (male) Switch Resistance value
(internal short circuit) When turned off 1 MΩ min.
Across 1 and 3
1 Ω max.
Possible cause and Standard value

When turned ON
★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
Failure on the boom gine.
2 shock-less relay
(internal short circuit) If you can restore the normal operation by swapping the right side relay with C51
another one, a failure exists on the boom shock-less relay.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the boom ing turned off.
shock-less solenoid B13 (male), B15 (male) Resistance value
3
(internal disconnec-
tion/short circuit) Across 1 and 2 20 – 30 Ω
Across 1 and ground 1 MΩ min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
switch on.
Hot short on the wir-
Across the wiring harness and ground between C51 (female) 1V
4 ing harness (contact Voltage
5 and B13 (female) 1, B15 (female) 1 and B14 (female) 1 max.
with 24V circuit)
Across the wiring harness and ground between C22 (female) 1V
Voltage
3 and C51 (female) 1 max.

PC1800-6 20-713
TROUBLESHOOTING E-4

Circuit diagram relevant to the boom shock-less solenoid

20-714 PC1800-6
TROUBLESHOOTING E-5

E-5 Machine pushup function does not work normally

Nature of
• Machine pushup function does not work normally
trouble (1)
Relevant
• When the machine pushup function is set to the high pressure, the solenoid is demagnetized.
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the ing turned off.
Possible cause and Standard value

machine pushup C19 (male) Switch Resistance value

1
switch (internal short
circuit) When turned off 1 MΩ min.
Across 1 and 2
When turned ON 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the
ing turned off.
machine pushup
2 solenoid (internal B22 (male) Resistance value
disconnection/short Across 1 and 2 20 – 30 Ω
circuit)
Across 1 and ground 1 MΩ min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short on the wir- switch on.
3 ing harness (contact
with 24 V circuit) Across the wiring harness and ground between C19 (female) 1V
Voltage
2 and B22 (female) 1 and B23 (female) 1 max.

Circuit diagram relevant to the machine pushup solenoid

PC1800-6 20-715
TROUBLESHOOTING E-5

Nature of
• Cancellation of the machine pushup function becomes unavailable.
trouble (2)
Relevant
• When the machine pushup function is set to the low pressure, the solenoid is energized.
information

Cause Standard value, Remarks for Troubleshooting

Failure on the fuse/ When the fuse is burnt out or the circuit breaker is shut down, troubles such as ground fail-
1
circuit breaker ure must be present on the circuit (see the cause 7).
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the ing turned off.
machine pushup C19 (male) Switch Resistance value
2
switch (internal dis-
connection) When turned off 1 MΩ min.
Across 1 and 2
When turned ON 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the diode ing turned off.
3
Possible cause and Standard value

(internal short circuit) B23 (male) Resistance

Across 1 and 2 1 MΩ min.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the
ing turned off.
machine pushup
4 solenoid (internal B22 (male) Resistance value
disconnection/short Across 1 and 2 20 – 30 Ω
circuit)
Across 1 and ground 1 MΩ min.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Disconnection in the Across the wiring harnesses between fuse 6 and C19 Resistance 1Ω
wiring harness (dis- (female) 1 value max.
5
connection/improper Across the wiring harnesses between C19 (female) 2 and Resistance 1Ω
connector contact) B22 (female) 1 value max.
Across the wiring harnesses between B22 (female) 2 and Resistance 1Ω
ground value max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Ground failure on ing turned off.
the wiring harness Across the wiring harness and ground between fuse 6 and Resistance 1 MΩ
6
(contact with GND C19 (female) 1 and other relevant circuits value min.
circuit) Across the wiring harness and ground between C19 (female) Resistance 1 MΩ
2 and B22 (female) 1 as well as B23 (female) 1 value min.

20-716 PC1800-6
TROUBLESHOOTING E-6

E-6 Travel alarm is not sounded

Nature of
• Travel alarm is not sounded
trouble
• If short circuit occurs on the travel alarm, the failure code [DV20KB] is memorized on the CGC monitor.
Relevant
• You can monitor operational state of the travel alarm from the machine monitor.
information
Monitoring code: 23

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch ON and then start troubleshooting by starting the en-
gine.
Machine monitor Left travel lever Bit display
Failure in the left At neutral Goes off
1 Monitoring code 21 – [5]
travel signal In forward/reverse operation Comes on
When normal display is not available on the monitor, check the trouble according to the pro-
cedures described in the "Machine monitor does not normally show the bit display of left
travel".
★Prepare by turning the starting switch ON and then start troubleshooting by starting the en-
gine.
Possible cause and Standard value

Machine monitor Right travel lever Bit display

Failure in the right At neutral Goes off
2 Monitoring code 20 – [2]
travel signal In forward/reverse operation Comes on
When normal display is not available on the monitor, check the trouble according to the pro-
cedures described in the "Machine monitor does not normally show the bit display of right
travel".
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the travel ing turned off.
3 alarm (internal dis-
T11 (male) Resistance value
connection)
Across 1 and 2 5 – 25 Ω
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the wiring harnesses between FC03 (female) 8 and Resistance 1Ω
4
connection/improper T11 (female) 2 value max.
connector contact) Resistance 1Ω
Across the harnesses between T11 (female) 1 and ground
value max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the pump ing turned off.
5
controller FC03 (female) Resistance value
Across 8 and ground 5 – 25 Ω

Travel alarm-related circuit diagram

PC1800-6 20-717
TROUBLESHOOTING E-7

E-7 All the machine monitor lamps do not come on for 3 seconds after the starting
switch is turned ON

Nature of
• Full display of the machine monitor does not come on.
trouble (1)
Relevant • When the all-point display of the CGC monitor is not turned ON as the starting switch is depressed,
information check the main power system for any failure.

Cause Standard value, Remarks for Troubleshooting

Failure on the circuit When the circuit breaker is shut down, troubles such as ground failure must be present on
1
breaker the circuit (see the cause 3).
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Disconnection in the Resistance 1Ω
Across the harnesses between P02 (female) 4 8 and C80
Possible cause and Standard value

wiring harness (dis- value max.

2
connection/improper Across the wiring harnesses between P01 (female) 9 and Resistance 1Ω
connector contact) C74 value max.
Across the harnesses between P02 (female) 1 9 and Resistance 1Ω
ground value max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Ground failure on ing turned off.
the wiring harness Across the harness and ground between P02 (female) 4 8 Resistance 1 MΩ
3
(contact with GND and C80 as well as other relevant circuits value min.
circuit) Across the harnesses between P01 (female) 9 and C74 as Resistance 1 MΩ
well as other relevant circuits value min.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off or on.
Failure on the P01, P02 Starting switch Voltage
4
machine monitor
Across P02 4 8 and 1 9 When turned off 20 – 30 V
Across P01 9 and ground When turned ON 20 – 30 V

Nature of
• Part of the machine monitor lamps do not come on
trouble (2)
Relevant
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure on the machine

1 It is an internal failure and troubleshooting is not available.
monitor

20-718 PC1800-6
TROUBLESHOOTING E-7

Related electrical circuit of machine monitor

PC1800-6 20-719
TROUBLESHOOTING E-8, E-9

E-8 When the starting switch is turned ON, machine monitor lamps all stayed lighted
up and do not go out

Nature of
• When the starting switch is turned ON, machine monitor lamps all stayed lighted up and do not go out
trouble
Relevant
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure on the machine

1 It is an internal failure and troubleshooting is not available.
monitor

E-9 Machine monitor lamps which is lighted up when the starting switch is turned
ON, do not exactly represent the machine operating status

Nature of • Machine monitor lamps turned ON by the starting switch do not exactly represent the machine operating
trouble status
Relevant • When the machine monitor is replaced, turn the starting switch off once and then turn it on again to check
information the display.

Cause Standard value, Remarks for Troubleshooting

Possible cause and

★Start troubleshooting by turning the starting switch on

Standard value

Machine monitor Screen display

Failure on the machine
1 Monitoring code 01 01 A80
monitor
If above monitoring display is normal, the model selection signal is normally recog-
nized. In this case, there must a failure on the machine monitor.
Failure in the model Check whether the failure code (DA2SKQ) is displayed. If yes, implement the trou-
2
selection signal bleshooting procedures applicable to that code.

20-720 PC1800-6
TROUBLESHOOTING E-10

E-10 A basic check item flashes on the machine monitor while the starting switch is
turned ON

Nature of
• Radiator water level monitor flashes
trouble (1)
Relevant
• If the radiator water level goes low, the CGC monitor also displays the trouble (yellow screen).
information

Cause Standard value, Remarks for Troubleshooting

Failure in the front
Possible cause and

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
Standard value

1 engine radiator water

dures applicable to the failure code [B@BCZK].
level switch system
Failure in the rear
Check the display on the CGC monitor, too, to implement the troubleshooting proce-
2 engine radiator water
dures applicable to the failure code [b@BCZK].
level switch system
Failure on the machine
3 If causes 1 and 2 are innocent, there must be a failure on the machine monitor.
monitor

Nature of
• Engine oil level monitor flashes
trouble (2)
Relevant
• If the engine oil level goes low, the CGC monitor also displays the trouble (yellow screen).
information

Cause Standard value, Remarks for Troubleshooting

Failure in the front
Possible cause and

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
Standard value

1 engine oil level switch

dures applicable to the failure code [B@BAZK].
system
Failure in the rear
Check the display on the CGC monitor, too, to implement the troubleshooting proce-
2 engine oil level switch
dures applicable to the failure code [b@BAZK].
system
Failure on the machine
3 If causes 1 and 2 are innocent, there must be a failure on the machine monitor.
monitor

Nature of
• Hydraulic oil level monitor flashes
trouble (3)
Relevant
• If the hydraulic oil level goes low, the CGC monitor also displays the trouble (yellow screen).
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the hydraulic Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1
oil level switch system dures applicable to the failure code [B@HAZK].

Failure on the machine

2 If cause 1 is innocent, there must be a failure on the machine monitor.
monitor

PC1800-6 20-721
TROUBLESHOOTING E-11

E-11 While the engine is in operation, a caution item flashes on the machine monitor

Nature of
• Front engine battery charge level monitor flashes
trouble (1)
Relevant • If the front engine battery charge level goes low, the CGC monitor also displays the trouble (yellow
information screen).

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the front

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1 engine battery charg-
dures applicable to the failure code [AB00KE].
ing system

Failure on the machine

2 If cause 1 is innocent, there must be a failure on the machine monitor.
monitor

Nature of
• Rear engine charge level monitor flashes
trouble (2)
• If the rear engine charge level goes low, the CGC monitor also displays the trouble (yellow screen).
Relevant
• As the rear engine is started, the rear engine charge level monitor comes on a little later than the front
information
engine charge level monitor. It is, however, not a trouble.

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the rear

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1 engine battery charg-
dures applicable to the failure code [aB00KE].
ing system

Failure on the machine

2 If cause 1 is innocent, there must be a failure on the machine monitor.
monitor

Nature of
• Fuel level monitor flashes
trouble (3)
Relevant
• If the level gauge display goes to the level 1 (leftmost position), the fuel volume monitor starts flashing.
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Check the display on the fuel gauge, too, to implement the troubleshooting proce-
Failure in the fuel level
1 dures described in the "Fuel gauge of the machine monitor does not indicate cor-
sensor system
rectly".

Failure on the machine

2 If cause 1 is innocent, there must be a failure on the machine monitor.
monitor

Nature of
• Front engine air cleaner clogging monitor flashes
trouble (4)
Relevant • If clogging occurs on the front engine air cleaner, the CGC monitor also displays the trouble (yellow
information screen).

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the front

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1 engine air cleaner
dures applicable to the failure code [AA10NX].
pressure switch system

Failure on the machine If the above potential cause is innocent, there must be a failure on the machine mon-
2
monitor itor.

20-722 PC1800-6
TROUBLESHOOTING E-11

Nature of
• Rear engine air cleaner clogging monitor flashes
trouble (5)
Relevant • If clogging occurs on the rear engine air cleaner, the CGC monitor also displays the trouble (yellow
information screen).

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the rear

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1 engine air cleaner
dures applicable to the failure code [aA10NX].
pressure switch system

Failure on the machine

2 If the above cause is innocent, there must be a failure on the machine monitor.
monitor

Nature of
• Hydraulic oil filter clogging monitor flashes
trouble (6)
Relevant
• If clogging occurs on the hydraulic oil filter, the CGC monitor also displays the trouble (red screen).
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the hydraulic

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1 oil clogging detection
dures applicable to the failure code [6014NX].
system

Failure on the machine

2 If the above cause is innocent, there must be a failure on the machine monitor.
monitor

PC1800-6 20-723
TROUBLESHOOTING E-12

E-12 While the engine is in operation, an emergency stop item flashes on the machine
monitor

Nature of • The engine water temperature/hydraulic oil temperature monitor, and the front engine water tempera-
trouble (1) ture display lamp flash.
• If display of the front engine water temperature gauge goes to level 8 (second from the rightmost posi-
Relevant tion) or 9 (rightmost position), the engine water temperature/hydraulic oil temperature monitor, and the
information front engine water temperature display lamp start flashing.
• If the front engine water is overheated, the CGC monitor also displays the trouble (red screen).

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the front

engine high water tem- Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1
perature sensor sys- dures applicable to the failure code [B@BCNS].
tem
Failure on the machine
2 If the above cause is innocent, there must be a failure on the machine monitor.
monitor

Nature of • The engine water temperature/hydraulic oil temperature monitor, and the rear engine water temperature
trouble (2) display lamp flash.
• If display of the rear engine water temperature gauge goes to level 8 (second from the rightmost posi-
Relevant tion) or 9 (rightmost position), the engine water temperature/hydraulic oil temperature monitor, and the
information rear engine water temperature display lamp start flashing.
• If the rear engine water is overheated, the CGC monitor also displays the trouble (red screen).

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the rear

engine high water tem- Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1
perature sensor sys- dures applicable to the failure code [b@BCNS].
tem
Failure on the machine
2 If the above cause is innocent, there must be a failure on the machine monitor.
monitor

Nature of • The engine water temperature/hydraulic oil temperature monitor, and the hydraulic oil display lamp
trouble (3) flash.
• If display of the hydraulic oil temperature gauge goes to level 8 (second from the rightmost position) or
Relevant 9 (rightmost position), the engine water temperature/hydraulic oil temperature monitor and the hydraulic
information oil temperature display lamp start flashing.
• If the hydraulic oil is overheated, the CGC monitor also displays the trouble (red screen).

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the hydraulic

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1 oil temperature sensor
dures applicable to the failure code [B@HANS].
system

Failure on the machine

2 If the above cause is innocent, there must be a failure on the machine monitor.
monitor

20-724 PC1800-6
TROUBLESHOOTING E-12

Nature of
• Radiator water level monitor flashes
trouble (4)
Relevant
• If the radiator water level goes low, the CGC monitor also displays the trouble (yellow screen).
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and

Failure in the front

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
Standard value

1 engine radiator water

dures applicable to the failure code [B@BCZK].
level switch system
Failure in the rear
Check the display on the CGC monitor, too, to implement the troubleshooting proce-
2 engine radiator water
dures applicable to the failure code [b@BCZK].
level switch system
Failure on the machine If the above causes 1 and 2 are innocent, there must be a failure on the machine
3
monitor monitor.

Nature of
• Front engine oil pressure monitor flashes.
trouble (5)
Relevant
• If the front engine oil pressure goes low, the CGC monitor also displays the trouble (red screen).
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the front

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1 engine oil pressure
dures applicable to the failure code [B@BAZG].
switch system

Failure on the machine

2 If the above causes is innocent, there must be a failure on the machine monitor.
monitor

Nature of
• Rear engine oil pressure monitor flashes.
trouble (6)
Relevant
• If the rear engine oil pressure goes low, the CGC monitor also displays the trouble (red screen).
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the rear

Check the display on the CGC monitor, too, to implement the troubleshooting proce-
1 engine oil pressure
dures applicable to the failure code [b@BAZG].
switch system

Failure on the machine

2 If the above causes is innocent, there must be a failure on the machine monitor.
monitor

PC1800-6 20-725
TROUBLESHOOTING E-13

E-13 Warm-up monitor unintended comes on or flashes on the machine monitor

though the warm-up operation is not turned ON

Nature of • Warm-up monitor unintended comes on or flashes on the machine monitor though the warm-up opera-
trouble tion is not turned ON.
Relevant
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Failure on the pre-
1 heating switch (inter- C82 (male) Preheating switch Resistance value
Possible cause and Standard value

nal short circuit) When turned off 1 MΩ min.

Across 1 and 2
When turned ON 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
switch on.
Hot short in the wir-
Across the wiring harness and ground between C82 (female) 1V
2 ing harness (contact Voltage
2 and C61 (female) 3 max.
with 24V circuit)
Across the wiring harness and ground between C61 (female) 1V
Voltage
6 – P01 (female) H, – C98 (female) 1, – C52 (female)1 max.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
switch on.
Failure on the P01 Preheating switch Voltage
3
machine monitor
When turned off 1 V max.
Across H and ground
When turned ON 20 – 30 V

20-726 PC1800-6
TROUBLESHOOTING E-13

Related electrical circuit of engine preheat, start, charging

PC1800-6 20-727
TROUBLESHOOTING E-14

E-14 Swing lock monitor does not come on

Nature of
• Swing lock monitor does not come on as the swing lock switch is turned ON.
trouble (1)
Relevant • Start the troubleshooting after making sure that the lock is applied (when the lock is not applied, imple-
information ment the troubleshooting procedures applicable to the failure code to [DW45KA] or [DW45KB].

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Failure on the swing
1 lock switch (internal C17 (female) Swing lock switch Resistance value
Possible cause and Standard value

disconnection) When turned off 1 MΩ min.

Across 1 and 2
When turned ON 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the harnesses between P01 (female) 5 and C17 Resistance 1Ω
2
connection/improper (male) 1 value max.
connector contact) Resistance 1Ω
Across the harnesses between C17 (male) 2 and ground
value max.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
switch on.
Failure on the P01 Swing lock switch Voltage
3
machine monitor
When turned off 20 – 30 V
Across 5 and ground
When turned ON 1 V max.

Nature of
• Swing lock monitor does not come on as the emergency swing holding release switch is turned ON.
trouble (2)
Relevant • Start the troubleshooting after making sure that the swing is released (when the swing is not released,
information implement the troubleshooting procedures applicable to the failure code to [DW45KA] or [DW45KB].

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the emer-
ing turned off.
gency swing holding
1 brake release switch B08 (male) Swing release switch Resistance value
(internal disconnec- When turned off 1 MΩ min.
Possible cause and Standard value

tion) Across 4 and 6

When turned ON 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the harnesses between FC02 (female) 2 and B08 Resistance 1Ω
2
connection/improper (female) 6 value max.
connector contact) Resistance 1Ω
Across the harnesses between B08 (female) 4 and ground
value max.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
switch on.
Failure on the pump Swing holding brake
3 FC02 Voltage
controller release switch
When turned off 20 – 30 V
Across 2 and ground
When turned ON 1 V max.
Failure on the
4 If potential causes 1 to 3 are innocent, there must be a failure on the machine monitor.
machine monitor

20-728 PC1800-6
TROUBLESHOOTING E-14

Related electrical circuit of swing lock switch, emergency swing holding blake release switch

PC1800-6 20-729
TROUBLESHOOTING E-15

E-15 Engine water temperature gauge is not correct.

Nature of
• Display of the front engine water temperature gauge is not correct
trouble (1)
• Signal from the front engine high water temperature sensor is received from the engine controller.
Relevant
• If trouble occurs on the front engine high water temperature sensor system, the failure code [B@BCNS]
information
is sometimes displayed.

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the front
ing turned off.
engine high water
1 temperature sensor TWH (male) Resistance value
(internal disconnec- Across 1 and 2 3.5 – 90 kΩ
tion/short circuit)
Across 1 2 and ground 1 MΩ min.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
Possible cause and Standard value

wiring harness (dis- Across the wiring harnesses between FE02 (female) Q and Resistance 1Ω
2
connection/improper TWH (female) 1 value max.
connector contact) Across the wiring harnesses between FE02 (female) ] and Resistance 1Ω
TWH (female) 2 value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FE02 Resistance 1 MΩ
cuit) (female) Q and TWH (female) 1 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FE02 1V
Voltage
(female) Q and TWH (female) 1 max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Failure on the front FE02 (female) Resistance value
5
engine controller
Across Q and ] 3.5 k – 90 kΩ
Across Q ] and ground 1 MΩ min.
Failure on the
6 If potential causes 1 to 5 are innocent, there must be a failure on the machine monitor.
machine monitor

Circuit diagram relevant to the front engine high water temperature sensor

20-730 PC1800-6
TROUBLESHOOTING E-15

Nature of
• Display of the rear engine water temperature gauge is not correct
trouble (2)
• Signal from the rear engine high water temperature sensor is received from the engine controller.
Relevant
• If trouble occurs on the rear engine high water temperature sensor system, the failure code [b@BCNS]
information
is sometimes displayed.

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the rear
ing turned off.
engine high water
1 temperature sensor TWH (male) Resistance value
(internal disconnec- Across 1 and 2 3.5 k – 90 kΩ
tion/short circuit)
Across 1 2 and ground 1 MΩ min.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
Possible cause and Standard value

wiring harness (dis- Across the wiring harnesses between RE02 (female) Q and Resistance 1Ω
2
connection/improper TWH (female) 1 value max.
connector contact) Across the wiring harnesses between RE02 (female) ] and Resistance 1Ω
TWH (female) 2 value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between RE02 Resistance 1 MΩ
cuit) (female) Q and TWH (female) 1 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between RE02 1V
Voltage
(female) Q and TWH (female) 1 max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Failure on the rear RE02 (female) Resistance value
5
engine controller
Across Q and ] 3.5 k – 90 kΩ
Across Q ] and ground 1 MΩ min.
Failure on the
6 If potential causes 1 to 5 are innocent, there must be a failure on the machine monitor.
machine monitor

Circuit diagram relevant to the rear engine high water temperature sensor

PC1800-6 20-731
TROUBLESHOOTING E-16

E-16 Display of the machine monitor's hydraulic oil temperature gauge is not correct

Nature of
• Display of the hydraulic oil temperature gauge is not correct
trouble
• Signal from the hydraulic oil temperature sensor is received from the pump controller.
Relevant
• If trouble occurs on the hydraulic oil temperature sensor system, the failure code [DGS1KX] is some-
information
times displayed.

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the
ing turned off.
hydraulic oil temper-
1 ature sensor (inter- T16 (male) Resistance value
nal disconnection/ Across 1 and 2 3.5 k – 90 kΩ
short circuit)
Across 1 and ground 1 MΩ min.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
Possible cause and Standard value

wiring harness (dis- Across the wiring harnesses between FC01 (female) 3 and Resistance 1Ω
2
connection/improper T16 (female) 1 value max.
connector contact) Across the wiring harnesses between FC01 (female) K and Resistance 1Ω
T16 (female) 2 value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FC01 Resistance 1 MΩ
cuit) (female) 3 and T16 (female) 1 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC01 1V
Voltage
(female) 3 and T16 (female) 1 max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Failure on the pump FC01 (female) Resistance value
5
controller
Across 3 and K 3.5 k – 90 kΩ
Across 3 and ground 1 MΩ min.
Failure on the
6 If potential causes 1 to 5 are innocent, there must be a failure on the machine monitor.
machine monitor

Circuit diagram relevant to the hydraulic oil temperature sensor

20-732 PC1800-6
TROUBLESHOOTING E-17

E-17 Display of fuel gauge is not correct

Nature of
• Display of the fuel gauge is not correct
trouble
Relevant
• Signal from the fuel level sensor is received from the pump controller.
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Failure on the fuel
level sensor (inter- T12 (male) Remaining fuel volume Resistance value
1
nal disconnection/ Approximately 12 Ω
short circuit) Filled up with fuel
Across 1 and sensor body max.
Vacant Approximately 85 to 110 Ω
Disconnection in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Possible cause and Standard value

wiring harness (dis- ing turned off.

2
connection/improper Across the wiring harnesses between FC01 (female) 8 and Resistance 1Ω
connector contact) T12 (female) 1 value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FC01 Resistance 1 MΩ
cuit) (female) 8 and T12 (female) 1 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC01 1V
Voltage
(female) 8 and T12 (female) 1 max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
ing turned off.
Failure on the pump FC01 (female) Remaining fuel volume Resistance value
5
controller Approximately 12 Ω
Filled up with fuel
Across 8 and ground max.
Vacant Approximately 85 to 110 Ω
Failure on the
6 If potential causes 1 to 5 are innocent, there must be a failure on the machine monitor.
machine monitor

Circuit diagram relevant to the fuel level sensor

PC1800-6 20-733
TROUBLESHOOTING E-18

E-18 Alarm buzzer of the machine monitor does not work normally

Nature of
• Alarm buzzer does not sound
trouble (1)
• The alarm buzzer is sounded, when the starting switch is turned ON, or when the machine monitor
switch is operated, or when an emergency stop monitor is flashed on the machine monitor, or when the
Relevant
user code is displayed.
information
• If short circuit occurs on the alarm buzzer circuit, the system records the failure code [DV00KY] on CGC
monitor and stops the output to the alarm buzzer.

Cause Standard value, Remarks for Troubleshooting

Failure on the circuit When circuit breaker is shut down, troubles such as ground failure must be present on the
1
breaker circuit (see the cause 4).
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Failure on the alarm ing turned off.
2 buzzer (internal dis-
C01 (male) Resistance value
Possible cause and Standard value

connection)
Across 1 and 2 200 Ω
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the wiring harnesses between P01 (female) 7 and Resistance 1Ω
3
connection/improper C01 (female) 1 value max.
connector contact) Resistance 1Ω
Across the wiring harnesses C01 (female) 2 and C80
value max.
Ground failure on ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
the wiring harness ing turned off.
4
(contact with GND Across the wiring harness and ground between C01 (female) Resistance 1 MΩ
circuit) 2 – C80, – C54 (female)1, – other relevant circuits. value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Failure on the switch on.
5
machine monitor P01 (female) Voltage
Across 7 and ground 20 – 30 V

Nature of
• Can't stop the alarm buzzer sounds.
trouble (2)
Relevant
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Possible cause and Standard value

Failure on the alarm ing turned off.

1 buzzer (internal dis-
C01 (male) Resistance value
connection)
Across 1 and ground 1 MΩ min.
Ground failure on ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
the wiring harness ing turned off.
2
(contact with GND Across the wiring harness and ground between P01 (female) Resistance 1Ω
circuit) 7 and C01 (female) 1 value max.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Failure on the switch on.
3
machine monitor P01 (female) Voltage
Across 7 and ground 20 – 30 V

20-734 PC1800-6
TROUBLESHOOTING E-18

Related electrical circuit of alarm buzzer

PC1800-6 20-735
TROUBLESHOOTING E-19

E-19 Clock and service meter are not correctly displayed

Nature of
• The clock and service meter do not come up as the starting switch is turned ON.
trouble (1)
Relevant
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure on the machine

1 Since it is an internal failure, troubleshooting is not available.
monitor

Nature of
• Service meter does not start counting while the engine is running.
trouble (2)
• The service meter is started as the front or rear engine's engine revolution sensor signal or the battery
Relevant
charge signal is entered while the VHMS controller power is turned ON
information
(the VHMS controller is responsible for the counting done by the service meter).

Cause Standard value, Remarks for Troubleshooting

Failure in the VHMS
1 controller power sup- Implement the troubleshooting applicable to the failure code [DBB0KK].
ply system
Failure in the front
Possible cause and

2 engine revolution sen- Implement the troubleshooting applicable to the failure code [DLE2MA].
Standard value

sor system
Failure in the front
3 Implement the troubleshooting applicable to the failure code [AB00KE].
engine charge system
Failure in the rear
4 engine revolution sen- Implement the troubleshooting applicable to the failure code [dLE2MA].
sor system
Failure in the rear
5 Implement the troubleshooting applicable to the failure code [AB00KE].
engine charge system
Failure on the machine When above causes 1 to 5 are innocent, there must be a failure on the machine mon-
6
monitor itor.

Nature of • When the starting switch is turned off, and when the clock switch is pressed, the service meter is not
trouble (3) displayed.
Relevant
information

Cause Standard value, Remarks for Troubleshooting

Possible cause and
Standard value

Failure in the machine

Implement the troubleshooting procedures described in "All the machine monitor
1 monitor power supply
lamps do not come on for 3 seconds after the starting switch is turned ON."
system

Failure on the machine

2 When the above cause is innocent, there must be a failure on the machine monitor.
monitor

20-736 PC1800-6
TROUBLESHOOTING E-20

E-20 Bit display for boom RAISE is not correctly displayed

Nature of • Among the monitoring functions, bit display of the boom RAISE oil pressure switch is not correctly dis-
trouble played.
Relevant
• Boom RAISE oil pressure switch: Monitoring code 20-bit [4]
information

Cause Standard value, Remarks for Troubleshooting

Failure in the boom ★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
RAISE oil pressure B32 (male) Boom lever Resistance value
1 switch (internal dis-
connection/short cir- At neutral 1 MΩ min.
Across 1 and 2
cuit) In RAISE operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Possible cause and Standard value

Disconnection in the ing turned off.

wiring harness (dis- Across the harnesses between FC03 (female) = and B32 Resistance 1Ω
2
connection/improper (female) 2 value max.
connector contact) Resistance 1Ω
Across the harnesses between B32 (female) 1 and ground
value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FC03 Resistance 1 MΩ
cuit) (female) = and B32 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC03 1V
Voltage
(female) = and B32 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC03 Boom lever Voltage
5
controller At neutral 20 – 30 V
Across = and ground
In RAISE operation 1 V max.

Circuit diagram relevant to the boom RAISE oil pressure switch

PC1800-6 20-737
TROUBLESHOOTING E-21

E-21 Bit display for boom LOWER is not correctly displayed

Nature of • Among the monitoring functions, bit display of the boom LOWER oil pressure switch is not correctly dis-
trouble played.
Relevant
• Boom LOWER oil pressure switch: Monitoring code 20-bit [3]
information

Cause Standard value, Remarks for Troubleshooting

Failure in the boom ★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
LOWER oil pres- B33 (male) Boom lever Resistance value
1 sure switch (internal
disconnection/short At neutral 1 MΩ min.
Across 1 and 2
circuit) In LOWER operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Possible cause and Standard value

Disconnection in the ing turned off.

wiring harness (dis- Across the harnesses between FC03 (female) J and B33 Resistance 1Ω
2
connection/improper (female) 2 value max.
connector contact) Resistance 1Ω
Across the harnesses between B33 (female) 1 and ground
value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FC03 Resistance 1 MΩ
cuit) (female) J and B33 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC03 1V
Voltage
(female) J and B33 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC03 Boom lever Voltage
5
controller At neutral 20 – 30 V
Across J and ground
In LOWER operation 1 V max.

Circuit diagram relevant to the boom LOWER oil pressure switch

20-738 PC1800-6
TROUBLESHOOTING E-22

E-22 Bit display for arm IN is not correctly displayed

Nature of
• Among the monitoring functions, bit display of the arm IN oil pressure switch is not correctly displayed.
trouble
Relevant
• Arm IN oil pressure switch: Monitoring code 20-bit [5]
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure in the arm IN
oil pressure switch B41 (male) Arm lever Resistance value
1
(internal disconnec- At neutral 1 MΩ min.
tion/short circuit) Across 1 and 2
In arm IN operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Possible cause and Standard value

Disconnection in the ing turned off.

wiring harness (dis- Across the harnesses between FC03 (female) T and B41 Resistance 1Ω
2
connection/improper (female) 2 value max.
connector contact) Resistance 1Ω
Across the harnesses between B41 (female) 1 and ground
value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FC03 Resistance 1 MΩ
cuit) (female) T and B41 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC03 1V
Voltage
(female) T and B41 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC03 Arm lever Voltage
5
controller At neutral 20 – 30 V
Across T and ground
In arm IN operation 1 V max.

Circuit diagram relevant to the arm IN oil pressure switch

PC1800-6 20-739
TROUBLESHOOTING E-23

E-23 Bit display for arm OUT is not correctly displayed

Nature of
• Among the monitoring functions, bit display of the arm OUT oil pressure switch is not correctly displayed.
trouble
Relevant
• Arm OUT oil pressure switch: Monitoring code 20-bit [6]
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure in the arm IN
oil pressure switch B40 (male) Arm lever Resistance value
1
(internal disconnec- At neutral 1 MΩ min.
tion/short circuit) Across 1 and 2
In dump operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Possible cause and Standard value

Disconnection in the ing turned off.

wiring harness (dis- Across the harnesses between FC03 (female) _ and B40 Resistance 1Ω
2
connection/improper (female) 2 value max.
connector contact) Resistance 1Ω
Across the harnesses between B40 (female) 1 and ground
value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FC03 Resistance 1 MΩ
cuit) (female) _ and B40 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC03 1V
Voltage
(female) _ and B40 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC03 Arm lever Voltage
5
controller At neutral 20 – 30 V
Across _ and ground
In dump operation 1 V max.

Circuit diagram relevant to the arm OUT oil pressure switch

20-740 PC1800-6
TROUBLESHOOTING E-24

E-24 Bit display for bucket CURL is not correctly displayed

Nature of • Among the monitoring functions, bit display of the bucket CURL oil pressure switch is not correctly dis-
trouble played.
Relevant
• Bucket CURL oil pressure switch: Monitoring code 21-bit [1]
information

Cause Standard value, Remarks for Troubleshooting

Failure in the bucket ★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
CURL oil pressure B34 (male) Bucket lever Resistance value
1 switch (internal dis-
connection/short cir- At neutral 1 MΩ min.
Across 1 and 2
cuit) In digging operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Possible cause and Standard value

Disconnection in the ing turned off.

wiring harness (dis- Across the harnesses between FC03 (female) 9 and B34 Resistance 1Ω
2
connection/improper (female) 2 value max.
connector contact) Resistance 1Ω
Across the harnesses between B34 (female) 1 and ground
value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FC03 Resistance 1 MΩ
cuit) (female) 9 and B34 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC03 1V
Voltage
(female) 9 and B34 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC03 Bucket lever Voltage
5
controller At neutral 20 – 30 V
Across 9 and ground
In digging operation 1 V max.

Circuit diagram relevant to the bucket CURL oil pressure switch

PC1800-6 20-741
TROUBLESHOOTING E-25

E-25 Bit display for bucket DUMP is not correctly displayed

Nature of • Among the monitoring functions, bit display of the bucket DUMP oil pressure switch is not correctly dis-
trouble played.
Relevant
• Bucket DUMP oil pressure switch: Monitoring code 21-bit [2]
information

Cause Standard value, Remarks for Troubleshooting

Failure in the bucket ★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
DUMP oil pressure B35 (male) Bucket lever Resistance value
1 switch (internal dis-
connection/short cir- At neutral 1 MΩ min.
Across 1 and 2
cuit) In dump operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Possible cause and Standard value

Disconnection in the ing turned off.

wiring harness (dis- Across the harnesses between FC03 (female) I and B35 Resistance 1Ω
2
connection/improper (female) 2 value max.
connector contact) Resistance 1Ω
Across the harnesses between B35 (female) 1 and ground
value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FC03 Resistance 1 MΩ
cuit) (female) I and B35 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC03 1V
Voltage
(female) I and B35 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC03 Bucket lever Voltage
5
controller At neutral 20 – 30 V
Across I and ground
In dump operation 1 V max.

Circuit diagram relevant to the bucket DUMP oil pressure switch

20-742 PC1800-6
TROUBLESHOOTING E-26

E-26 Bit display for swing is not correctly displayed

Nature of
• Among the monitoring functions, bit display of the swing oil pressure switch is not correctly displayed.
trouble
Relevant
• Swing oil pressure switch: Monitoring code 20-bit [1]
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
Failure in the swing
gine.
left oil pressure
1 switch (internal dis- B42 (male) Swing lever Resistance value
connection/short cir- At neutral 1 MΩ min.
cuit) Across 1 and 2
In swing left operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
Failure in the swing
gine.
right oil pressure
2 switch (internal dis- B43 (male) Swing lever Resistance value
connection/short cir-
Possible cause and Standard value

At neutral 1 MΩ min.
cuit) Across 1 and 2
In swing right operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the wiring harnesses between FC03 (female) S and Resistance 1Ω
3
connection/improper B42 (female) 2 as well as B43 (female) 2 value max.
connector contact) Across the harnesses between B42 (female) 1 and ground Resistance 1Ω
as well as B43 (female) 1 and ground. value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
4
tact with GND cir- Across the wiring harness and ground between FC03 Resistance 1 MΩ
cuit) (female) S and B42 (female) 2 as well as B43 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
5 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC03 1V
Voltage
(female) S and B42 (female) 2 as well as B43 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC03 Swing lever Voltage
6
controller At neutral 20 – 30 V
Across S and ground
In left/right operation 1 V max.

20-744 PC1800-6
TROUBLESHOOTING E-26

Circuit diagram relevant to the swing left/swing right oil pressure switch

PC1800-6 20-745
TROUBLESHOOTING E-27

E-27 Bit display for LH travel is not correctly displayed

Nature of
• Among the monitoring functions, bit display of the LH travel oil pressure switch is not correctly displayed.
trouble
Relevant
• LH travel oil pressure switch: Monitoring code 21-bit [5]
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
Failure in the LH
gine.
travel forward left oil
1 pressure switch B38 (male) LH travel lever Resistance value
(internal disconnec- At neutral 1 MΩ min.
tion/short circuit) Across 1 and 2
In forward operation 1 Ω max.
Failure in the LH ★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
travel reverse swing gine.
right oil pressure B39 (male) LH travel lever Resistance value
2
switch (internal dis-
Possible cause and Standard value

connection/short cir- At neutral 1 MΩ min.

Across 1 and 2
cuit) In reverse operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the wiring harnesses between FC02 (female) C and Resistance 1Ω
3
connection/improper B38 (female) 2 as well as B39 (female) 2 value max.
connector contact) Across the harnesses between B38 (female) 1 and ground Resistance 1Ω
as well as B39 (female) 1 and ground. value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
4
tact with GND cir- Across the wiring harness and ground between FC02 Resistance 1 MΩ
cuit) (female) C and B38 (female) 2 as well as B39 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
5 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC02 1V
Voltage
(female) C and B38 (female) 2 as well as B39 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC02 LH travel lever Voltage
6
controller At neutral 20 – 30 V
Across C and ground
In forward/reverse operation 1 V max.

20-746 PC1800-6
TROUBLESHOOTING E-27

Circuit diagram relevant to the LH travel forward/LH travel reverse oil pressure switch

PC1800-6 20-747
TROUBLESHOOTING E-28

E-28 Bit display for RH travel is not correctly displayed

Nature of
• Among the monitoring functions, bit display of the RH travel oil pressure switch is not correctly displayed.
trouble
Relevant
• RH travel oil pressure switch: Monitoring code 20-bit [1]
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
Failure in the RH
gine.
travel forward left oil
1 pressure switch B36 (male) RH travel lever Resistance value
(internal disconnec- At neutral 1 MΩ min.
tion/short circuit) Across 1 and 2
In forward operation 1 Ω max.
Failure in the RH ★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
travel reverse swing gine.
right oil pressure B37 (male) RH travel lever Resistance value
2
switch (internal dis-
Possible cause and Standard value

connection/short cir- At neutral 1 MΩ min.

Across 1 and 2
cuit) In reverse operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the wiring harnesses between FC02 (female) R and Resistance 1Ω
3
connection/improper B36 (female) 2 as well as B37 (female) 2 value max.
connector contact) Across the harnesses between B36 (female) 1 and ground Resistance 1Ω
as well as B37 (female) 1 and ground. value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
4
tact with GND cir- Across the wiring harness and ground between FC02 Resistance 1 MΩ
cuit) (female) R and B36 (female) 2 as well as B37 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
5 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC02 1V
Voltage
(female) R and B36 (female) 2 as well as B37 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC02 RH travel lever Voltage
6
controller At neutral 20 – 30 V
Across R and ground
In forward/reverse operation 1 V max.

20-748 PC1800-6
TROUBLESHOOTING E-28

Circuit diagram relevant to the RH travel forward/RH travel reverse oil pressure switch

PC1800-6 20-749
TROUBLESHOOTING E-29

E-29 Bit display for the service is not correctly displayed

Nature of
• Among the monitoring functions, bit display of the service oil pressure switch is not correctly displayed.
trouble
Relevant
• Service oil pressure switch: Monitoring code 21-bit [4]
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
Failure in the service gine.
oil pressure switch OPT (male) Attachment Resistance value
1
(internal disconnec-
tion/short circuit) At neutral 1 MΩ min.
Across 1 and 2
In operation 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Possible cause and Standard value

Disconnection in the ing turned off.

wiring harness (dis- Across the wiring harnesses between FC02 (female) Y and Resistance 1Ω
2
connection/improper OPT (female) 2 value max.
connector contact) Resistance 1Ω
Across the harnesses between OPT (female) 1 and ground
value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between FC02 Resistance 1 MΩ
cuit) (female) Y and OPT (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
4 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC02 1V
Voltage
(female) Y and OPT (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Failure on the pump FC02 Attachment Voltage
5
controller At neutral 20 – 30 V
Across Y and ground
In operation 1 V max.

Circuit diagram relevant to the service oil pressure switch

20-750 PC1800-6
TROUBLESHOOTING E-30

E-30 Bit display for the bottom OPEN, CLOSE is not correctly displayed

Nature of • Among the monitoring functions, bit display of the bottom OPEN, CLOSE oil pressure switch is not cor-
trouble rectly displayed.
Relevant
• Bottom OPEN, CLOSE oil pressure switches: Monitoring code 21-bit [4]
information

Cause Standard value, Remarks for Troubleshooting

★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
Failure in the bottom
gine.
OPEN oil pressure
1 switch (internal dis- BD01 (male) Bottom OPEN switch Resistance value
connection/short cir- When turned off 1 MΩ min.
cuit) Across 1 and 2
When turned ON 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting by starting the en-
Failure in the bottom
gine.
CLOSE oil pressure
2 switch (internal dis- BD02 (male) Bottom CLOSE switch Resistance value
connection/short cir- When turned off 1 MΩ min.
Possible cause and Standard value

cuit) Across 1 and 2

When turned ON 1 Ω max.
★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the wiring harnesses between FC02 (female) Y and Resistance 1Ω
3
connection/improper BD01 (female) 2 as well as BD02 (female) 2 value max.
connector contact) Across the harnesses between BD01 (female) 1 and ground Resistance 1Ω
as well as BD02 (female) 1 and ground. value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
4
tact with GND cir- Across the wiring harness and ground between FC02 (female) Resistance 1 MΩ
cuit) Y and BD01 (female) 2 as well as BD02 (female) 2 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Hot short in the wir- switch on.
5 ing harness (contact
with 24V circuit) Across the wiring harness and ground between FC02 (female) 1V
Voltage
Y and BD01 (female) 2 as well as BD02 (female) 2 max.
★Prepare by turning the starting switch off and then start troubleshooting by starting engine.
Bottom OPEN switch
Failure on the pump FC02 Voltage
6 Bottom CLOSE switch
controller
When turned off 20 – 30 V
Across Y and ground
When turned ON 1 V max.

20-752 PC1800-6
TROUBLESHOOTING E-30

Circuit diagram relevant to the bottom OPEN/bottom CLOSE oil pressure switches

PC1800-6 20-753
TROUBLESHOOTING E-31

E-31 Air conditioner does not work

Nature of
• Front air conditioner does not work
trouble (1)
Relevant
• For the electric circuit diagram of the air conditioner component, refer to the Section 90.
information

Cause Standard value, Remarks for Troubleshooting

Failure on the fuse/ When the fuse is burnt out or the circuit breaker is shut down, troubles such as ground fail-
1
circuit breaker ure must be present on the circuit (see the cause 3).
Possible cause and Standard value

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the wiring harnesses between fuse 10 and FA3 Resistance 1Ω
2
connection/improper (female) 2 5 value max.
connector contact) Resistance 1Ω
Across the harnesses between FA3 (female) 6 and ground
value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between fuse 10 and Resistance 1 MΩ
cuit) FA3 (female) 2 5 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Failure on the front switch on.
4 air conditioner com-
FA3 (female) Voltage
ponent
Across 2 5 and 6 20 – 30 V

Nature of
• Rear air conditioner does not work
trouble (2)
Relevant • For the electric circuit diagram of the air conditioner component, refer to the Structure and Function Vol-
information ume "Air Conditioning System".

Cause Standard value, Remarks for Troubleshooting

Failure on the fuse/ When the fuse is burnt out or the circuit breaker is shut down, troubles such as ground fail-
1
circuit breaker ure must be present on the circuit (see the cause 3).
Possible cause and Standard value

★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
Disconnection in the ing turned off.
wiring harness (dis- Across the wiring harnesses between fuse 11 and RA3 Resistance 1Ω
2
connection/improper (female) 2 5 value max.
connector contact) Resistance 1Ω
Across the harnesses between RA3 (female) 6 and ground
value max.
Ground failure in the ★Prepare by turning the starting switch off and then start troubleshooting with the switch be-
wiring harness (con- ing turned off.
3
tact with GND cir- Across the wiring harness and ground between fuse 11 and Resistance 1 MΩ
cuit) RA3 (female) 2 5 value min.
★Prepare by turning the starting switch off and then start troubleshooting by turning the
Failure on the rear switch on.
4 air conditioner com-
RA3 (female) Voltage
ponent
Across 2 5 and 6 20 – 30 V

20-754 PC1800-6
TROUBLESHOOTING E-31

Related electrical circuit of air conditioner unit power source

PC1800-6 20-755
 TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)

TABLE OF FAILURE MODES AND CAUSES .............................................................................................20-802

PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC SYSTEM................................................20-804
HOW TO READ THE TROUBLESHOOTING FLOW ..................................................................................20-809
H-1. Speeds of all work equipment, swing, travel are slow or lack power...................................................20- 811
H-2. There is excessive drop in engine speed, or engine stalls ..................................................................20-812
H-3. No work equipment, travel, swing move ..............................................................................................20-814
H-4 Abnormal noise generated (around pump) ...........................................................................................20-816
H-5. Work equipment speed is slow (boom, arm, bucket) ...........................................................................20-817
H-6. Work equipment (boom, arm, bucket) does not move (but travel and swing are normal) ...................20-818
H-7. Excessive hydraulic drift (boom, arm, bucket) .....................................................................................20-818
H-8. Excessive time lag ...............................................................................................................................20-819
H-9. Excessive shock when boom is stopped (when shockless switch is ON) ...........................................20-819
H-10. Defective actuation of machine push-up function ..............................................................................20-819
H-11. When heavy lift is ON, boom RAISE speed is slow or lacks power ...................................................20-820
H-12. Travel deviation is excessive during compound operations...............................................................20-821
H-13. Machine deviates naturally to one side during travel operations .......................................................20-822
H-14. Deviation is excessive when starting .................................................................................................20-826
H-15. Travel speed is slow ..........................................................................................................................20-828
H-16. Travel does not move (one side only)................................................................................................20-828
H-17. Does not swing ..................................................................................................................................20-829
H-18. Swing speed is slow or swing acceleration is poor............................................................................20-830
H-19. Excessive overrun when stopping swing ...........................................................................................20-831
H-20. Excessive shock when stopping swing..............................................................................................20-832
H-21. Excessive abnormal noise when stopping swing...............................................................................20-832
H-22. Excessive hydraulic drift of swing ......................................................................................................20-833

PC1800-6 20-801
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES

TABLE OF FAILURE MODES AND CAUSES

Pump TVC Control valve

Parts causing failure

Control pump, relief valve

Straight travel valve

Main relief valve

Suction valve
CO•NC valve

Pump proper

Valve proper
Safety valve
Servo valve

Solenoid
Strainer

Spool

Spool
Failure mode

PTO
Speeds of all work equipment, swing, travel are slow or lack
All work equipment,

power
travel, swing

There is excessive drop in engine speed, or engine stalls

No work equipment, travel, swing move

Abnormal noise generated (around pump)

Boom is slow or lacks power

Arm is slow or lacks power
Bucket is slow or lacks power
Boom does not move
Work equipment

Arm does not move

Bucket does not move
Excessive hydraulic drift
Excessive time lag
Excessive shock when boom is stopped (shockless switch ON)
Defective actuation of machine push-up function
Boom raise speed is slow or lacks power when heavy lift switch
is ON
Travel deviation excessive during compound operations
Direction of deviation is same in
Machine deviates naturally to FORWARD and REVERSE
Travel system

one side during travel opera-

tions Direction of deviation is different
in FORWARD and REVERSE
Deviation is excessive when starting
Travel speed is slow
Does not move (one side only)
Both left and right
Does not swing
One direction only

Swing speed is slow or swing Both left and right

acceleration is poor One direction only
Swing system

Excessive overrun when stop- Both left and right

ping swing One direction only
Excessive shock when stopping swing
Excessive abnormal noise when stopping swing
When swing holding brake is
Excessive hydraulic drift of released
swing When swing holding brake is
applied

: Boom RAISE only

20-802 PC1800-6
 Shockless boom valve

Jet sensor (relief valve, orifice)

PC1800-6
PPC valve

Center swivel joint

Straight travel

Shockless boom
TROUBLESHOOTING

2-stage main relief

CO cancel
Solenoid

2-stage safety relief

Swing holding brake

Brake

Internal leakage

Safety valve

Suction valve
Swing motor

Motor proper

Safety valve

Motor proper

Internal leakage
Travel motor

Brake

Swing machinery

Final drive

Hydraulic cylinder

Lift check valve

Engine system
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1

H-11

H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
Troubleshooting code

20-803
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC SYSTEM

PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC

SYSTEM
Measuring points for No.3, 4F pumps and V3
1. Combinations and Operations of Hydraulic control valves
Pumps [31]: Main relief pressure (CGC monitor)
PC1800's work equipment and travelling [32]: TVC valve output pressure (oil pressure
hydraulic system are consisted of four monitor)
HPV095+095 piston pumps and four control [33]: CO/NC valve output pressure (CGC moni-
valves. See the figure to the right. tor)
No.1 pump and F side of No.2 pump are merged [34]: Jet sensor output pressure/high pressure
and conducted to V1 control valve (4-spool (oil pressure monitor)
valve at upper left side) and No.1 pump and R [35]: Jet sensor output pressure/low pressure
side of No.2 pump are merged and conducted to (oil pressure monitor)
V2 control valve (5-spool valve at lower left
side). Likewise, No.3 pump and F side of No.4 Measuring points for No.3, 4R pumps and V4
pump are merged and conducted to V3 control control valves
valve (4-spool valve at upper right side) and [41]: Main relief pressure (CGC monitor)
No.3 and R side of No.4 pump are merged and [43]: CO/NC valve output pressure (CGC moni-
conducted to V4 control valve (5-spool valve at tor)
lower right side). [44]: Jet sensor output pressure/high pressure
Thus, when travel speed of the work equipment (oil pressure monitor)
is low or its output horsepower is insufficient and [45]: Jet sensor output pressure/low pressure
travel deviation is observed at the same time, (oil pressure monitor)
you can use the following matrix to identify
which pump or control vale system is responsi- Measuring points for swing F/R pumps and
ble for the given trouble. swing control valves
★ The swing circuit is independent from the [51]: Main relief pressure (CGC monitor)
work equipment and travel circuits. [53]: CO/NC valve output pressure (CGC moni-
tor)
Measuring points for No.1, 2F pumps and V1 [54]: Jet sensor output pressure/high pressure
control valves (oil pressure monitor)
[11]: Main relief pressure (CGC monitor) [55]: Jet sensor output pressure/low pressure
[12]: TVC valve output pressure (oil pressure (oil pressure monitor)
monitor)
[13]: CO/NC valve output pressure (CGC moni- Measuring points for control pump
tor) [61]: Control relief pressure (CGC monitor)
[14]: Jet sensor output pressure/high pressure
(oil pressure monitor)
[15]: Jet sensor output pressure/low pressure
(oil pressure monitor)

Measuring points for No.1, 2R pumps and V2

control valves
[21]: Main relief pressure (CGC monitor)
[23]: CO/NC valve output pressure (CGC moni-
tor)
[24]: Jet sensor output pressure/high pressure
(oil pressure monitor)
[25]: Jet sensor output pressure/lower pressure
(oil pressure monitor)

20-804 PC1800-6
TROUBLESHOOTING PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC SYSTEM

Combinations of Pumps and Control Valves and Oil Pressure Measuring Points

★ The hydraulic pumps shown are viewed from the

left side of the machine and the control valves
are viewed from the front side of the machine.

PC1800-6 20-805
TROUBLESHOOTING PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC SYSTEM

2. Procedures for troubleshooting

Work equipment speed is slow (its power
has been decreased and its travel deviates)
but swing operation is normal:

Causes of failures between pumps and control valves

Causes
Notes on diagnosis
a b c d e f g h i j k l
1) For a major speed drop possibly caused by a pump
failure, check the oil filters before troubleshooting. Front Rear
2) For a minor speed drop, check the oil filters when P2 P4
P1 P3
the problem is not solved through adjustments of oil F R F R
pressures in the relevant pieces of equipment.
★ Check if metal particles stuck to line oil filter or return
oil filter, in order to find damaged pump.

Front pump

Front pump
Rear pump

Rear pump
CO • NC

CO • NC

CO • NC

CO • NC
Servo

Servo

Servo

Servo
Remedy
No.
Diagnosis
1 Work equipment speed is slow and travel deviates toward right.
2 Bucket (dump) speed is particularly slow. (in item 1)
3 Travel deviates toward left.
When outlet hoses have been
4 replaced between F and R of P3 Both L.H. and R.H. travel slows down.
pump:
5 The condition remains unchanged.
6 Travel deviates toward left.
When outlet hoses have been
7 replaced between F and R of P1 Both L.H. and R.H. travel slows down.
pump:
8 The condition remains unchanged.
When outlet hoses have been
replaced between F and R of P2
9 Travel deviates toward left.

10 pump: The condition remains unchanged.

11 Work equipment speed is slow and travel deviates toward left.

12 Bottom cylinder (loader) is particularly slow (in item 11)
13 Travel deviates toward right.
When outlet hoses have been
14 replaced between F and R of P3 Both L.H. and R.H. travel slows down.
pump:
15 The condition remains unchanged.
16 Travel deviates toward right.
When outlet hoses have been
17 replaced between F and R of P1 Both L.H. and R.H. travel slows down.
pump:
18 The condition remains unchanged.
19 When outlet hoses have been
replaced between F and R of P4
Travel deviates toward right.

20 pump: The condition remains unchanged.

Main relief pressure of V1 valve has been decreased in 10 above (this valve
21
may be replaced with V2 valve)
Main relief pressure of V3 valve has been decreased in 10 above (this valve
22
may be replaced with V4 valve)
Main relief pressure of V2 valve has been decreased in 18 above (this valve
23
may be replaced with V1 valve)
Main relief pressure of V4 valve has been decreased in 18 above (this valve
24
may be replaced with V3 valve)

20-806 PC1800-6
TROUBLESHOOTING PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC SYSTEM

Causes
m n o p q r s t
Left Right

V1 V2 V3 V4
Jet sensor

Jet sensor

Jet sensor
Jet sensor

Main relief

Main relief

Main relief

Main relief

PC1800-6 20-807
TROUBLESHOOTING PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC SYSTEM

Steps for inspecting a servo valve or pump body failure

The servo valves are interchangeable between P1 F×, P3 F× and P2 R, P4 R, and between P2 F, P4 F
1. Replacing servo valves

and P1 R, P3 R.

2. Inspecting servo pistons for action

Remove caps from both sides and manually move the servo pistons to check for their action.

Piping diagram for pumps for work equipment, travel

(When changing hose connection for troubleshooting)

20-808 PC1800-6
TROUBLESHOOTING HOW TO READ THE TROUBLESHOOTING FLOW

HOW TO READ THE TROUBLESHOOTING FLOW

Troubleshooting code number and nature of the trouble
Troubleshooting number and nature of the trouble are listed in the upper left corner of the troubleshooting
flow.

Sub-classification
When a different troubleshooting approach is employed for the seemingly same trouble depending on the
model, system or nature of the trouble, the troubleshooting approach will be further classified into a), b) and
so on. Select the approach applicable to your troubleshooting. When such sub-classification is not pre-
pared, you are to implement the troubleshooting procedures stepwise from the start.

Overall precautions
Commonly applicable precautions for the given troubleshooting are described following the ★ mark.
Those precautions headed by the ★ mark are omitted in . Be sure to observe these precautions when
executing the checkion described in .

How to proceed with the troubleshooting

Yes

• When is indicated for the current step, select YES or NO to proceed to the next step after im-
No
plementing the checkion or measurement specified in .
(Note: The number attached in the right side shoulder of is just organizing the workflow. It does
not represent a sequence in the procedure.)
• If YES or NO chosen after the checkion or measurement is directly connected to the cause, you must
take the corrective action(s) provided on the right side of the cause.
• An checkion or measurement method or a pass/fail criterion is provided beneath . When your finding
is consistent with to the criteria or question, select YES. If not, select NO.
• Preparations required or criteria to be referenced for the checkion/measurement are also provided under
. You are requested to read them carefully before starting the checkion or measurement work. Oth-
erwise, you might employ an illegal equipment operation or handling practice thereby damaging the
equipment.

Troubleshooting tools
For the tools required for the troubleshooting, reference the Testing and Adjusting Volume of this Shop Man-
ual.

<Examples of Descriptions in the Troubleshooting Flow>

H-10 Deviation to one side results during travelling.

★ Make sure that the normal travel speed is maintained.
b) A deviating direction when travelling forward is not identical with that in travelling reverse.

Cause Remedy

Failure on swivel joint O-

2 YES Repair or
ring
Is stroke of the replace
YES control valve
1 spool normal?
Defective operation in
Is relief pressure lever linkage or control Repair or
normal when the • 6mm NO valve spool replace
travel motor is
relieved?
+0.5 Low main relief valve set Adjustment or
• 15.7 0 MPa
{160 +50 kg/cm2} NO pressure replacement
• Engine at high
idling

PC1800-6 20-809
TROUBLESHOOTING H-1

H-1. Speeds of all work equipment, swing, travel are slow or lack power

★ Carry out troubleshooting in the DH mode.

★ Check that no abnormal noise is being generated from the main pump before carrying out troubleshooting.
(If there is any abnormal noise, carry out troubleshooting for H-4.)

Cause Remedy

YES Carry out

troubleshooting in H-13

4 YES
Go to A
1 Is main relief
YES pressure normal
Is there travel at CO cancel?
deviation?
3
+1.0
Go to B
Is output • 29.4 2.0 MPa NO
YES pressure of TVC +10
{300 20 kg/cm }2
• Max. 220 mm/20 solenoid valve • Engine at high
m travel normal? idling 7 YES Defective adjustment of
• Engine at high Adjust
2 • See Table 1. Does condition TVC solenoid valve
idling
• Engine at high become normal
• Lever operated Is control pump
fully relief pressure idling NO when TVC solenoid
valve is adjusted?
NO normal? Defective TVC solenoid
Replace
NO valve
+0.34
• 3.13 0 MPa
2
{32 +3.5
0 kg/cm } Carry out
• Engine at high troubleshooting from
idling NO Item 2 in H-3

5 YES
Pump body Replace
Is engine speed
From A at arm relief
normal? Defective engine system
(Refer to Engine Shop
• See Table 2. NO Manual)
• Engine at high
idling
6 YES Defective main relief Adjust or
Is output valve replace
pressure of CO
From B cancel solenoid
valve normal? Defective operation of Correct or
• Min. 3.13 MPa NO CO cancel solenoid valve replace
{Min. 32 kg/cm2}
• Engine at high
idling
Table 1

Control lever at neutral Min. 1.76 MPa {18 kg/cm2}

H mode, Table 2
boom RAISE relief 1.48 0.2 MPa {15 2 kg/cm2}
Heavy lift 1,750 100 rpm
Heavy lift ON,
boom RAISE relief 1.41 0.2 MPa {14.3 2 kg/cm2} DH mode 1,750 100 rpm

PC1800-6 20-811
TROUBLESHOOTING H-2

H-2. There is excessive drop in engine speed, or engine stalls

★ Carry out troubleshooting in the DH mode.

YES

2
Is CO valve • Output pressure
YES becomes normal.
output pressure
• Problem does not
normal at relief?
3 change.

• At normal relief: Does output • Output pressure

Min. 0.54 MPa pressure become becomes
normall.
{5.5 kg/cm2} NO normal when CO
• Condition
1 • At CO cancel: valve is adjusted? becomes normal.
Same pressure as
TVC pressure • Output pressure
Is TVC valve set does not become
• Engine at high
pressure normal? normal.
idling

• See Table 1. • Set pressure

• Engine at high becomes normal.
idling • Problem does not

4 change.

Does condition • Set pressure

become normal becomes normal.
when TVC valve set • Condition
NO
pressure is adjusted? becomes normal.

Same conditions
• Set pressure does
as Item 1. not become
normal.

Table 1

Control levers at neutral Min. 1.76 MPa {18 kg/cm2}

DH mode,
boom RAISE relief 1.48 ± 0.2 MPa {15 ± 2 kg/cm2}

Heavy lift ON,

boom RAISE relief 1.41 ± 0.2 MPa {14.3 ± 2 kg/cm2}

20-812 PC1800-6
TROUBLESHOOTING H-2

Cause Remedy

See Engine Shop Manual –

Defective adjustment of
Adjust
CO valve

Defective CO valve Replace

Defective adjustment of Adjust

TVC solenoid valve

Defective TVC solenoid Replace

valve

PC1800-6 20-813
TROUBLESHOOTING H-3

H-3. No work equipment, travel, swing move

★ Carry out troubleshooting in the DH mode.

★ When auto-deceleration is normal.
★ Check operation of safety valve before starting troubleshooting.

Cause Remedy

Excessive leakage inside

YES
equipment of applicable See Note
3 system
Is control pump
YES relief pressure
normal when (1) –
(14) in Fig. 1 is 4 YES
Defective control pump Replace
blocked? Is foreign material
2
+0.34 found in strainer
When control • 3.13 0 MPa
YES pump pressure {32 0 kg/cm2}
+3.5 NO at outlet port of
measurement plug control pump? Adjust or
• Engine at high Defective control pump
is removed, does replace
oil come out?
idling NO relief valve
1 • See the note.
When main pump
pressure • Defective PTO
measurement plug Repair or
• Defective gear pump
is removed, does NO replace
(broken shaft, etc.)
oil come out?
For both Items 1 and 2, if oil does not
come out, the PTO is defective.
Defective PTO Repair
NO

NOTE: Measure the control relief pressure for blocks 1 – D respectively to isolate a defective unit before
repair or replacement.

20-814 PC1800-6
TROUBLESHOOTING H-3

H-3 Related circuit diagram

PC1800-6 20-815
TROUBLESHOOTING H-4

H-4 Abnormal noise generated (around pump)

Cause Remedy

YES
Clogged strainer Clean
2

YES Is strainer
clogged? YES
Loose piping clamp Tighten
3
Is problem
removed when
1 piping between
NO tank and pump is 4 YES
Defective pump Replace
tightened? Are metal wear
Is hydraulic tank particles found in
oil level normal?
NO drained hydraulic Inspect again
oil? Operate for a short time
depending on
and watch for any
NO change in symptoms change in
symptoms

Lack of hydraulic oil Add hydraulic

NO oil

20-816 PC1800-6
TROUBLESHOOTING H-5

H-5. Work equipment speed is slow (boom, arm, bucket)

★ When swing and travel are normal.

(If there is travel deviation, and the speed is slow for independent operation of the swing or bucket DUMP,
carry out troubleshooting first for H-13 Machine deviates naturally to one side during travel operations.
★ Carry out troubleshooting in the DH mode.

Cause Remedy

Abnormality inside
3 YES
hydraulic cylinder Repair
Is actuation (clogging of port, etc.)
YES pressure of
2 cylinder
abnormally high? Defective operation of Correct or
YES Is output • Engine at high NO control valve spool replace
pressure of PPC
idling
valve normal?
• Lever operated
1 fully Defective operation of
• Min. 2.74 MPa Replace
Is hydraulic drift {28 kg/cm2} NO PPC valve
of slow cylinder • Engine at high
within standard idling
value? YES Defective hydraulic Repair or
4
cylinder piston packing replace
• See table1. Does speed of
• Engine stopped downward
movement become
NO faster when lever is 5 YES Defective safety (suction)
operated? Repair
Does condition valve
See TESTING become normal
AND when safety
NO (suction) valve is
ADJUSTING.
interchanged? Defective control valve or
It is also possible Repair
to measure See Note 1. NO spool
leakage of
cylinder.
• Max. 20 cc/min
• Engine at high
idling

Table1 mm/15min
Back hoe Loading shovel
Boom Max. 90 (Max. 50) Max. 240
Arm Max. 250 (Max. 105) Max. 60
Bucket Max. 80 (Max. 30) Max. 20
( ):when no load in bucket

Note 1. The safety-suction valves have common

mounts.
However, the settings are different for each
cylinder, so be sure to replace the valves in
their original positions after completion of
the troubleshooting.
There is a pilot hose only at the boom
LOWER end.

PC1800-6 20-817
TROUBLESHOOTING H-6, H-7

H-6. Work equipment (boom, arm, bucket) does not move (but travel and swing are
normal)

★ When boom, arm, and bucket are each operated independently.

Cause Remedy

1 YES Defective control valve Correct or

spool replace
Is output
pressure of PPC
valve normal?
Defective PPC valve Replace
• Min. 2.74 MPa NO
{28 kg/cm2}
• Engine at high
idling

H-7. Excessive hydraulic drift (boom, arm, bucket)

Cause Remedy

YES Defective hydraulic

Replace
1 cylinder piston packing
Does speed of
downward
movement become
faster when lever is 2 YES Defective operation of
operated? Does condition safety-suction valve Replace
become normal
• See TESTING when safety-suction
AND NO valve is
ADJUSTING interchanged? Defective operation of
• It is also control valve spool Replace
See Note 1. NO
possible to
measure
leakage of
cylinder.
• Max. 20 cc/min
• At relief
• Engine at high
idling

Note 1. The safety-suction valves have common

mounts.
However, the settings are different for each
cylinder, so be sure to replace the valves in
their original positions after completion of
the troubleshooting.
There is a pilot hose only at the boom
LOWER end.

20-818 PC1800-6
TROUBLESHOOTING H-8, H-9, H-10

H-8. Excessive time lag

★ When the work equipment speed is normal. (If the work equipment speed is also slow, carry out troubleshoot-
ing first from Item 2 of H-5.)

Cause Remedy
Time lag unit: sec
Boom Max. 5.0
Defective operation of
suction valve
Replace Arm Max. 5.0
Bucket Max. 6.0

H-9. Excessive shock when boom is stopped (when shockless switch is ON)

Cause Remedy

Defective operation of
1 YES shockless valve Repair or
(defective closing of replace
Does shockless check valve)
solenoid valve
move smoothly? Defective operation of
Repair or
shockless solenoid valve
NO replace
(valve remains open)

H-10. Defective actuation of machine push-up function

★ When electrical system is normal.

Cause Remedy

1 YES
Defective safety valve Replace
Is output pressure
of machine push-
up solenoid valve
normal? Defective operation of Correct or
NO solenoid valve replace
• At low pressure
setting:
Min. 3.13 MPa
{Min. 32 kg/cm2}
• At high pressure
setting: 0MPa
{0kg/cm2}
• Engine at high
idling

PC1800-6 20-819
TROUBLESHOOTING H-11

H-11. When heavy lift is ON, boom RAISE speed is slow or lacks power

Cause Remedy

Defective control valve

2 YES Repair or
main relief valve (high-
Is 2-stage relief replace
pressure side)
YES solenoid valve
1 outlet pressure
normal? Defective operation of 2-
Is CO cancel stage relief solenoid Repair or
solenoid valve • See Table. NO valve replace
outlet pressure • Engine at high
normal? idling
• See Table. Defective operation of Repair or
• Engine at high NO CO cancel solenoid valve replace
idling

Table
Measurement conditions Solenoid valve outlet pressure
Heavy lift switch OFF 0 MPa {0 kg/cm2}
Heavy lift switch ON + boom RAISE Min. 3.13 MPa {Min. 32 kg/cm2}

20-820 PC1800-6
TROUBLESHOOTING H-12

H-12. Travel deviation is excessive during compound operations

★ When independent operation of travel is normal.

★ Carry out troubleshooting in the DH mode.

Cause Remedy

1 YES Defective operation of Repair or

Is output pressure straight travel valve replace
of straight travel
solenoid valve
normal? Defective operation of
Repair or
straight travel solenoid
NO replace
• Travel and work valve
equipment
operated
simultaneously :
Min. 3.13 MPa
{Min. 32 kg/cm2}
• Engine at high
idling

PC1800-6 20-821
TROUBLESHOOTING H-13

H-13. Machine deviates naturally to one side during travel operations

★ When travel speed is normal.

★ Carry out troubleshooting in the DH mode.

a. Direction of deviation is same in FORWARD and REVERSE

YES

YES

4
Are metal particles
YES found in oil YES
1 drained from final
drive on side of
Was it possible to deviation? 5
locate abnormality Does condition return
in troubleshooting to normal when travel
chart? deviation is adjusted
NO according to specified YES
3 procedure?
Is amount of oil 6
YES drained from See TESTING
AND Is leakage from
travel motor swivel joint
ADJUSTING.
normal? NO packing normal?
• Max. 30 /min
2 • Engine at high • Min. 100 cc/min
idling • Engine at high NO
Is output
idling
pressure of PPC
See TESTING AND
NO valve normal?
ADJUSTING.
• Min. 2.74 MPa NO
{28 kg/cm2}
• Engine at high
idling
NO

20-822 PC1800-6
TROUBLESHOOTING H-13

Cause Remedy

See Cause column in Adjust, repair,

troubleshooting chart or replace

Repair or
Defective final drive
replace

Defective adjustment of
Adjust
pump

7 YES
Defective control valve Replace
Does direction of
deviation change
when hoses between
swivel joint and motor
are interchanged? Repair or
Defective travel motor
NO replace

Defective swivel joint

Repair
packing

Excessive leakage inside Replace

motor

Defective PPC valve Replace

PC1800-6 20-823
TROUBLESHOOTING H-13

b. Direction of deviation is different in FORWARD and REVERSE

Cause Remedy

YES Defective swivel joint

Repair
packing
1
3 YES Defective operation of
Is deviation as Replace
control valve spool
shown in Fig. 1? Is output
YES
pressure of PPC
2 valve normal?
Is relief pressure Defective PPC valve Replace
at travel motor • Min. 2.74 MPa NO
NO relief normal? {28 kg/cm2}
• Engine at high

•
+1.0
31.4 –2.0 MPa idling Drop in set pressure of
Repair
{320 +10 2
–20 kg/cm } NO travel motor safety valve
• Engine at high
idling

20-824 PC1800-6
TROUBLESHOOTING H-14

H-14. Deviation is excessive when starting

★ Machine travel speeds are appropriate.

★ See H-13 "Machine tends to deviate either side while it travels" for a case involving constant travel deviation.
For travel deviation while controlling work equipment, jump to H-13 "Travel deviation is excessive during
compound operations" before this diagnostic step.
★ Deaerate the circuit before starting this diagnostic step.
★ Diagnose the problem in the DH. mode.

YES

3
Is turning direction
YES reversed after
YES
replacing outlet
hoses between F and
R sides of P1 pump? 4
Is turning direction
reversed after
replacing outlet YES
NO hoses between F and
R sides of P3 pump? 5
2
Is turning direction
YES Relief pressure at reversed after
replacing outlet YES
control circuit
NO hoses between F and
appropriate? R sides of P2 pump? 6
+0.34 Is turning direction
• 3.13 0 MPa reversed after
{32 0 kg/cm2}
+3.5 replacing outlet
NO hoses between F and
• Engine at full R sides of P4 pump?
throttle
NO
H-6
NO

1 YES
Does machine deviate
when starting only 10
when switching
R.H/L.H travel lever Is turning direction
from N to full stroke YES reversed after
position? replacing outlet YES
hoses between F and
R sides of P1 pump? 11
Is turning direction
reversed after
replacing outlet
9 NO hoses between F and 12 YES
NC valve output R sides of P3 pump? Is turning direction
YES pressure at high- reverses after
replacing outlet
speed side NO hoses between F and
appropriate? R sides of P2 pump?
• With track shoe turning NO
with no load:
8 Min. 1.8 MPa
Differential pressure {Min.18 kg/cm2}
of jet sensor at high- • With lever in neutral
speed side (outer position:
NO Max. 0.55 MPa NO
track) appropriate? {Max. 5.5 kg/cm2}
• Engine at full throttle

• With lever in
neutral: NO 13 YES
• Max. 1.5 MPa Is turning direction
{Max. 15 kg/cm2} reversed after
• With lever at full replacing relief valves
in jet sensor?
stroke position:
Max. 0.2 MPa NO
{Max. 2.0 kg/cm2}
• Engine at full
throttle

20-826 PC1800-6
TROUBLESHOOTING H-14

Note 1: 3 through 6 and 10 through 12 indicate a case in which the machine tends to turn to the right. Where
the machine tends to turn to the left, the side of all pumps changes to the R side.
Note 2: To check the operations of servo pistons, remove the cap from both sides and then manually move
them.
Note 3: To determine which parts are malfunctioning (servo valve or servo piston), replace the servo valves.
(The servo valves at F side (R side) of P2 and P4 motors are compatible with those at R side (F side)
of P1 and P3 motors).

Cause Remedy

Malfunctioning servo valve

or servo piston at side of Replace
P1 pump

Malfunctioning servo valve

or servo piston at side of Replace
P3 pump

Malfunctioning servo valve

or servo piston at side of Replace
P2 pump

Malfunctioning servo valve

or servo piston at side of Replace
P4 pump

7 YES The brake at travel motor Replace motors

Is turning direction shaft driven is defective
reversed when one
set of travel motor
is replaced? The brake at travel motor Replace motors
NO shaft not driven defective

Malfunctioning servo valve

or servo piston at side of Replace
P1 pump

Malfunctioning servo valve

or servo piston at side of Replace
P3 pump

Malfunctioning servo valve

or servo piston at side of Replace
P2 pump

Malfunctioning servo valve

or servo piston at side of Replace
P4 pump

CO-NC valve malfunction Replace

Defective jet sensor relief Replace

valve

Defective jet sensor orifice

Replace

PC1800-6 20-827
TROUBLESHOOTING H-15, H-16

H-15. Travel speed is slow

★ When there is no travel deviation.

★ Carry out troubleshooting in the DH mode.
If main relief pressure has dropped, the work equipment will lack power even during normal operations.

Cause Remedy

2 YES Drop in main relief Adjust

Is outlet pressure pressure
YES of CO cancel
1 solenoid valve
normal? Defective operation of Repair or
Is output
• Min. 3.13 MPa NO CO cancel solenoid valve replace
pressure of PPC
valve normal? {Min. 32 kg/cm2}
• Engine at high

• Min. 2.74 MPa idling

Defective PPC valve Replace
{28 kg/cm2} NO
• Engine at high
idling

H-16. Travel does not move (one side only)

★ Carry out troubleshooting in the DH mode.

Cause Remedy

2 YES Correct or
Defective final drive replace
Is any foreign
YES material found in
oil drained from
1 final drive? Travel motor brake Replace motor
Is main relief NO dragging assembly
pressure at
motor relief
normal? 3 YES Defective travel motor Replace safety
• At travel relief: Is oil pressure at safety valve valve
+1.0
31.4 –2.0 MPa motor relief normal
{320 +10 2
–20 kg/cm } NO
when safety valve is
• Engine at high interchanged? Replace motor
idling Defective travel motor
See Item 1 for NO assembly
the standard
value.

20-828 PC1800-6
TROUBLESHOOTING H-17

H-17. Does not swing

★ When other work equipment and travel are normal.

★ Carry out troubleshooting in the DH mode.
★ Turn the swing lock switch OFF.

Cause Remedy

3 YES Repair or
Drop swing machinery
Is any foreign replace
YES material found in
2 oil drained from
swing machinery?
Is oil pressure of Defective swing motor
brake or swing motor Replace
[Both left and right]
swing brake NO
solenoid valve
outlet port normal?
Defective operation of
• See Table 1 Correct or
swing brake solenoid
1 • Engine at high NO replace
valve
Is problem with idling
swing in both left
and right directions
or in one direction 5 YES
only?
Defective safety valve Replace
Is problem reversed
YES when left and right
4 safety valves are
interchanged?
Is output Go to A
[One direction only] pressure of PPC NO
valve normal?

• Min. 2.74 MPa Defective PPC valve Replace

{28 kg/cm2} NO
• Engine at high
idling
6 YES Defective swing motor Replace
suction valve
Does control
From A valve spool move
smoothly?
Defective operation of Correct or
NO control valve spool replace

Table 1

Measuring condition Solenoid valve outlet pressure

9 sec after switching 0 MPa {0 kg/cm2}

lever to neutral position

When lever is operated Min. 3.13 MPa {Min. 32kg/cm2}

PC1800-6 20-829
TROUBLESHOOTING H-18

H-18. Swing speed is slow or swing acceleration is poor

★ When other work equipment and travel are normal.

(However, if there is travel deviation (deviation to right), carry out troubleshooting first for H-13 Machine
deviates naturally to one side during travel operations.
★ Carry out troubleshooting in the DH mode.

Cause Remedy

3 YES Defective swing Repair or

Is foreign material machinery replace
YES found in oil
2 drained from
swing machinery? Swing motor brake
Repair or
Is drain amount dragging or internal
NO replace
[Both left and right] from swing defect
motor normal

• 10 /min Excessive leakage inside Repair or

1 • Engine at high NO swing motor replace
Is swing speed slow idling
in both directions or
in one direction 5 YES
only? Adjust or
Defective safety valve
Is problem reversed replace
YES when left and right
4 safety valves are
interchanged?
Is output It is also possible to Go to A
[One direction only] pressure of PPC NO
measure relief oil
valve normal? pressure.
+2.45
• 28.4 0 MPa {290 +25 2
0 kg/cm }
• Engine at high idling
• Min. 2.74 MPa
Defective PPC valve Replace
{28 kg/cm2} NO
• Engine at high
idling
6 YES Defective swing motor Replace
suction valve
Does control
From A valve spool move
smoothly?
Defective operation of Replace
NO control valve spool

20-830 PC1800-6
TROUBLESHOOTING H-19

H-19. Excessive overrun when stopping swing

a. Both left and right

Cause Remedy
Excessive leakage inside swing motor Repair or replace

b. One direction only

Cause Remedy

2 YES
Defective PPC valve Replace
Is problem reversed
YES when left and right
PPC valve output
1 hoses are
interchanged? Defective swing motor Replace
Does swing spool
NO safety valve
of control valve
move smoothly?
Defective operation of Correct or
swing spool of control replace
NO valve

PC1800-6 20-831
TROUBLESHOOTING H-20, H-21

H-20. Excessive shock when stopping swing

★ When swing speed is normal.

Cause Remedy

3 YES Defective swing Repair

Is foreign material machinery
YES found in oil
2 drained from
swing machinery? Defective swing motor
Is oil pressure at Replace
[Both left and right]
swing brake NO brake
solenoid valve
1 outlet port normal?
Is shock excessive • See Table 1 Defective swing brake
in both left and right Replace
• Engine at high NO solenoid valve
directions or in one
direction only?
idling

[One direction only] Defective safety valve Replace

When the swing has been operated and
the lever is returned to the neutral
position, the oil pressure becomes 0 after
approx. 4 sec.
Table 1

Measuring condition Solenoid valve outlet pressure

9 sec after switching 0 MPa {0 kg/cm2}

lever to neutral position
When lever is Min. 3.13 MPa {Min. 32 kg/cm2}
operated

H-21. Excessive abnormal noise when stopping swing

Cause Remedy

Defective operation of
YES Clean
swing motor safety-
1 suction valve
Does condition
become normal
when swing motor YES Defective swing motor
safety-suction valve Replace
2 safety-suction valve
is cleaned?
Does condition
become normal
when swing motor
NO safety-suction valve 3 YES Defective swing Repair or
is replaced? Is foreign material machinery replace
found in oil
NO drained from
swing machinery? Defective back pressure Correct or
NO valve replace

20-832 PC1800-6
TROUBLESHOOTING H-22

H-22. Excessive hydraulic drift of swing

a. When swing holding brake is released

Cause Remedy

2 YES Defective swing motor

Replace
Is problem reversed safety valve
when left and right
[One direction only]
safety valves are
1 interchangedl?
Defective swing motor Correct or
Is hydraulic drift NO suction valve replace
excessive in both
left and right
directions or in one
direction only? 3 YES Defective control valve Replace
swing spool
Is drain amount
[Both left and right] from swing
motor normal?
Excessive leakage inside Repair or
• 25 /min NO swing replace
• Engine at high
idling
• At swing relief

b. When swing holding brake is applied

Cause Remedy

1 YES Defective operation of Repair or

Is output pressure swing holding brake replace
of swing holding
brake solenoid
valve norma?
Defective operation of
swing holding brake Correct or
• Min. 2.74 MPa NO
replace
{28 kg/cm2} solenoid valve
• When 9 seconds
has passed after
all swing and
work equipment
control levers
have been
returned to
neutral.
• Engine at high
idling

PC1800-6 20-833
 TROUBLESHOOTING OF WORK EQUIPMENT
AUTOMATIC CONTROL SYSTEM (W-MODE)
[LOADING SHOVEL]

METHOD OF USING TROUBLESHOOTING FLOWCHART......................................................................20-902

ABNORMALITY JUDGEMENT STANDARDS FOR SELF-DIAGNOSTIC SYSTEM...................................20-903
TROUBLESHOOTING ................................................................................................................................20-905
W-1. In arc digging mode (auto level digging switch OFF), horizontal digging or bucket angle
compensation is carried out ..................................................................................................................20-908
W-2. In horizontal digging mode, does not carry out horizontal digging......................................................20-909
W-3. In horizontal digging mode (bucket angle revise switch OFF), bucket angle compensation is
carried out .............................................................................................................................................20-916
W-4. In horizontal digging + bucket angle compensation mode, carries out horizontal digging
but does not carry out bucket angle compensation ..............................................................................20-917
W-5. In horizontal digging + bucket angle compensation mode, carries out bucket angle compensation
but does not carry out horizontal digging ..............................................................................................20-920
W-6. In horizontal digging + bucket angle compensation mode, does not carry out horizontal digging
or bucket angle compensation ..............................................................................................................20-922
W-7. Impossible to carry out horizontal digging or bucket angle compensation..........................................20-929

★ Precautions when carrying out troubleshooting

1. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
2. Always connect any disconnected connectors before going on to the next step.

PC1800-6 20-901
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING FLOWCHART

METHOD OF USING TROUBLESHOOTING FLOWCHART

Troubleshooting code number and problem
The title at the top of the troubleshooting chart gives the troubleshooting code number and the problem with
the machine.

General precautions
When carrying out troubleshooting for the problem, precautions that apply to all items are given at the top of
the page under the title and marked with ★.
The common precautions marked ★ at the top of the page are not given in the (box formed by a broken
line) on the left, but must always be followed when carrying out the check given in the on the right.

Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the model, component,
or problem. In such cases, the failure mode is further divided into sections marked with small letters (for
example, a), b)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the
flowchart.

Method of following troubleshooting chart

NOTE: The number written at the top right corner of the is an index number; it does not indicate the
order to follow.)
• To the left of the there is (box formed by a broken line). This contains the procedure and
conditions needed for inspection and measurement of the item in the . Before starting inspection
or measurement, always read the instructions for the procedure carefully, and make sure that you
understand them.
• Check or measure the item inside , and judge if the result is YES or NO. If the judgement values
in the are correct or the answer to the question inside the is YES, follow the YES line; if
the judgement value is not correct, or the answer to the question is NO, follow the NO line. Con-
tinue the troubleshooting for the next item in the same way.
Following the YES or NO lines according to the results of the inspection or measurement will lead
finally to the Cause and Remedy block. Check the cause and take the action given as the remedy.

Troubleshooting tools
Details of the tools needed for troubleshooting are given separately in the table of TOOLS FOR TESTING,
ADJUSTING, AND TROUBLESHOOTING.

<Example of troubleshooting>

E-20 Error code [E-70] [Excess current in fuel supply pump PCV1 system]
★ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Always connect any disconnected connectors before going on the next step.

Table 1 Table 2
PV1 (male) Resistance value CN7 (male) Resistance value
Between (1) and (2) 2.3 – 5.3 Ω Between (10) and (11) 2.3 – 5.3 Ω
Between (1)(2) and ground Min. 1 MΩ Between (10)(11) and ground Min. 1 MΩ

20-902 PC1800-6
 ABNORMALITY JUDGEMENT STANDARDS FOR
TROUBLESHOOTING SELF-DIAGNOSTIC SYSTEM

ABNORMALITY JUDGEMENT STANDARDS FOR

SELF-DIAGNOSTIC SYSTEM
1. Abnormality in power supply
When the input voltage drops by the battery voltage drop below 15V or rises beyond 36V owing to alternator
failure or power circuit harness failure, the protection circuit for the power circuit will be activated to cutoff
the power supply to the internal circuits of the control box and all LED go out.

2. Control box failure

When computer circuit inside the control box goes out of order, the green colored LED1 goes out and the
red colored LED2, LED3 and LED4 turn on.

3. Boom EPC solenoid circuit failure

When the boom EPC solenoid circuit shorts or disconnected, the solenoid current will be cutoff to zero and
the red colored LED2 only turns on.

4. Bucket EPC solenoid circuit failure

When the bucket EPC solenoid circuit shorts or disconnected, the solenoid current will be cutoff to zero and
the red colored LED3 only turns on.

5. Boom potentiometer circuit failure

When the input voltage for the potentiometer drops below 0.5V, or rises beyond 4.7V, the green colored
LED1 goes out, the red colored LED2 flashes and the red colored LED3 and LED4 turn on.
At this time, horizontal digging and bucket angle compensation are not carried out.

6. Arm potentiometer circuit failure

When the input voltage for the potentiometer drops below 0.5V, or rises beyond 4.7V, the green colored
LED1 turns off, the red colored LED3 flashes and the red colored LED2 and LED4 go out.
At this time, horizontal digging and bucket angle compensation are not carried out.

7. Arm-OUT oil pressure switch circuit failure

When the signal coming from the arm potentiometer changes toward the arm-OUT direction while the oil
pressure switch is off, the system determines that oil pressure switch circuit failure occurred and red-col-
ored LED2 flashes.
At this time, horizontal digging and bucket angle compensation are not carried out.

8. Boom RAISE and LOWER oil pressure switch circuits failures

When the signal coming from the boom potentiometer changes while the oil pressure switch is being turned
off, the system determines that oil pressure switch circuit failure occurred and red-colored LED3 flashes.
At this time, horizontal digging and bucket angle compensation are not carried out.

9. Arm-IN, bucket-CURL and bucket-DUMP oil pressure switches

When the signal coming from the arm potentiometer changes toward the arm-IN direction while the oil pres-
sure switch is off, the system determines that oil pressure switch circuit failure occurred and red-colored
LED4 flashes.
At this time, horizontal digging and bucket angle compensation are not carried out.

PC1800-6 20-903
TROUBLESHOOTING TROUBLESHOOTING

TROUBLESHOOTING
1. How to read the judgement table
This judgement table chart is a means to determine if the failure phenomenon occurring with the work
equipment automatic control system is of the electric circuit failure or of the hydraulic • mechanical circuit
failure, before starting the troubleshooting, then to go to the electric circuit troubleshooting (E-mode) or to
the hydraulic • mechanical circuit troubleshooting (H-mode).
When using this judgment table, check the self-diagnosis indications (by the four LED’s being installed on
the surface of the work controller) to determine which trouble shooting to be done.

Self-diagnosis indication checks

When the indication by the self-diagnosis and the ● in the judgement table coincide, → Go to E-mode or H-
mode shown on the R.H. end of the table.
When indication is not displayed by the self-diagnosis indication, → Go to "Is the failure indication dis-
played?"

Lamp indications
Normal
1 2 3 4
Green 1
Arc digging mode
Red 2
Horizontal digging mode
Horizontal digging mode + Bucket angle
compensation mode
Red 3
Arm-OUT oil pressure switch activated

Red 4 or Boom RAISE or LOWER oil pressure

switch activated
Arm-IN, bucket oil pressure switch
activated
Lamp indications
Circuit where failure is occurring
1 2 3 4

Work controller

Boom EPC solenoid valve

Bucket EPC solenoid valve

Boom potentiometer

Arm potentiometer

Arm-OUT oil pressure switch

Boom RAISE, LOWER oil pressure

switch
Arm-IN, bucket oil pressure switch

Turns on. Flashes. Goes out.

PC1800-6 20-905
TROUBLESHOOTING TROUBLESHOOTING

2. Judgement table

Self-diagnosis indication checks

Is the failure indication displayed?

Work Boom EPC Bucket EPC Boom Arm

Check equipment solenoid solenoid potentiometer potentiometer
controller circuit circuit circuit circuit
items circuit

Green Goes out. Green Goes out. Green Goes out. Green Goes out. Green Goes out.
Red Turns on. Red Turns on. Red Goes out. Red Flashes. Red Turns on.
Red Turns on. Red Goes out. Red Turns on. Red Turns on. Red Flashes.
Red Turns on. Red Goes out. Red Goes out. Red Turns on. Red Turns on.

Operating under the low idling run of the engine:

Checking
Failure modes conditions ★ If any other failure indication is displayed other than the marked
items in the chart below, complex failures are occurring.

Because the system is so structured that power supply to the controller is not turned on under
the arc digging mode, so if horizontal digging can be carried out under the arc digging mode,
Horizontal digging or bucket angle it means that the power supply to the controller is being turned on.
1 compensation is carried out under the arc
digging mode.

2 Horizontal digging cannot be made under the

horizontal digging mode.

3 Bucket angle compensation is also carried out

under the horizontal digging mode.

YES
Although horizontal digging can be carried out,
bucket angle compensation cannot be carried
4 out under the "horizontal digging + bucket NO
angle compensation" mode.

YES
Although bucket angle compensation can be
carried out, horizontal digging cannot be made
5
under the "horizontal digging + bucket angle
compensation" mode. NO

Neither horizontal digging nor bucket angle

compensation can be carried out under the
6
"horizontal digging + bucket angle
compensation" mode.

20-906 PC1800-6
TROUBLESHOOTING TROUBLESHOOTING

Self-diagnosis indication checks

Is the failure indication displayed? Are indications displayed normally? Trouble-

shooting
Arm-OUT Boom Arm-IN, Lamp does Horizontal "Horizontal Indication appearance while
oil pressure RAISE and bucket-CURL not turn on digging digging + the "horizontal digging mode"
switch LOWER oil and under the mode bucket angle or "horizontal digging +
circuit pressure bucket-DUMP arc digging compensation bucket angle compensation
switch oil pressure mode. mode" mode" is displayed
circuits switch circuits
Green Goes out. Green Goes out. Green Goes out. Green Goes out. Green Turns on. Green Flashes. If the LED3 If the LED2
(Red) turns on (Red) turns on
Red Flashes. Red Goes out. Red Goes out. Red Goes out. Red Goes out. Red Goes out. while the while the
Red Goes out. Red Flashes. Red Goes out. Red Goes out. Red Goes out. Red Goes out. boom-RAISE arm-OUT
lever is being lever is being
Red Goes out. Red Goes out. Red Flashes. Red Goes out. Red Goes out. Red Goes out. operated. operated.

YES Electric circuit

Is the failure failures
indication
displayed? Is the indication
displayed normally?
NO
Because the system is so structured that power supply to the controller is not turned on
under the arc digging mode, so if horizontal digging can be carried out under the arc digging
mode, it means that the power supply to the controller is being turned on.
W-1

YES
W-2 (a)
YES
W-7
NO W-2 (b)
NO

W-3

W-4 (a)
YES
W-7
W-4 (b)
NO

W-5 (a)
YES
W-7
W-5 (b)
NO

YES
W-6 (a)
YES
W-7
NO W-6 (b)
NO

PC1800-6 20-907
TROUBLESHOOTING W-1

W-1. In arc digging mode (auto level digging switch OFF), horizontal digging or
bucket angle compensation is carried out

Cause Remedy

Short circuit with power

2 YES source in wiring harness Repair or
Is voltage between between H03 (male) (4) replace
YES H03 (female) (4) and L01 (female) (1)
1 and machine Short circuit with power
normal? source in wiring harness Repair or
Is resistance between
C33 (male) (1) and • Max. 1 V NO between C33 (female) (2) replace
(2) as shown in Table • Disconnect H03. and H03 (female) (4)
1? • Turn starting switch ON.
• Turn auto level digging switch OFF. Defective auto level
• Turn starting
digging switch Replace
switch OFF. NO
• Disconnect C33.
• Operate auto level
digging switch.

Table 1
Switch operation Resistance
ON Max. 1 Ω
OFF Min. 1 MΩ

W-1 Related electrical circuit diagram

20-908 PC1800-6
TROUBLESHOOTING W-2

W-2. In horizontal digging mode, does not carry out horizontal digging

a. When self-diagnostic display is giving "abnormal display"

a)-(1) When self-diagnostic display lamp lights up (arc digging mode display)
★ Check that fuse 8 is normal.

Cause Remedy

3 YES
Defective work controller Replace
Is voltage between
YES L01 (female) (1) Defective contact or
2 and machine disconnection in wiring
normal? harness between L01 Repair or
Is voltage between
(female) (1) and H03 replace
YES H03 (female) (4) • 20 – 30 V NO (male) (4)
and machine • Same conditions
1 normal? Defective contact or
as Item 2. disconnection in wiring
Is resistance • 20 – 30 V harness between H03
between C33 (male) Repair or
• Turn starting NO (female) (4) – C33 (female) replace
(1) and (2) as shown (2) or between C33 (female)
in Table 1? switch ON.
• Turn auto level (1) – battery (+) terminal
• Disconnect C33. digging switch ON.
Defective auto level
• Operate auto level Replace
NO digging switch
digging switch.

Table 1
Switch operation Resistance
ON Max. 1 Ω
OFF Min. 1 MΩ

a)-(2) Abnormality in work controller

Cause Remedy

Defective work controller Replace

a)-(3) Abnormality in boom EPC solenoid system

Cause Remedy

2 YES
Defective work controller Replace
Is resistance between
YES L01 (female) (5) and Defective contact,
(6) normal and is it disconnection, or short circuit
1 insulated from
Is resistance with ground in wiring harness
machine? between B30 (female) (1) – Repair or
between B30 (male)
• Between (5) and (6): NO L01 (female) (5) or between replace
(1) and (2) normal 10 – 30 Ω
and is it insulated B30 (female) (2) – L01 (female)
• Between (5), (6) and machine: Min. 1 MΩ
from machine? (6)
• Turn starting switch OFF.
• Between (1) and (2): • Disconnect L01.
10 – 30 Ω Defective boom EPC valve Replace
• Between (1), (2) and
NO
machine: Min. 1 MΩ
• Turn starting switch
OFF.
• Disconnect B30.

PC1800-6 20-909
TROUBLESHOOTING W-2

a)-(4) Abnormality in boom potentiometer system

Cause Remedy

3 YES
Is voltage between Defective work controller Replace
L02 (2) and (3) as
YES shown in Table, and Defective contact or
2 does it change
smoothly when boom disconnection in wiring
Is voltage between is operated? harness between J05B Repair or
J05B (A) and (B) as
YES shown in Table, and • Start engine. NO (female) (B) and L02 (male) replace
does it change (2)
smoothly when boom
(3) is GND.
1 is operated? Defective boom
• Start engine. potentiometer or defective Adjust or
Is voltage between installation of boom replace
J05B (female) (A)
NO
potentiometer
and (C) as shown in
Defective contact or
Table?
disconnection in wiring harness
4 YES Repair or
• Disconnect J05. between J05B (female) (C) –
Is voltage between L02 (male) (1) or between replace
• Turn starting
L02 (female) (1) J05B (female) (A) – L02 (male)
switch ON. (3)
NO and (3) as shown in
Table?
Defective work controller Replace
• Disconnect L02. NO
• Turn starting
switch ON.

Table
J05 L02 Voltage (V)
(A) - (C) (1) - (3) 7.3 - 7.35
(A) - (B) (2) - (3) 0.5 - 4.7

20-910 PC1800-6
TROUBLESHOOTING W-2

a)-(5) Abnormality in arm potentiometer system

Cause Remedy

4 YES
Is voltage between Defective work controller Replace
L02 (5) and (6) as
YES shown in Table, and Defective contact or
3 does it change
smoothly when arm is disconnection in wiring
Is voltage between harness between J06A Repair or
J06A (A) and (B) as operated?
YES shown in Table, and NO (female) (2) and L02 (male) replace
• Start engine.
does it change (5)
2 smoothly when arm is
operated? Defective contact or
Is voltage between
J06C (A) and (B) as disconnection in wiring
YES • Start engine. Repair or
shown in Table, and harness between J06C
does it change NO (female) (B) and J06A (male)
replace
smoothly when arm is
operated? (2)
1 • Start engine. Defective arm potentiometer or
defective installation of arm Adjust or
Is voltage between NO potentiometer replace
J06C (female) (A)
Defective contact or
and (C) as shown in disconnection in wiring harness
Table? between J06C (female) (1) –
YES Repair or
J06A (male) (1) or between
• Disconnect J06C. 5 replace
J06C (female) (3) – J06A
• Turn starting (male) (3)
Is voltage between
switch ON. J06A (female) (1)
(Engine stopped) Defective contact or
NO and (3) as shown in 6 YES disconnection in wiring harness Repair or
Table? between J06A (female) (3) – replace
Is voltage between
L02 (male) (4) or between J06
• Disconnect J06A. L02 (female) (4)
(female) (1) – L02 (male) (6)
• Turn starting NO and (6) as shown in
switch ON. Table?
(Engine stopped) Defective work controller Replace
• Disconnect L02. NO
• Turn starting
switch ON.
(Engine stopped)
Table
F01 J06 L02 Voltage (V)
(1) - (3) (1) - (3) (4) - (6) 7.3 - 7.35
(1) - (2) (1) - (2) (5) - (6) 0.5 - 4.7

a)-(6) Abnormality in arm (OUT) oil pressure switch system

Cause Remedy

2 YES
Defective work controller Replace
Is resistance between
YES L02 (male) (10) and
1 machine as shown in Defective contact or
Table? disconnection in wiring
Is resistance between harness between B49 Repair or
B49 (male) (1) and • Turn starting NO (female) (2) and L02 replace
(2) as shown in switch OFF. (male) (10)
Table?
• Disconnect L02.
• Turn starting Defective arm bottom oil
pressure switch Replace
switch OFF. NO
• Disconnect B49.

Table
Arm lever at OUT Max. 10 Ω
Arm lever at neutral Min. 100 kΩ

PC1800-6 20-911
TROUBLESHOOTING W-2

a)-(7) Abnormality in boom (RAISE, LOWER) oil pressure switch system

Cause Remedy

2 YES
Defective work controller Replace
Is resistance between
YES L02 (male) (11) and
1 machine as shown in Defective contact or
Table? disconnection in wiring
Is resistance between harness between B44 Repair or
B44, B45 (male) (1) • Turn starting NO (female) (2), B45 (female) replace
and (2) as shown in switch OFF. (2) – L02 (male) (11)
Table?
• Disconnect L02.
Defective boom oil
• Turn starting pressure switch (B44, B45) Replace
switch OFF. NO
• Disconnect B44,
B45.

Table
Boom lever at RAISE or LOWER Max. 10 Ω
Boom lever at neutral Min. 100 kΩ

a)-(8) Abnormality in arm (IN) • bucket oil pressure switch system

Cause Remedy

2 YES
Defective work controller Replace
Is resistance between
YES L02 (male) (12) and Defective contact or
1 machine as shown in disconnection in wiring
Table? harness between B46
Is resistance between Repair or
(female) (2), B47 (female)
B46, B47, B48 (male) • Turn starting NO replace
(2), B48 (female) (2) – L01
(1) and (2) as shown switch OFF. (male) (12)
in Table? • Disconnect L02.
Defective arm IN, bucket
• Turn starting oil pressure switch (B46, Replace
switch OFF. NO B47, B48)
• Disconnect B46,
B47, B48.

Table
Arm lever at IN or bucket lever operated Max. 10 Ω
Levers at neutral Min. 100 kΩ

For the items marked , run the engine for approx. 10 seconds to charge the accumulator, then stop the engine
and carry out the check.

20-912 PC1800-6
TROUBLESHOOTING W-2

W-2 a)-(1), a)-(3) Related electrical circuit diagram

PC1800-6 20-913
TROUBLESHOOTING W-2

W-2 a)-(4), a)-(5), a)-(6), a)-(7) related electrical circuit diagram

20-914 PC1800-6
TROUBLESHOOTING W-2

b) When self-diagnostic display is giving "normal display"

Cause Remedy

YES Go to W-7 of Hydraulic

—
System
1
Does LED2 light 3 YES
up when lever is Defective work controller Replace
operated to arm Is resistance between
OUT?
YES L02 (male) (10) and
2 machine as shown in Defective contact or
• Start engine. Table? disconnection in wiring
Is resistance between harness between B49 Repair or
B49 (male) (1) and • Turn starting NO (female) (2) and L02 replace
NO (2) as shown in switch OFF.
Table?
(male) (10)
• Disconnect L02.

• Turn starting Defective arm bottom oil Replace

switch OFF. NO pressure switch
• Disconnect B49.

Table
Arm lever at OUT Max. 10 Ω
Arm lever at neutral Min. 100 kΩ

For the items marked , run the engine for approx. 10 seconds to charge the accumulator, then stop the engine
and carry out the check.

W-2 b) Related electrical circuit diagram

PC1800-6 20-915
TROUBLESHOOTING W-3

W-3. In horizontal digging mode (bucket angle revise switch OFF), bucket angle com-
pensation is carried out

Cause Remedy

2 YES
Defective work controller Replace
Is voltage between
YES H03 (female) (3)
1 and machine as Short circuit with power
shown in Table?
Is voltage between source in wiring harness Repair or
C34 (2) and • Disconnect H03. NO between C34 (female) (2) replace
machine as shown • Turn starting switch ON. and H03 (female) (3)
in Table? • Turn bucket angle revise switch OFF.

• Turn starting Defective bucket angle

revise switch Replace
switch ON. NO
• Turn bucket angle
revise switch OFF.

Table

Bucket angle ON 24 V
revise switch OFF 0V

W-3 Related electrical circuit diagram

20-916 PC1800-6
TROUBLESHOOTING W-4

W-4. In horizontal digging + bucket angle compensation mode, carries out horizontal
digging but does not carry out bucket angle compensation

a. When self-diagnostic display is giving "abnormal display"

a)-(1) Auto level digging mode display

• Auto level digging switch ON.

Cause Remedy

3 YES
Defective work controller Replace
Is voltage between
YES L01 (female) (3) Defective contact or
2 and machine as disconnection in wiring
shown in Table? harness between H03 Repair or
Is voltage between
YES H03 (female) (3) (male) (3) and L01 replace
• Disconnect L01. NO
and machine as (female) (3)
1 • Turn starting switch ON. (Engine stopped)
shown in Table? • Turn bucket angle revise switch ON. Defective contact or
Is voltage disconnection in wiring
• Disconnect H03. harness between C34 (female) Repair or
between C34 (2)
• Turn starting NO (2) – H03 (female) (3) or replace
and machine as
switch ON. (Engine between C34 (female) (1) –
shown in Table?
stopped). battery (+) terminal
• Turn starting • Turn bucket angle revise switch ON.
switch ON. Defective bucket angle Replace
• Turn bucket angle
NO revise switch
revise switch ON.

Table

Bucket angle ON Approx. 24 V

revise switch OFF 0V

a)-(2) Abnormality in boom EPC solenoid system

Cause Remedy

2 YES
Defective work controller Replace
Is resistance between
YES L01 (female) (7) and Defective contact or
(8) normal and is it disconnection in wiring
1 insulated from
Is resistance machine? harness between B31
(female) (1) and L01 (female) Repair or
between B31 (male)
• Between (7) and (8): NO (7) or between B31 (female) replace
(1) and (2) normal
10 – 30 Ω (2) and L01 (female) (8)
and is it insulated
• Between (7), (8) and machine: Min. 1 MΩ
from machine?
• Turn starting switch OFF.
• Between (1) and • Disconnect L01. Defective bucket EPC
(2): 10 – 30 Ω solenoid valve Replace
NO
• Between (1), (2)
and machine:
Min. 1 MΩ
• Turn starting
switch OFF.
• Disconnect B31.

PC1800-6 20-917
TROUBLESHOOTING W-4

b. When self-diagnostic display is giving "normal display"

Cause Remedy

YES Go to W-7 of Hydraulic

—
System
1
Does LED3 light 3 YES
up when lever is Defective work controller Replace
operated to boom Is resistance between
RAISE?
YES L02 (male) (11) and
2 machine as shown in Defective contact or
• Start engine. Table? disconnection in wiring
• Operate boom Is resistance between harness between B44 Repair or
B44, B45 (male) (1) • Turn starting NO replace
RAISE when arm (female) (2), B45 (female)
and (2) as shown in switch OFF.
top pin height is NO Table? (2) – L02 (male) (11)
• Disconnect L02.
more than 5.8 m. Defective boom RAISE,
• Turn starting LOWER oil pressure Replace
switch OFF. NO switch
• Disconnect B44,
B45.

Table
Boom lever operated Max. 10 Ω
Boom lever at neutral Min. 100 kΩ

For the items marked , run the engine for approx. 10 seconds to charge the accumulator, then stop the engine
and carry out the check.

20-918 PC1800-6
TROUBLESHOOTING W-4

W-4 Related electrical circuit diagram

PC1800-6 20-919
TROUBLESHOOTING W-5

W-5. In horizontal digging + bucket angle compensation mode, carries out bucket
angle compensation but does not carry out horizontal digging

a. When self-diagnostic display is giving "abnormal display"

Cause Remedy

2 YES
Defective work controller Replace
Is resistance between
YES L01 (female) (5) and Defective contact or
(6) normal and is it disconnection in wiring
1 insulated from
Is resistance between machine? harness between B30
(female) (1) – L01 (female) Repair or
B30 (male) (1) and
• Between (5) and (6): NO (5) or between B30 (female) replace
(2) normal and is it 10 – 30 Ω.
insulated from (2) – L01 (female) (6)
• Between (5), (6) and machine: Min. 1 MΩ
machine? • Turn starting switch OFF.
• Between (1) and • Disconnect L01. Defective boom EPC
Replace
(2): 10 – 30 Ω. NO solenoid valve
• Between (1), (2)
and machine:
Min. 1 MΩ.
• Turn starting
switch OFF.
• Disconnect B30.

b. When self-diagnostic display is giving "normal display"

Cause Remedy

YES
Defective work controller Replace

1
Does LED2 light 3 YES
up when lever is Defective work controller Replace
operated to arm Is resistance between
OUT?
YES L02 (male) (10) and
2 machine as shown in Defective contact or
• Start engine. Table? disconnection in wiring
Is resistance between harness between B49 Repair or
B49 (male) (1) and • Turn starting NO (female) (2) and L02 replace
NO (2) as shown in switch OFF.
Table?
(male) (10)
• Disconnect L02.

• Turn starting Defective arm OUT oil Replace

switch OFF. NO pressure switch
• Disconnect B49.

Table
Arm lever at OUT Max. 10 Ω
Arm lever at neutral Min. 100 kΩ

For the items marked , run the engine for approx. 10 seconds to charge the accumulator, then stop the engine
and carry out the check.

20-920 PC1800-6
TROUBLESHOOTING W-5

W-5 Related electrical circuit diagram

PC1800-6 20-921
TROUBLESHOOTING W-6

W-6. In horizontal digging + bucket angle compensation mode, does not carry out
horizontal digging or bucket angle compensation
a) When self-diagnostic display is giving "abnormal display"
a)-(1) When self-diagnostic display does not light up

Cause Remedy

3 YES
Defective work controller Replace
Is voltage between
YES L01 (female) (1) Defective contact or
2 and machine as disconnection in wiring
shown in Table? harness between H03 Repair or
Is voltage between
(male) (4) and L01 replace
YES H03 (female) (4) • Turn starting NO (female) (1)
and machine as switch ON.
1 shown in Table? Defective contact,
(Engine stopped) disconnection, or short circuit
Is resistance • Turn starting with ground in wiring harness
between C33 (male) Repair or
switch ON. between C33 (female) (2) –
(1), (2) – machine as NO H03 (female) (4) or between replace
shown in Table? (Engine stopped) C33 (female) (1) – battery (+)
terminal
• Turn starting
switch ON. Defective auto level Replace
NO Table digging switch

Auto level ON Approx. 24 V

digging switch OFF 0V

a)-(2) Abnormality in work controller

Defective work controller Replace

a)-(3) Abnormality in boom EPC solenoid system

2 YES
Defective work controller Replace
Is resistance between
YES L01 (female) (5) and Defective contact,
(6) normal and is it
1 insulated from disconnection, or short circuit
Is resistance machine? with ground in wiring harness
between B30 (female) (1) – Repair or
between B30 (male)
• Between (5) and (6): NO L01 (female) (5) or between replace
(1) and (2) normal 10 – 30 Ω
and is it insulated B30 (female) (2) – L01 (female)
• Between (5), (6) and machine: Min. 1 MΩ (6)
from machine? • Turn starting switch OFF.
• Between (1) and • Disconnect L01.
Defective boom EPC valve Replace
(2): 10 – 30 Ω NO
• Between (1), (2) and
machine: Min. 1 MΩ
• Turn starting switch OFF.
• Disconnect B30.

a)-(4) Abnormality in bucket EPC solenoid system

2 YES
Defective work controller Replace
Is resistance between
YES L01 (female) (7) and Defective contact or
(8) normal and is it disconnection in wiring
1 insulated from
Is resistance machine? harness between B31
(female) (1) and L01 (female) Repair or
between B31 (male)
• Between (7) and (8): NO (7) or between B31 (female) replace
(1) and (2) normal 10 – 30 Ω
and is it insulated (2) and L01 (female) (8)
• Between (7), (8) and machine: Min. 1 MΩ
from machine? • Turn starting switch OFF.
• Between (1) and • Disconnect L01. Defective bucket EPC
(2): 10 – 30 Ω solenoid valve Replace
NO
• Between (1), (2) and
machine: Min. 1 MΩ
• Turn starting switch OFF.
• Disconnect B31.

20-922 PC1800-6
TROUBLESHOOTING W-6

a)-(5) Abnormality in boom potentiometer system

Cause Remedy

3 YES
Is voltage between Defective work controller Replace
L02 (2) and (3) as
YES shown in Table, and Defective contact or
2 does it change
smoothly when boom disconnection in wiring
Is voltage between is operated? harness between J05B Repair or
J05B (A) and (B) as
YES shown in Table, and • Start engine. NO (female) (B) and L02 (male) replace
does it change (2)
smoothly when boom
1 is operated? Defective boom
• Start engine. potentiometer or defective Adjust or
Is voltage between installation of boom replace
J05A (female) (A)
NO
potentiometer
and (C) as shown in
Defective contact or
Table?
disconnection in wiring harness
4 YES Repair or
• Disconnect J05A. between J05B (female) (C) –
Is voltage between L02 (male) (1) or between replace
• Turn starting
L02 (female) (1) J05B (female) (A) – L02 (male)
switch ON. (3)
NO and (3) as shown in
Table?
Defective work controller Replace
• Disconnect L02. NO
• Turn starting
switch ON.

Table
J05 L02 Voltage (V)
(A) - (C) (1) - (3) 7.3 - 7.35
(A) - (B) (2) - (3) 0.5 - 4.7

PC1800-6 20-923
TROUBLESHOOTING W-6

a)-(6) Abnormality in arm potentiometer system

Cause Remedy

4 YES
Is voltage between Defective work controller Replace
L02 (5) and (6) as
YES shown in Table, and Defective contact or
3 does it change
smoothly when arm is disconnection in wiring
Is voltage between harness between J06A Repair or
J06A (1) and (2) as operated?
YES shown in Table, and NO (female) (2) and L02 (male) replace
• Start engine.
does it change (5)
2 smoothly when arm is
Is voltage between operated? Defective contact or
J06C (A) and (B) as • Start engine. disconnection in wiring Repair or
YES shown in Table, and harness between J06C
does it change NO replace
smoothly when arm is (female) (B) and J06A (male)
operated? (2)
1 • Start engine. Defective arm potentiometer or
defective installation of arm Adjust or
Is voltage between NO potentiometer replace
J06C (female) (A)
Defective contact or
and (C) as shown in disconnection in wiring harness
Table? between J06C (female) (1) –
YES Repair or
J06A (male) (1) or between
• Disconnect J06C. 5 J06C (female) (3) – J06A replace
• Turn starting (male) (3)
Is voltage between
switch ON. J06A (female) (1) Defective contact or
NO and (3) as shown in 6 YES disconnection in wiring harness Repair or
Table? between J06A (female) (3) – replace
Is voltage between
L02 (male) (4) or between
• Disconnect J06A. L02 (female) (4) J06A (female) (1) – L02 (male)
• Turn starting NO and (6) as shown in (6)
switch ON. Table?
Defective work controller Replace
• Disconnect L02. NO
• Turn starting
switch ON.

Table
J06C J06A L02 Voltage (V)
(A) - (C) (1) - (3) (4) - (6) 7.3 - 7.35
(A) - (B) (1) - (2) (5) - (6) 0.5 - 4.7

20-924 PC1800-6
TROUBLESHOOTING W-6

a)-(7) Abnormality in arm (OUT) oil pressure switch system

Cause Remedy

2 YES
Defective work controller Replace
Is resistance between
YES L02 (male) (10) and
1 machine as shown in Defective contact or
Table? disconnection in wiring
Is resistance between harness between B49 Repair or
B49 (male) (1) and • Turn starting NO (female) (2) and L02 replace
(2) as shown in switch OFF. (male) (10)
Table?
• Disconnect L02.
• Turn starting Defective arm bottom oil
pressure switch Replace
switch OFF. NO
• Disconnect B49.

Table
Arm lever at OUT Max. 10 Ω
Arm lever at neutral Min. 100 kΩ

a)-(8) Abnormality in boom (RAISE, LOWER) oil pressure switch system

Cause Remedy

2 YES
Defective work controller Replace
Is resistance between
YES L02 (male) (11) and
1 machine as shown in Defective contact or
Table? disconnection in wiring
Is resistance between harness between B44 Repair or
B44, B45 (male) (1) • Turn starting NO (female) (2), B45 (female) replace
and (2) as shown in switch OFF. (2) – L02 (male) (11)
Table?
• Disconnect L02.
Defective boom oil
• Turn starting pressure switch (B44, B45) Replace
switch OFF. NO
• Disconnect B44,
B45.

Table
Boom lever at RAISE or LOWER Max. 10 Ω
Boom lever at neutral Min. 100 kΩ

PC1800-6 20-925
TROUBLESHOOTING W-6

a)-(9) Abnormality in arm (IN) oil pressure switch system

Cause Remedy

2 YES
Defective work controller Replace
Is resistance between
YES L02 (male) (12) and Defective contact or
1 machine as shown in disconnection in wiring
Table? harness between B46
Is resistance between Repair or
(female) (2), B47 (female)
B46, B47, B48 (male) • Turn starting NO replace
(2), B48 (female) (2) – L01
(1) and (2) as shown switch OFF.
in Table?
(male) (12)
• Disconnect L02.
Defective arm IN, bucket
• Turn starting oil pressure switch (B46, Replace
switch OFF. NO B47, B48)
• Disconnect B46,
B47, B48.

Table
Arm lever at IN or bucket lever operated Max. 10 Ω
Levers at neutral Min. 100 kΩ

For the items marked , run the engine for approx. 10 seconds to charge the accumulator, then stop the engine
and carry out the check.

20-926 PC1800-6
TROUBLESHOOTING W-6

W-6 a)-(1), a)-(3), a)-(4) Related electrical circuit diagram

PC1800-6 20-927
TROUBLESHOOTING W-6

W-6 a)-(5), a)-(6), a)-(7), a)-(8), a)-(9) Related electrical circuit diagram

20-928 PC1800-6
TROUBLESHOOTING W-7

W-7. Impossible to carry out horizontal digging or bucket angle compensation

★ Carry out after confirming that all the items for W Mode (Troubleshooting of Electrical System) are normal.

Cause Remedy

2 YES Defective operation of Repair or

Is outlet pressure of shuttle valve replace
bottom open priority
YES shuttle valve normal
1 and does spool move
lightly when operated
Is outlet pressure of by hand? Defective bottom open
EPC valve normal Replace
•
+0.5
2.9 –0.3 MPa NO priority shuttle valve
and does spool move
lightly when operated {30 +5 2
–3 kg/cm }
by hand?
+0.5 Defective operation of EPC
• 2.9 –0.3 MPa Repair or
{30 +5 2 NO valve spool replace
–3 kg/cm }

PC1800-6 20-929
 30 DISASSEMBLY AND
ASSEMBLY

METHOD OF USING MANUAL.......................30- 3 REMOVAL AND INSTALLATION OF

PRECAUTIONS WHEN CARRYING OUT REVOLVING FRAME ASSEMBLY ............ 30-39
OPERATION ..............................................30- 5 REMOVAL AND INSTALLATION OF
SPECIAL TOOL LIST ......................................30- 7 SWING CIRCLE ASSEMBLY .................... 30-40
SKETCHES OF SPECIAL TOOLS...............30-9- 1 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY ............ 30-41
FUEL SUPPLY PUMP ............................30-9- 4 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY ............ 30-42
FUEL INJECTOR ASSEMBLY................30-9- 7 REMOVAL AND INSTALLATION OF IDLER
REMOVAL AND INSTALLATION OF CUSHION CYLINDER ASSEMBLY ........... 30-50
NOZZLE TIP ...........................................30-9-10 DISASSEMBLY AND ASSEMBLY OF IDLER
REMOVAL AND INSTALLATION OF CUSHION CYLINDER ASSEMBLY ........... 30-51
ENGINE FRONT SEAL...........................30-9-12 DISASSEMBLY AND ASSEMBLY OF IDLER
REMOVAL AND INSTALLATION OF ADJUSTMENT CYLINDER ASSEMBLY ... 30-52
ENGINE REAR SEAL .............................30-9-14 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY ....................... 30-53
CYLINDER HEAD ASSEMBLY...............30-9-19 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF FRONT IDLER ASSEMBLY ...................... 30-55
FUEL COOLER ASSEMBLY .....................30-10 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY .................................... 30-56
AFTERCOOLER ASSEMBLY ....................30- 11 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY ............... 30-58
HYDRAULIC OIL COOLER ASSEMBLY ...30-12 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY ............... 30-59
RADIATOR ASSEMBLY ............................30-13 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY ................... 30-61
FUEL TANK ASSEMBLY ...........................30-14 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF ENGINE, TRACK ROLLER ASSEMBLY................... 30-62
PTO, HYDRAULIC PUMP ASSEMBLY......30-16 REMOVAL AND INSTALLATION OF CONTROL •
REMOVAL AND INSTALLATION OF PTO PTO LUBRICATION PUMP ASSEMBLY ... 30-64
ASSEMBLY ................................................30-20 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF PTO SWING PUMP ASSEMBLY ....................... 30-65
ASSEMBLY ................................................30-23 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF NO. 1, 3 PUMP ASSEMBLY ...................... 30-66
CENTER SWIVEL JOINT ASSEMBLY ......30-26 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF NO. 2, 4 PUMP ASSEMBLY ...................... 30-67
CENTER SWIVEL JOINT ASSEMBLY ......30-27 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY ............... 30-68
TRAVEL MOTOR ASSEMBLY ...................30-28 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF TRAVEL PILOT RELIEF VALVE ASSEMBLY........... 30-69
MOTOR BRAKE VALVE ASSEMBLY ........30-29 DISASSEMBLY AND ASSEMBLY OF
DISASSEMBLY AND ASSEMBLY OF PILOT RELIEF VALVE ASSEMBLY........... 30-70
FINAL DRIVE ASSEMBLY .........................30-30 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF MAIN RELIEF VALVE ASSEMBLY
SWING MOTOR ASSEMBLY.....................30-38 (FOR SWING)............................................ 30-71

PC1800-6 30-1
(6)
DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF

MAIN RELIEF VALVE ASSEMBLY ARM CYLINDER ASSEMBLY ....................30-92
(FOR WORK EQUIPMENT, TRAVEL) ...... 30-72 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY..............30-93
SWING CONTROL VALVE ASSEMBLY.... 30-73 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF BUCKET CYLINDER ASSEMBLY..............30-94
SWING CONTROL VALVE ASSEMBLY.... 30-74 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF BOTTOM DUMP CYLINDER ASSEMBLY .30-95
CONTROL VALVE ASSEMBLY ................. 30-76 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF HYDRAULIC CYLINDER ASSEMBLY .... 30- 97
CO, NC VALVE ASSEMBLY ...................... 30-80 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF HYDRAULIC CYLINDER ASSEMBLY .... 30-104
SERVO VALVE ASSEMBLY ...................... 30-81 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY............................... 30-108
TVC VALVE ASSEMBLY ........................... 30-82 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY............................... 30-109
PPC VALVE ASSEMBLY (FOR TRAVEL) . 30-83 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF ARM ASSEMBLY ..................................... 30-111
PPC VALVE ASSEMBLY (FOR TRAVEL) . 30-84 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF ARM ASSEMBLY ..................................... 30-112
PPC VALVE ASSEMBLY REMOVAL AND INSTALLATION OF
(FOR WORK EQUIPMENT, SWING) ........ 30-85 BOOM ASSEMBLY .................................. 30-114
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF
PPC VALVE ASSEMBLY BOOM ASSEMBLY .................................. 30-116
(FOR WORK EQUIPMENT, SWING) ........ 30-86 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY ............. 30-118
BOOM CYLINDER ASSEMBLY ................ 30-87 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY .............. 30-119
BOOM CYLINDER ASSEMBLY ................ 30-89 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF VHMS CONTROLLER ............................. 30-120
ARM CYLINDER ASSEMBLY ................... 30-91

30-2 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1 When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
2 Any special techniques applying only to the installation procedure are marked , and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation proce-
dure it applies to.

(Example)
REMOVAL .....................................................................Title of operation
k ................................................................................Precautions related to safety when carrying out the
operation
1. X X X X (1) ..............................................................Step in operation
★ .............................................................................Technique or important point to remember when
removing XXXX (1).
2. (2):.......................................................... Indicates that a technique is listed for use dur-
ing installation
3. assembly (3)

6 ......................................................................Quantity of oil or water drained

INSTALLATION..............................................................Title of operation
• Carry out installation in the reverse order to removal.
.........................................................................Technique used during installation
★ .............................................................................Technique or important point to remember when
installing (2)
• Adding water, oil ...............................................Step in operation
★.......................................................................Point to remember when adding water or oil

5 ..................................................................Quantity when filling with oil and water

2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.

3. Listing of special tools

1 For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.

PC1800-6 30-3
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

4. General tightening torque table (when using torque wrench)

★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the
table below.

Thread diameter Width across flats

SAD00481 SAD00482

mm mm kgm Nm
6 10 1.35 ± 0.15 13.2 ± 1.4
8 13 3.2 ± 0.3 31.4 ± 2.9
10 17 6.7 ± 0.7 65.7 ± 6.8
12 19 11.5 ± 1.0 112 ± 9.8
14 22 18.0 ± 2.0 177 ± 19
16 24 28.5 ± 3 279 ± 29
18 27 39 ± 4 383 ± 39
20 30 56 ± 6 549 ± 58
22 32 76 ± 8 745 ± 78
24 36 94.5 ± 10 927 ± 98
27 41 135 ± 15 1320 ± 140
30 46 175 ± 20 1720 ± 190
33 50 225 ± 25 2210 ± 240
36 55 280 ± 30 2750 ± 290
39 60 335 ± 35 3280 ± 340

Seal surface

5. Table of tightening torques for flared nuts SAD00483

★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table be-
low.
Thread diameter Width across flats Tightening torque
mm mm kgm Nm
14 19 2.5 ± 0.5 24.5 ± 4.9
18 24 5±2 49 ± 19.6
22 27 8±2 78.5 ± 19.6
24 32 14 ± 3 137.3 ± 29.4
30 36 18 ± 3 176.5 ± 29.4
33 41 20 ± 5 196.1 ± 49
36 46 25 ± 5 245.2 ± 49
42 55 30 ± 5 294.2 ± 49

6. Table of tightening torques for split flange bolts

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats Tightening torque
mm mm kgm Nm
10 14 6.7 ± 0.7 65.7 ± 6.8
12 17 11.5 ± 1 112 ± 9.8
16 22 28.5 ± 3 279 ± 29

30-4 PC1800-6
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
★ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes

Nominal number Plug (nut end) Nut (elbow end)

02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628

2) Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.

Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
Taper 1/8
12 07049-01215 12 10 15
øD

ød

14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22 L
20 07049-02025 20 17 25
DEW00401
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34

PC1800-6 30-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

30-6 PC1800-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

SPECIAL TOOL LIST

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity :t .......... Cannot be substituted, must always be installed (used)
:q .......... Extremely useful if available or can be substituted with commercially available
part
a New/Remodel :N............ Tools with new part numbers, newly developed for this model
:R............ Tools with upgraded part numbers, remodeled from items already available for
other models
:Blank: ... Tools already available for other models, can be used without any modification

a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Nature of work Part No. Part Name Nature of work, remarks

795-471-1700 Remover t 1
Removal and installation of 795-471-1520 • Block 1
A Pulling out of drive gear
fuel supply pump assembly 795-471-1530 • Bolt 1
01435-01085 • Bolt 2
Removal and installation of
B 795T-471-1550 Wrench t 1 Q Fixing of injector assembly
nozzle tip
795-521-1110 Push tool t 1
Removal and installation of 790-101-5221 Grip t 1
C Press fitting of oil seal
engine front seal 01010-51225 Bolt t 1
01050-31640 Bolt t 3
1 795-931-1100 Seal puller t 1 Pulling out of oil seal
795-521-1131 Push tool t 1
790-101-5421 Grip t 1 Press fitting of oil seal
2
01010-51240 Bolt t 1 (Standard type)
Removal and installation of 01050-31625 Bolt t 3
D
engine front seal 795-931-1210 Sleeve jig t 1
795-931-1220 Sleeve jig t 1 Press fitting of oil seal
3
01050-31625 Bolt t 3 (Sleeve type)
01050-31645 Bolt t 3
4 790-331-1110 Wrench q 1 Tightening of flywheel bolt
Removal and installation of Tightening of cylinder head
E 790-331-1110 Wrench q 1
cylinder head assembly bolt
Engine • PTO • hydraulic
pump assembly

Control • PTO • lubrication

pump assembly
Removal, installation of
A 769-770-1301 Oil stopper t 1
hydraulic pump
Swing pump assembly

No. 1, 3 pump assembly

No. 2, 4 pump assembly

1 790-501-5000 Unit repair stand t 1
A 2 790-901-2110 Bracket t 1
Travel motor assembly Disassembly and assembly
3 790-901-1440 Plate t 1
B 799-301-1500 Oil leak tester t 1

PC1800-6 30-7
(6)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Nature of work Part No. Part Name Nature of work, remarks

C 796-720-3500 Wrench t 1
1 796-730-2120 Screwdriver t 1 Disassembly and assembly
Travel motor assembly
D 2 796-720-2220 Wrench t 1
3 795-630-1810 Torque wrench t 1 Assembly
790-450-1200 Remover t 1
Puller
2 790-101-2102 t 1 Removal of shaft
Final drive assembly A (294 kN {30 ton})
3 790-101-1102 Pump t 1
791-585-1510 Installer t 1 Installation of floating seal
1 790-501-5000 Unit repair stand t 1
A 2 790-901-2110 Bracket t 1
3 790-901-1440 Plate t 1
B 799-301-1500 Oil leak tester t 1
Assembly
C 796-720-3500 Wrench t 1
1 796-730-2120 Screwdriver t 1
Swing motor assembly D 2 796-720-2220 Wrench t 1
3 795-630-1810 Torque wrench t 1
790-501-5000 Unit repair stand t 1
A 1 790-901-2110 Bracket t 1
2 790-901-1470 Plate t 1 Disassembly
1 796-730-2120 Screwdriver t 1
B
2 796-720-2220 Wrench t 1
790-101-5621 Plate t 1
Swing machinery 1 790-101-5641 Grip t 1 Press fitting of oil seal
F
assembly 01010-51240 Bolt t 1
2 796T-626-1120 Push tool t 1 Q Press fitting of bearing
790-401-1700 Lifting tool t 1 Removal and installation of
Track roller assembly A
1 790-434-1021 Adapter t 1 track roller assembly
1 790-434-1501 Remover t 1
Cylinder (1,471 Removal and installation of
Track shoe assembly A 2 790-101-4300 t 1
kN {150 ton}) master pin
3 790-101-1102 Pump t 1
790-501-5000 Unit repair stand t 1
1 790-901-2110 Bracket t 1
A Disassembly and assembly
2 790-901-1331 Plate t 1
3 796-720-1020 Plate t 1
Guide (Rocker
1 790-445-2900 t 1
cam angle: Min.)
Hydraulic pump B Guide
assembly 2 790-445-2800 (Rocker cam t 1
angle: Max.)
1 795-630-1803 Torque wrench set t 1 Assembly
C 2 796-720-2220 Socket t 1
3 796-730-2120 Screwdriver t 1
795-630-1803 Torque wrench set t 1
D
796-720-2220 Socket t 1

30-8 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Nature of work Part No. Part Name Nature of work, remarks

Cylinder repair Disassembly, assembly of

1 790-502-1003 t 1
stand hydraulic cylinder
2 790-720-1000 Expander t 1 Installation of piston ring
796-720-1690 Ring t 1 Compression of piston ring
07281-02169 Clamp t 1 (Bucket cylinder)
3
796-720-1710 Ring t 1 Compression of piston ring
07281-02909 Clamp t 1 (Boom and arm cylinders)
790-201-1701 Push tool kit t 1 Press fitting of roll bushing
790-201-1881 Push tool t 1
790-101-5021 Grip t 1 Bucket cylinder
01010-50816 Bolt t 1
791-863-1110 Push tool t 1
4
790-101-5421 Grip t 1 Arm cylinder
Hydraulic cylinder assembly U 01010-51240 Bolt t 1
792-725-1300 Push tool t 1
790-101-5421 Grip t 1 Boom cylinder
01010-51240 Bolt t 1
790-201-1500 Push tool kit t 1 Press fitting of dust seal
790-201-1690 Plate t 1
790-101-5021 Grip t 1 Bucket cylinder
01010-51240 Bolt t 1
792-715-1400 Plate t 1
5
790-101-5421 Grip t 1 Arm cylinder
01010-51240 Bolt t 1
792-725-1500 Plate t 1
790-101-5421 Grip t 1 Boom cylinder
01010-51240 Bolt t 1
796T-870-1150 Sleeve t 1 Q
796T-870-1170 Sleeve t 1 Q
796-870-1180 Adapter t 1
796T-870-1190 Plate t 1 Q
796-900-1230 Screw t 1
Arm assembly V Pulling out of boom top pin
01582-33024 Nut t 1
01643-33080 Washer t 1
Puller (1,471 kN
790-101-4000 t 1
{150 ton})
790-101-1102 Pump t 1
799-703-1200 Service tool kit t 1
Vacuum pump
799-703-1100 t 1
(100 V)
Devices related to air condi- Vacuum pump Filling with air conditioner
X 799-703-1110 t 1
tioner (220 V) gas (R134a)
Vacuum pump
799-703-1120 t 1
(240 V)
799-703-1401 Gas leak detector t 1

PC1800-6 30-9
(6)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

B Wrench

F2 Push tool

30-9-1 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

V Sleeve

V Sleeve

PC1800-6 30-9-2
(6)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

V Plate

30-9-3 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP

REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP

SPECIAL TOOLS

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

795-471-1700 Remover t 1
795-471-1520 • Block 1
A
795-471-1530 • Bolt 1
01435-01085 • Bolt 2

REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery. 9. Remove cover (20) on the timing gear case
side.
1. Close the fuel valve and release the residual
pressure in the fuel system. For details, see
TESTING AND ADJUSTING, Releasing residual
pressure in fuel system.

2. Disconnect fuel tubes (1) and (2) and remove

fuel filter assembly (3).

3. Disconnect tubes (4) and (5) and remove corro-

sion filter assembly (6).

4. Remove fuel tubes (1) and (2) disconnected in

step 2.
10. Remove nut (23) and washer (24).
a Take care not to drop the nut and washer
into the engine.

5. Disconnect fuel supply pump wiring connectors

PCV1 (7) and PCV2 (8) and engine G speed
sensor wiring connector (9).

6. Remove fuel hoses (10) and (11) and clamp

(12), and then remove fuel tube (13) and lubrica-
tion tube (14).

7. Remove tube clamps (15) and (16), and then

remove fuel high-pressure tubes (17) and (18).

8. Remove bracket (19).

PC1800-6 30-9-4
(6)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP

11. Set tool A. INSTALLATION

• Carry out installation in the reverse order to
removal.

3 Joint bolt fuel tubes (1) and (2):

14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Supply pump side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm}

3 Joint bolt of fuel hose (10):

(Filter side)

14.8 – 19.6 Nm {1.5 – 2.0 kgm}

3 Joint bolt of fuel tube (13):

(Supply pump side)

12. Remove the 4 mounting bolts. Using tool A, 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
remove fuel supply pump assembly (30). (Supply pump side)
a Take care not to drop key (31). 17.7 – 22.6 Nm {1.8 – 2.3 kgm}
a Do not remove tool A until the fuel supply (Block side)
pump assembly is installed again. (If tool A

3 Joint bolt of tubes (4) and (5):

is removed, engagement of the idler gear
and fuel supply pump drive gear may
change.) 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

3 Joint bolt of lubrication tube (14):

7.9 – 12.7 Nm {0.8 – 1.3 kgm}
(Supply pump side)
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
(Cylinder block side)

3 Mounting bolt of clamp (12):

9.8 ± 1 Nm {1.0 ± 0.1 kgm}

30-9-5 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP

3 Mounting nut of fuel supply pump drive

gear: 176 – 196 Nm {18 – 20 kgm}

• Procedure for fuel supply pump and tube

1. Install supply pump (30), bracket (29), and
high-pressure tubes (26) and (27) and
tighten the mounting bolts/nuts with your fin-
gers.

2. Tighten the sleeve nuts of high-pressure

3 Slotted nut:
tubes (26) and (27) permanently.

39.2 – 58.8 Nm {4 – 6 kgm}

(Common rail side)
39.2 – 49 Nm {4 – 5 kgm}
(Supply pump side)

3. Tighten the mounting bolts of supply pump

(30) permanently.
a Apply LOCTITE to the mounting bolts.

4. Tighten the mounting bolts of bracket (29)

permanently.

5. Install high-pressure tube clamps (31), (32),

and (33) for the stay and upper and lower
parts and tighten the mounting bolts with
your fingers.

PC1800-6 30-9-6
(6)
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR

REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY

REMOVAL 5. Disconnect injector wiring connector (9).
k Disconnect the cable from the negative (–) ter- a To disconnect the fuel injector wiring con-
minal of the battery. nector, insert flat-head screwdriver [3] in
stepped part "a" and move it in direction "X",
1. Remove oil tubes (1) and (2), oil filter (3), and pressing stopper "b".
bracket (4).
6. Remove cylinder head cover (10).
2. Remove exhaust connector bracket (5).

3. Remove heat insulation cover (6) and turbo-

charger lubricating oil inlet tube (7).
(No.5 cylinder only)

7. Remove the mounting bolts and rocker arm

assembly (11).
a Loosen locknut (12), and then loosen adjust-
ment screw (13) by 2 – 3 turns so that an ex-
4. Remove injector inlet high-pressure tube (8). cessive force will not be applied to the push
rod when the rocker arm assembly is in-
stalled.

30-9-7 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR

8. Remove 2 nuts (15) of the upper solenoid valve INSTALLATION

of fuel injector (14) and pull out spring clamp • Carry out installation in the reverse order to
(16). removal.

9. Remove the bolt of clamp (17), and then remove

1 mounting bolt (20) of holder (19) of connector 3 Joint bolt of lubrication tube:
(having an O-ring) (18) with a hexagonal wrench. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

10. Remove holder (19) and push connector (18)

inward to remove. 3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}

a When tightening the mounting bolts, check

that the ball of the adjustment screw is fitted

3 Mounting bolt:
securely to the socket of the push rod.

93 – 103 Nm {9.5 – 10.5 kgm}

a After tightening the locknut, adjust the valve
clearance. For details, see TESTING AND
ADJUSTING, ADJUSTING VALVE CLEAR-

3 Locknut: 53 – 64.7 Nm {5.4 – 6.6 kgm}

NACE.

11. Remove holder (21) of fuel injector assembly

(14), and then remove fuel injector assembly
(14). a Check high pressure pipe as following items.
a Insert an L-shaped bar under the connector If there is any of those defects, it can cause
of the injector and pry off the injector slowly. fuel leakage. In this case, replace the high-
a Do not grip the solenoid valve on the injector pressure pipe.
with pliers, etc. to remove. • Check the taper seal of its joint (Part "a":
a When removing only the injector to replace it Part of 2 mm from the end) for visible
or nozzle tip, observe the following. lengthwise slit "b" and spot "c".
• Before performing the above described • Check part "d" (End of taper seal: Part at
work to remove the injector, loosen the 2 mm from the end) for stepped-type
mounting bolts which are fixing one of wear caused by fatigue which your nail
high-pressure tube clamps No. 1 – No. 6 can feel.
near the injector to the air intake mani-
fold.
• Remove the sleeve of the high-pressure
tube on the injector side, too. While sep-
arating the high-pressure tube so that its
end will not touch the hollow of the injec-
tor, pull out the injector.

PC1800-6 30-9-8
(6)
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR

a Check that there is not dirt in the injector 1) Take out wiring harness connector (25)
sleeve. through the connector insertion opening
a Procedure for installing fuel injector with O-ring (26) removed.
1) Fit the gasket and O-ring to the fuel injector 2) Fit O-ring (26) and apply engine oil
and apply engine oil (SAE No. 30) to them. (SAE30) to its periphery.
2) Insert holder (21) in fuel injector (14). Direct 3) Install connector holder (27) and push it
the injector connector toward the fuel high- in.
pressure tube insertion hole and insert the 4) Secure connector holder (27) with
fuel injector assembly and holder together. mounting bolt (20).

3) Fit the ball washer to bolt (22) and tighten 5) Install wiring terminal (29) to the injector
them into holder (21) with your fingers. terminal (28) and tighten 2 nuts (15).
4) Insert high-pressure tube sleeve (23) 6) Install spring clamp (16) and tighten wir-
through the fuel high-pressure tube insertion ing harness holder clamp (31) with bolt
part and tighten it with your fingers, match- (32).
ing it to injector connector (24). a Tense the wires and press them

3 Terminal nut:
5) Tighten bolt (22) of holder (21) permanently. against the injector body.
a Apply engine oil to the spherical part of
the ball washer (to fit the ball washer). 1.8 – 2.2 Nm {0.18 – 0.22 kgm}
a After tightening the holder permanently,
remove the high-pressure tube sleeve
and install the other injectors similarly in

3 Holder mounting bolt:

order.

58.8 – 73.5 Nm {6.0 – 7.5 kgm}

a Procedure for installing fuel injector wiring

harness assembly
• It is difficult to insert the connector after
the O-ring is fitted to it.

30-9-9 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY NOZZLE TIP

REMOVAL AND INSTALLATION OF NOZZLE TIP

a [EPA regulations] 3. Loosen retaining nut (4) with 19-mm deep
For countries subject to EPA regulations, the socket [3].
entire nozzle assembly of the common rail
engine shall be replaced if any of its compo-
nents needs to be replaced. For other coun-
tries, the following procedure may be applied for
replacing the nozzle tip.

SPECIAL TOOLS

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

B 795T-471-1550 Wrench t 1 Q
4. Remove retaining nut (4) from injector assembly
(3).
REMOVAL
1. Fix tool B in vice [1]. 5. Lift nozzle assembly (5) perpendicularly upward
a Do not pinch the injector directly in the vice. to remove it.
a Do not remove tip guide (6). (Disassembling
the portion after the tip guide is not allowed.)
a Be careful not to get the assembly dirty.

2. Set injector assembly (3) on tool B.

PC1800-6 30-9-10
(6)
DISASSEMBLY AND ASSEMBLY NOZZLE TIP

INSTALLATION 5. Mount nozzle assembly (3) and manually tighten

1. Fix tool B in vice [1]. retaining nut (2).
a Do not pinch the injector directly in the vice.

6. Set 19-mm deep socket (2) in the torque

2. Set injector assembly (1) on tool B. wrench, then tighten the retaining nut by follow-
ing the steps below.
3. Completely clean the lower body and screw sec- a Apply rust prevention oil on the nozzle body.
tions of retaining nut (2) with parts cleaner, and 1) Tighten with torque of 88.3 Nm {9.0 kgm}.
apply air blow. 2) Attach identification mark (6) to retaining nut
(2) and lower body (5).
3) Tighten at an angle of 45° (angle tighten-
ing).

4. Mount new nozzle assembly (3) so that the

assembly fits the knock pin of tip guide (4).
a Be careful not to drop the tip.

30-9-11 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL

REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

SPECIAL TOOLS INSTALLATION
1. Installation of front seal (2)

New/Remodel
a Before assembling the seal, check that there

Necessity
Symbol

are no scratches, burrs, flashes, or rust on

Sketch
Q'ty
Part No. Part Name
the housing, lip sliding surface, or at the cor-
ner of the end face of the crankshaft.
a When assembling the seal, do not coat the
795-521-1110 Push tool t 1 shaft and seal lip with oil or grease. Wipe off
790-101-5221 Grip t 1 all oil from the shaft.
C
01010-51225 Bolt t 1 a Do not remove the internal plastic tube (6)
01050-31640 Bolt t 3 from the standard seal until the seal is as-
sembled.

REMOVAL
1. Remove the radiator assembly. For details, see
REMOVAL OF RADIATOR ASSEMBLY.

2. Remove damper (1).

1) Put large inside diameter (b) end of internal

plastic tube (6) in contact with end of crank-
shaft (5).
a Be particularly careful to assemble fac-
ing in the correct direction.

3. Remove front seal (2).

PC1800-6 30-9-12
(6)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL

2) Hold metal ring of seal (2) with both hands 2. Installation of damper assembly
and push in with sudden force until it feels Fit damper assembly (1) and tighten with mount-

3 Mounting bolt:
that it has gone over large diameter of inter- ing bolts.
nal plastic tube (6).
3) After pushing seal in, remove internal plastic 245 – 308.7 Nm {25 – 31.5 kgm}
tube (6).
a When removing, be particularly careful
not to damage the seal lip.

4) Tighten bolts of tool C uniformly until end

face of tool C contacts end face of crank-
shaft (3) and press fit seal (2).
a When press fitting the seal, be extremely
careful not to damage the lip at the PTO
end when setting the tool in position.
a After press fitting the seal, remove all the
remains of the red sealant on the outside
circumference.

30-9-13 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

SPECIAL TOOLS 5. Remove rear seal (2).
a Measure the dimension from the end face of

New/Remodel
the housing.

Necessity
Symbol

Sketch
Q'ty
Part No. Part Name • Removing standard seal
Hook tip of tool D1 to metal ring of seal (2), and
use impact force of a slide hammer [1] to pull
1 795-931-1100 Seal puller t 1 out.
795-521-1131 Push tool t 1 a Before pulling out, knock the oil seal in slight-
790-101-5421 Grip t 1 ly. This separates the seal from the housing
2
01010-51240 Bolt t 1 and makes it easier to pull out the seal.
01050-31625 Bolt t 3 a Do not use a drill. The metal powder will get
D inside the engine.
795-931-1210 Sleeve jig t 1
795-931-1220 Sleeve jig t 1
3
01050-31625 Bolt t 3
01050-31645 Bolt t 3
4 790-331-1110 Wrench q 1

REMOVAL
1. Remove PTO assembly.
For details, see REMOVAL OF PTO ASSEM-
BLY.

2. Remove 1 mounting bolt of flywheel (1), and

install guide bolt [1].
• Removing seal with sleeve
3. Using eyebolts [2], sling flywheel (1), then 1) Hook tip of tool D1 to metal ring of seal (2),
remove remaining mounting bolts. and use impact force of a slide hammer [1]
to pull out.
4. Pull flywheel (1) out and lift off. a Before pulling out, knock the oil seal in
k The flywheel pilot portion is shallow, and it slightly. This separates the seal from the
may fall out suddenly, so be careful not to flywheel housing (4) and makes it easier
get your fingers caught. to pull out the seal.

4
2) Using a chisel and hammer, cut sleeve (3)
Flywheel: 60kg and remove.
a Be extremely careful not to damage the
crankshaft when cutting the sleeve.
a Remove all the metal particles that are
produced.

PC1800-6 30-9-14
(6)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

• Standard seal • Seal with sleeve 1. Procedure for assembling standard seal
a Before assembling the seal, check that there
are no scratches, burrs, flashes, or rust on
the housing, lip sliding surface, or at the cor-
ner of the end face of the crankshaft (5).
a When assembling the seal (2), do not coat
the shaft and seal lip a with oil or grease.
Wipe off all oil from the shaft.
a Do not remove the internal plastic tube (6)
from the standard seal until the seal is as-
sembled.
1) Put large inside diameter end c of internal
plastic tube (6) in contact with end of crank-
shaft (5).
a Be particularly careful to assemble fac-
ing in the correct direction.

INSTALLATION
a With the Teflon seal (lay-down lip seal), check
the condition of the wear of the shaft, then select
either a standard seal or a seal with a sleeve,
and assemble the seal.
The condition of wear is judged by the smoothness
(depth of wear less than 10 µm when touched with
the flat of a finger). If there are no scratches,
assemble a standard seal; in all other cases,
assemble a seal with a sleeve.

• Standard seal • Seal with sleeve

30-9-15 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

2) Hold metal ring of seal (2) with both hands 2. Assembly procedure for seal with sleeve
and push in with sudden force. a Before assembling the seal, check that there
3) After pushing seal in, remove internal plastic are no scratches, burrs, flashes, or rust on
tube (6). the housing, lip sliding surface, or at the cor-
a When removing, be particularly careful ner of the end face of the crankshaft.
not to damage the seal lip. a When assembling the seal, do not coat the
shaft and the area between the sleeve (3)
and seal lip a with oil or grease. Wipe off all
oil from the crankshaft.
a Always handle the seal and sleeve as a set.
Never disassemble it.
1) Set sleeve/seal (7) to tool D3 (for press fit-

2 Surface of tube inside sleeve:

ting seal with sleeve).

Gasket sealant (LG-7)

4) Tighten 3 bolts uniformly until end face of

tool D2 (for press fitting seal) contacts end
face of crankshaft (5) and press fit seal (2).
a First, tighten tool D2 (for press fitting
seal) until bolt (45 mm) comes into con-
tact, then tighten with bolt (25 mm).
a When press fitting the seal, be extremely
careful not to damage the lip at the PTO
end when setting the tool in position.
a After press fitting the seal, remove all the
remains of the red sealant on the outside
circumference.

PC1800-6 30-9-16
(6)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

2) Put sleeve of seal in contact with end face of 3. Flywheel

crankshaft (5), then tighten 3 bolts uniformly Using eyebolt [4] (12 mm, P=1.75), raise fly-
until end face of tool D3 contacts end face of wheel (1) and tighten to crankshaft with mount-

2 Coat the thread and seat of the bolt

crankshaft (5) to press fit sleeve/seal (2). ing bolts.
a First, tighten tool D3 (for press fitting seal

4 Flywheel: 60 kg
with sleeve) until bolt (45 mm) comes into completely with SAE No. 30 engine oil.
contact, then tighten with bolt (25 mm).

3) Remove tool D3 (for press fitting seal with a Tighten the flywheel mounting bolts as fol-

2 Flywheel mounting bolt:

sleeve) and install tool D3 (for press fitting lows.
seal).
4) Tighten 3 bolts uniformly until end face of 1st step: Tighten to 112.7 – 122.5 Nm
tool D3 (for press fitting seal) contacts end {11.5 – 12.5 kgm}
face of crankshaft (5) to press fit sleeve/seal 2nd step:1) When using tool D4
(7). Tighten bolts a further 90° +30°
+0
a First, tighten tool D3 (for press fitting in order (1) to (6).
seal) until bolt (45 mm) comes into con- 2) When not using tool D4
tact, then tighten with bolt (25 mm). Make marks on bolt and fly-
a After press fitting the seal, remove all the wheel with paint, then tighten
remains of the red sealant on the outside
bolts a further 90° +30°
+0 in order
circumference.
(1) to (6).

30-9-17 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

Make marks on
flywheel and bolt

a After tightening, make one punch mark on

the bolt head to indicate the number of times
it has been tightend.
• If any bolt already has five punch marks,
do not reuse it. Replace it with a new
bolt.

a After installing the flywheel, use dial gauge

[1] to measure the face runout and radial ru-
nout.
a Face runout: Max. 0.30 mm
a Radial runout: Max. 0.30 mm

PC1800-6 30-9-18
(6)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

SPECIAL TOOLS 7. Remove cover (10) and air intake connector
(11).

New/Remodel
Necessity
Symbol

8. Disconnect dust indicator hose (12).

Sketch
Q'ty
Part No. Part Name
9. Disconnect dust indicator sensor connector, and
then disconnect dust indicator sensor (13) from
E 790-331-1110 Wrench q 1 the bracket. (Rear engine only)

10. Remove air intake connector (14) and bracket

(15).
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Remove the engine hood. For details, see

REMOVAL OF ENGINE, PTO, HYDRAULIC
PUMP ASSEMBLY.

2. Remove the hoses between turbocharger and

aftercooler and between the aftercooler and air
intake manifold.

3. Remove the heat insulation covers (3), (4), (5),

and (6).
11. Remove turbocharger lubricating oil inlet tube
4. Disconnect exhaust temperature sensor (7). (16).

5. Disconnect turbocharger lubricating oil outlet 12. Remove the mounting bolts and lift off turbo-
tube (8). charger and exhaust manifold assembly (17).

6. Remove exhaust connector (9).

30-9-19 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

13. Disconnect boost pressure sensor connector 25. Disconnect 5 high-pressure tube clamps (36).
(18).

14. Remove 2 oil tubes (19) and oil filter assembly

(20).

15. Disconnect fuel tubes (21) and (22) and remove

fuel filter assembly (23).

16. Disconnect tube (24) and remove tube (25).

17. Remove corrosion filter (26).

18. Remove fuel tubes (21) and (22) disconnected

in step 15.
26. Remove coolant tube (37) and fuel spill tube
19. Remove spill tube (27). (38).

27. Remove rubber cap (39) and high-pressure tube

(40).

28. Remove head cover (41).

20. Remove oil filler bracket (28).

21. Remove brackets (29), (30), (31), and (32).

22. Disconnect 6 high-pressure tube clamps (33).

29. Remove rocker arm assembly (42) and fuel
23. Disconnect wiring harness clamp (34). injec tor as sembl y ( 43). For details, see
REMOVAL OF FUEL INJECTOR ASSEMBLY.
24. Remove the mounting bolts and lift off air intake
manifold assembly (35).
a At this time, the intake air heaters come off.
a The wiring harness clamp and heater ground
wire are installed with the lower mounting
bolts.

PC1800-6 30-9-20
(6)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

30. Pull out push rod (44).

3 Joint bolt of fuel filter tubes (21) and
31. Remove the mounting bolts and cylinder head (22):
assembly (45). 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
(Supply pump side)
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
(Fuel filter side)

3 Joint bolt of corrosion resistor tubes

(24) and (25):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}

3 Joint bolt of spill tube (27):

9.8 – 12.7 Nm {1.0 – 1.3 kgm}

Procedure for installing air intake manifold

assembly
1) Fit the gaskets to both sides of the electrical
INSTALLATION intake air heater.
• Carry out installation in the reverse order to 2) Install the wiring harness to the electrical
removal. intake air heater and combine them with the
air intake manifold.
3) Tighten the mounting bolts of the air intake
3 Joint bolt of turbocharger lubricating oil manifold assembly in the order of [1] – [24]

3 Air intake manifold assembly mounting

inlet tube: shown below.
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
bolt: 59 – 74 Nm {6 – 7.5 kgm}

a After fitting the gasket, tighten the mounting

bolts of the exhaust manifold assembly in the

3 Exhaust manifold assembly mounting

order of [1] – [24] shown below.

bolt: 59 – 74 Nm {6 – 7.5 kgm}

30-9-21 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

• Assembly procedure for common rail injec-

tion pipe (Between common rail and injec-
tor).

3 Sleeve nut:
1. Install high-pressure pipe (61).

39.2 – 49 Nm {4 – 5 kgm}
a Precautions for installing sleeve nut on
injector side
1) Insert the sleeve nut in the head hole
from outside.
a Check that the O-rings are fitted to both
injector side and sleeve nut side.
2) After sleeve nut catches the threads of
the injector, turn it 2 turns with fingers,
then tighten it with a spanner.
a Control the tightening torque with a

3 Sleeve nut:
torque wrench of spanner type.

39.2 – 49 Nm {4 – 5 kgm}
a If the sleeve nut does not catch the
threads, push its end with a small span-
ner and turn its hexagonal part with the
torque wrench.
a After tightening the sleeve nut, check
that the O-ring is not projected from the
sleeve nut end.

2. Tighten the stay and upper and lower 3 Eye-joint bolt of coolant water tube:
clamps of high-pressure pipe clamp (57)
3 Eye-joint bolt of fuel spill tube (38):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
with fingers.
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3. Tighten upper and lower clamps (57)
securely.

3 Clamp bolt:
a Bend the rubber first.
a Check high pressure pipe as following items.
If there is any of those defects, it can cause
9.8 ± 1 Nm {1 ± 0.1 kgm}
fuel leakage. In this case, replace the high-
pressure pipe.
4. Tighten the stay securely.
• Check the taper seal of its joint (Part "a":
Part of 2 mm from the end) for visible
5. Tighten the stay and upper and lower
lengthwise slit "b" and spot "c".
clamps of high-pressure pipe side clamp
• Check part "d" (End of taper seal: Part at
(57) with fingers.
2 mm from the end) for stepped-type
wear caused by fatigue which your nail
6. Install high-pressure pipe clamp (66) and
can feel.
gate frame (67) temporarily.
1) Tighten high-pressure pipe clamp (66)
securely first.
2) Install gate frame (67) to special bolt

3 Clamp bolt:
(68) securely.

9.8 ± 1 Nm {1 ± 0.1 kgm}

7. Tighten high-pressure pipe side clamp (57)

3 Clamp bolt:
securely.

9.8 ± 1 Nm {1 ± 0.1 kgm}

8. Tighten stay (69) securely.

PC1800-6 30-9-22
(6)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

ii) When not using tool E

3 Head cover mounting bolt: Make marks on the all bolts and
14.7 – 34.3 Nm {1.5 – 3.5 kgm} cylinder head, then retighten
each bolt by 90° +30°
+0 in the order
of (1) – (6).
a Before tightening the cylinder head mounting a After tightening bolts (1) – (6),
bolts, check the following matter. tighten bolt (7) to 66.6 ± 7.4 Nm
1) Measure stem length "e" of each mounting {6.8 ± 0.8 kgm}.
bolt.
2) Using limit of bolt
• Short bolt: Must be shorter than 170.8 mm
• Long bolt: Must be shorter than 205.8 mm
3) If the mounting bolts are longer than the
above using limits or they have been tight-
ened 5 times (there are 5 punch marks on
them), do not reuse them but replace them.

a Tighten the mounting bolts in the order

shown bellow.
a A special socket is required to tighten the

3 Cylinder head mounting bolt:

head bolts.

1st time: 137 – 157 Nm {14 – 16 kgm}

• Refilling with coolant
2nd time: 284 – 294 Nm {29.0 – 30.0 kgm}
Add coolant through the coolant fillers of the
3rd time:
radiator to the specified level. Run the engine to
i) When using tool E
circulate the water through the system. Then,
Retighten each bolt by 90° +30°
+0 check the coolant level again.
in the order of (1) – (6).
5 Coolant: Approx. 110 l

30-9-23 PC1800-6
(6)
DISASSEMBLY AND ASSEMBLY FUEL COOLER

REMOVAL AND INSTALLATION OF FUEL COOLER ASSEMBLY

REMOVAL Front side
k Close the fuel tank valve. 4. Disconnect fuel cooler hoses (6) and (7).

1. Open radiator grille (1). 5. Loosen 4 fuel cooler mounting bolts (8) and
remove fuel cooler assembly (9).

Rear side
2. Disconnect fuel cooler hoses (2) and (3). INSTALLATION
• Carry out installation in the reverse order to
3. Loosen 4 fuel cooler mounting bolts (4) and removal.
remove fuel cooler assembly (5).

30-10 PC1800-6
DISASSEMBLY AND ASSEMBLY AFTERCOOLER

REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY

REMOVAL INSTALLATION
1. Remove engine hood (1), ladder (2), and grille • Carry out installation in the reverse order to
assembly (3). removal.

2. Loosen intake air hose clamps (4) and discon-

nect the hose.

3. Sling aftercooler (5), loosen bolts (6), and

remove the cooler assembly.

• Remove the aftercooler assembly on the front

side similarly.

PC1800-6 30-11
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER

REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER

ASSEMBLY
REMOVAL 7. Disconnect hydraulic oil cooler hoses (11) and
k Disconnect the cable from the negative (–) ter- (12) and tube (13).
minal of the battery.
k Lower the work equipment to the ground and 8. Remove tube bracket (14).
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
k Drain the hydraulic oil.

6 Hydraulic tank : Approx. 1,500 l

k Plug the disconnected hoses and tubes.

1. Remove the radiator grille, fuel cooler (1), and

aftercooler (2). For details, see REMOVAL OF
FUEL COOLER/AFTER COOLER.

2. Remove fuel cooler bracket (3).

9. Sling hydraulic oil cooler assembly (15), remove
3. Remove fuel hose clamp (4).
4 mounting bolts (16) on each side, and lift off
hydraulic oil cooler assembly (15).
4. Disconnect cooler hose (5).
4 Hydraulic oil cooler assembly: 200 kg
5. Remove side covers (6) and (7).

6. Remove muffler cover (8), radiator-side hood

(9), and cover (10). INSTALLATION
• Carry out installation in the reverse order to
removal.

• Refilling with oil (Hydraulic tank)

★ Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.

30-12 PC1800-6
DISASSEMBLY AND ASSEMBLY RADIATOR

REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY

REMOVAL 6. Sling radiator assembly (9), loosen radiator
1. Drain the cooling water. mounting bolts (10), and remove isolator (11).

2. Remove the radiator grille assembly, fuel cooler, 7. Lift off radiator assembly (9).
aftercooler, cover, hood, and hydraulic oil cooler
assembly. For details, see REMOVAL OF FUEL 4 Radiator assembly: 260 kg
COOLER/AFTERCOOLER/HYDRAULIC OIL
COOLER ASSEMBLY.

3. Disconnect radiator inlet hose (1), overflow hose

(2), and aeration hose (3).

4. Remove clamp (4) and disconnect aftercooler

air intake tube (5) and air intake hoses (6) and
(7).

5. Disconnect radiator outlet hose (8).

★ Disconnect the radiator outlet hose from the
radiator.

INSTALLATION
• Carry out installation in the reverse order to
removal.

• Refilling with water

★ Add water through the water filler to the
specified level. Run the engine to circulate
the water through the system. Then, check
the water level again.

• Refilling with oil (Hydraulic tank)

★ Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.

PC1800-6 30-13
DISASSEMBLY AND ASSEMBLY FUEL TANK

REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY

REMOVAL 4. Disconnect fuel tank bracket (3) and fuel level
k Disconnect the cable from the negative (–) ter- gauge wiring connector (4) and remove clamps
minal of the battery. (5).

1. Open the drain valve to drain the fuel. 5. Disconnect fuel tank bracket (6) and fuel return

Fuel tank: 2750 l (When full)

hoses (7) and remove 3 hose clamps (8).
6

2. Remove handrail (1).

6. Disconnect fuel supply hoses (9) and drain hose

(10) and remove fuel cable (11).

3. Disconnect fuel tank brackets (2) from the coun-

terweight.

7. Sling fuel tank assembly (12) and remove 6

mounting bolts (13).

30-14 PC1800-6
DISASSEMBLY AND ASSEMBLY FUEL TANK

8. Lift off fuel tank assembly (12). INSTALLATION

• Carry out installation in the reverse order to
4 Fuel tank assembly: 1,459 kg removal.

• Adjust the shim between the fuel tank bracket

and counterweight.

3 Fuel tank mounting bolt :

927 ± 103 Nm {94.5 ± 10.5 kgm}

PC1800-6 30-15
DISASSEMBLY AND ASSEMBLY ENGINE, PTO, HYDRAULIC PUMP

REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC

PUMP ASSEMBLY
REMOVAL 5. Disconnect overflow hoses (2) and dust indica-
k Disconnect the cable from the negative (–) ter- tor hose (3), then remove reserve tanks (4)
minal of the battery. together with bracket (5).
k Lower the work equipment completely to the
ground and stop the engine. Operate the control
levers several times to release the remaining
pressure in the hydraulic piping. Then loosen the
oil filler cap slowly to release the pressure inside
the hydraulic tank.
★ Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering. Mark
with tags to prevent mistakes when connecting.

1. Remove cover, then remove strainer (1) from

tank.

2. Remove rod from strainer, install tool A, assem-

6. Disconnect connector (6) and air cleaner intake
ble in tank, then fit spring and install cover.
pressure switch wiring (7), then remove bands
★ When not using tool A, loosen the drain
(8) and air cleaner assembly (9).
valve at the bottom of the hydraulic tank and
drain the oil.

6 Hydraulic tank : Approx. 1500 l

7. Remove drain hose (10) and cover (11), then

remove muffler assembly (12).

8. Disconnect engine room lamp wiring, then

3. Drain coolant.
remove engine hood (13).
4. Release air from air tank and close fuel supply
valve.

30-16 PC1800-6
DISASSEMBLY AND ASSEMBLY ENGINE, PTO, HYDRAULIC PUMP

Rear engine side 12. Disconnect aftercooler hose (20) and tube (21).

9. Remove belt cover (14), loosen the belt, and 13. Disconnect cooling water hose (22).
remove 2 air compressors (15) and place them ★ Disconnect the hose from the engine.
on the front engine side.
★ Do not discharge the refrigerant (R134a).

14. Remove fan guard (23).

10. Disconnect compressor hose clamps (16) and 15. Move the tension pulley to loosen and remove
remove fuel hoses (17) and hose clamps (18). fan belt (24).

11. Disconnect fuel strainer hoses (19). 16. Remove car heater hose clamp (28).

17. Disconnect rubber hose (25) and car heater

hoses (26) and (27).

18. Disconnect starting motor wire (29) and ground

wire (30).

PC1800-6 30-17
DISASSEMBLY AND ASSEMBLY ENGINE, PTO, HYDRAULIC PUMP

19. Disconnect wiring connectors (31) and remove 23. Disconnect outlet hoses (37) of swing, No. 1, 2,
bracket (32). 3 and No. 4 pump.
★ Remove the parts from the front engine sim-
ilarly to the above procedure. Air compres-
sors are not installed to the front engine,
however.

24. Disconnect drain hoses (38) of swing, No. 1, 2,

3 and No. 4 pump.

25. Disconnect control hoses (39).

20. Disconnect pump room lamp wiring (33).
26. Disconnect control pump tube (40).

21. Remove clamp, then disconnect hose (34).

27. Disconnect inlet tubes (41) of swing, No. 1, 2, 3,
22. Remove pump room door (35) and guard (36). 4 and control • PTO lubrication pump.

28. Disconnect outlet and inlet tubes (42) for PTO

lubricating and drain hose (43).

30-18 PC1800-6
DISASSEMBLY AND ASSEMBLY ENGINE, PTO, HYDRAULIC PUMP

29. Disconnect TVC solenoid connectors (44) of No. INSTALLATION

2, 4 pump, remove clamp, then disconnect wir- • Carry out installation in the reverse order to
ing harness from pump. removal.

3 Mounting bolt:
926.1 ± 102.9 Nm {94.5 ± 10.5 kgm}
★ After tightening the mounting bolts, adjust
the clearance at mounts (48) and (49), and
stoppers (50) with shims (51) so that they are
uniform.

30. Sling engine, PTO, and pump assembly, and

remove front (45) and rear (46) mounting bolts
on left and right.

31. Lift off engine, PTO, and pump assembly.

★ There will be interference from the fan pul- • Refilling with oil
ley, so raise slightly, then pull out the cushion ★ Add oil to the specified level. Run the engine
at the front mount and move to the rear while to circulate the oil through the system. Then
raising. check the oil level again.

4 Engine, PTO, pump assembly: • Refilling with water

26,000 kg ★ Add water to the specified level. Run the en-
gine to circulate the water through the sys-
tem. Then check the water level again.

• Bleeding air
★ Bleeding air from main pump.
For details, see TESTING AND ADJUST-
ING, Air bleeding from each component.

PC1800-6 30-19
DISASSEMBLY AND ASSEMBLY PTO

REMOVAL AND INSTALLATION OF PTO ASSEMBLY

REMOVAL 2. Lift off swing pump assembly (10).
★ The operation for front engine side is basically
the same as for the rear engine side. 4 Swing pump assembly: 140 kg

1. Hydraulic pump piping

1) Remove swing pump branch hose (1).

3. Lift off No. 1, 3 pump assembly (11).

4 No. 1, 3 pump assembly: 150 kg

2) Remove No. 2 pump branch hoses (2).
3) Remove PTO lubrication hose (3).

4. Lift off No. 2, 4 pump assembly (12).

4) Remove control pump tube (4). 4 No. 2, 4 pump assembly: 160 kg

5) Remove control hoses (5), (6), (7), (8), and
(9).

30-20 PC1800-6
DISASSEMBLY AND ASSEMBLY PTO

5. Lift off control • PTO lubrication pump assembly

(13).

6. Remove lubrication tubes (15), (16), (17), (18),

(19), (20), (21), (22), (23) and (24).

7. Lift off PTO assembly (24).

4 PTO assembly: 488 kg

PC1800-6 30-21
DISASSEMBLY AND ASSEMBLY PTO

8. Lift off output shaft (25). INSTALLATION

• Carry out installation in the reverse order to
9. Remove coupling (26). removal.

10. Remove plate (27).

3 Bolt:
110.3 ± 12.2 Nm {11.25 ± 1.25 kgm}

3 Bolt:
277.05 ± 31.85 Nm {28.25 ± 3.25 kgm}

30-22 PC1800-6
DISASSEMBLY AND ASSEMBLY PTO

DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY

DISASSEMBLY 4. Using puller 2, remove bearing from gear.
1. Screw in forcing screw and remove case (1), ★ Inside diameter of bearings for gears (2), (4)
then remove cover (9) from case (1). and (5): 65 mm
★ Check the number and thickness of the
shims.

ASSEMBLY
2. Remove gear assemblies (2), (3), (4) and (5). 1. Install bearing (6) (inside diameter: 120 mm) to
gear (3).

3. Using puller 1, remove bearing (6) (inside

diameter: 120 mm) from gear (3). 2. Install bearing (inside diameter: 65 mm) to gears
(2), (4) and (5).

PC1800-6 30-23
DISASSEMBLY AND ASSEMBLY PTO

3. Install outer race (7) (outside diameter: 180 mm) 5. Fit gasket and install case (1).
to cases (8) and cover (9). 3 Mounting bolt:
112.8 ± 9.8 Nm {11.5 ± 1 kgm}

6. Fit O-ring and shim, then install cover (9).

4. Install gear assemblies (5), (4), (3) and (2).

2 Bearing: Grease (G2-LI)
★ Select the thickness of shim for the cover as
follows.
1) Install cover (9) without fitting O-ring.
Rotate gear in direction of arrow (50 –
60 rpm), and tighten two bolts (10) uni-
formly to 19.6 Nm {2 kgm}.

30-24 PC1800-6
DISASSEMBLY AND ASSEMBLY PTO

2) Using feeler gauge, measure clearance

on right and left between case (1) and
cover (9).
3) Add clearance F and clearance G, then
decide shim thickness from table below.

Unit: mm
Thickness of shims
F+G
to use
– 0.2
Min. 0 – Under 0.10 0.3
Min. 0.10 – Under 0.32 0.4
Min. 0.32 – Under 0.49 0.5
Min. 0.49 – Under 0.68 0.6
Min. 0.68 – Under 0.88 0.7
Min. 0.88 – Under 1.08 0.8
Min. 1.08 – Under 1.28 0.9
Min. 1.28 – Under 1.46 1.0
Min. 1.46 – Under 1.65 1.1
Min. 1.65 – Under 1.85 1.2
Min. 1.85 – Under 2.05 1.3
Min. 2.05 – Under 2.25 1.4
Min. 2.25 – Under 2.44 1.5
Min. 2.44 – Under 2.63 1.6

PC1800-6 30-25
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT

ASSEMBLY
REMOVAL
k Lower the work equipment completely to the
ground and stop the engine. Then loosen the oil
filler cap slowly to release the pressure inside
the hydraulic tank.

1. Disconnect swivel joint bottom hoses (1), (4),

(5), (6), and (7).
★ Keep spacer (2) fitted to the hose (3), and
leave on the frame.

INSTALLATION
• Carry out installation in the reverse order to
removal.

★ Install so that the port at the bottom of the

swivel joint (port D) is facing the front right.

2. Disconnect swivel joint top hoses (8), (9), and

(10).

3. Disconnect clamp (11) of swing motor hose (for

swing holding brake solenoid valve) between
front and rear.

4. Pull out pin (12) and move link (13) towards

frame.

5. Sling swivel joint assembly.

★ Use the split flange bolt hole.

6. Remove bottom mounting bolts, then lift off • Refilling with oil
swivel joint assembly (14). ★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
4 Center swivel joint assembly: 69 kg the system. Then check the oil level again.
★ Add oil to replace the oil that leaked out
when the swivel joint was removed.

30-26 PC1800-6
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT

ASSEMBLY
DISASSEMBLY ASSEMBLY
1. Remove cover (1). 1. Assemble 6 slipper seals (8) in swivel rotor (4).

2. Remove snap ring (2). 2. Using push tool 2, press fit oil seal (7) in swivel
rotor (4), then install snap ring (6).
3. Using puller 1, pull out swivel rotor (4) and ring 2 Oil seal lip: Grease (G2-LI)
(3) from swivel shaft (5).
3. Set swivel shaft (5) on block, then using push
4. Remove snap ring (6), then remove oil seal (7) tool 3, tap swivel rotor (4) with a plastic ham-
and 6 slipper seals (8). mer to install.
★ When installing the rotor, be careful not to
damage the lip of the slipper seals or oil seal.

4. Install ring (3), then secure with snap ring (2).

5. Fit O-ring and install cover (1).

3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}

CEP00382

PC1800-6 30-27
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY

REMOVAL 3. Sling travel motor assembly (5), and remove
k Swing the work equipment 90°, then lower it mounting bolts, then remove travel motor
completely to the ground. assembly.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. 4 Travel motor assembly: 180 kg

1. Lift off covers (1) and (2).

4 Cover (1): 180 kg

4 Cover (2): 490 kg

INSTALLATION
• Carry out installation in the reverse order to
removal.

2. Disconnect hoses (3) and (4). 3 Mounting bolt:

★ Fit oil stoppers in the hoses after disconnect- 926.7 ± 103 Nm {94.5 ± 10.5 kgm}
ing them. Prepare an oil pan to catch the oil ★ If the mounting bolt holes for the motor can-
that flows out. not be aligned, release the brake. Remove
plug 1 (Thread dia. = 14 mm, Pitch = 2.0
mm) and apply hydraulic pressure.

★ After running the engine to circulate the oil in

the piping, add engine oil to the hydraulic
tank to the specified level. Then bleed the
air. For details, see TESTING AND AD-
JUSTING, Air bleeding from each compo-
nent.

30-28 PC1800-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR BRAKE VALVE

REMOVAL AND INSTALLATION OF TRAVEL MOTOR BRAKE

VALVE ASSEMBLY
REMOVAL INSTALLATION
k Swing the work equipment 90°, then lower it • Carry out installation in the reverse order to
completely to the ground. removal.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
3 Mounting bolt:
1. Lift off covers (1). 176.5 ± 19.6 Nm {18 ± 2 kgm}
★ After running the engine to circulate the oil in
4 Cover (1): 180 kg the piping, add engine oil to the hydraulic
tank to the specified level. Then bleed the
air. For details, see TESTING AND AD-
JUSTING, Air bleeding from each compo-
nent.

2. Disconnect hoses (4).

★ Fit oil stoppers in the hoses after disconnect-
ing them. Prepare an oil pan to catch the oil
that flows out.

3. Lift off brake valve assembly (3).

PC1800-6 30-29
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

DISASSEMBLY ii) Remove gears (10) and (11).
1. Case assembly ★ Bearing (12) interferes with gear
Using forcing screws (Thread dia. = 16 mm, (10), so pull up all three parts at the
Pitch = 2.0 mm), lift off case assembly (1). same time.

2. Case, gear assembly 3. Carrier assembly (small)

1) Screw in forcing screws, and lift off case and 1) Lift off carrier assembly (19).
gear assembly (5).

2) Disassemble carrier assembly as follows.

2) Disassemble case and gear assembly as i) Remove lock plate (21).
follows. ii) Push out shaft (22) with press.
i) Remove bolt (6) and holder (7), then
remove shaft (8) and spacer (9).

30-30 PC1800-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

iii) Remove gear (24) and bearing (25). 3) Disassemble carrier assembly as follows.
i) Remove lock plate (31).
ii) Using tool A, pull out shaft (32).

4. Ring gear (small)

Remove ring gear (18).
iii) Remove gear (35) and bearing (34).

5. Carrier assembly (large)

1) Turn over final drive assembly. 6. Shaft
2) Use 2 eyebolts (Thread dia. = 24 mm, Pitch Lift off shaft (41).
= 3.0 mm), and screw in forcing screws,
then remove carrier assembly (29). 7. Ring gear
1) Remove retainer (42).

PC1800-6 30-31
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

2) Lift off ring gear (43). ASSEMBLY

1. Housing
Assemble the following parts to housing (48).
1) Install spacer (49).
★ The wide side faces the flange.

8. Case assembly
Using eyebolts (Thread dia. = 24 mm, Pitch =
3.0 mm), raise case assembly (44), and remove
together with bearing.
2) Shrink fit bearing (50).
★ Shrink-fitting temperature: 100°C for ap-
prox. 2 hours
3) Using tool A, install floating seal (45).
★ Clean the seal surface with a sponge,
then coat thinly with engine oil.

2. Case
1) Assemble the following parts to case.
i) Expand fit bearing outer races (46) and
(47) to case (44).

30-32 PC1800-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

ii) Using tool A, install floating seal (45). 4. Ring gear

★ Clean the seal surface with a Using 2 wires, raise ring gear (43) and install.
sponge, then coat thinly with engine
oil.

5. Adjust preload, retainer

Adjust preload as follows.
2) Using 2 eyebolts (Thread dia. = 24 mm, 1) Tighten retainer (42) with 4 mounting bolts
Pitch = 3.0 mm), raise case assembly (44), uniformly.
then align seal, and install. 2) Remove mounting bolts, then rotate case
(44), and check that bearing also rotates
smoothly at the same time.
3) Tighten 4 bolts at 34.3 Nm {3.5 kgm} uni-
formly again.
4) Using depth micrometer from mounting bolt
hole, or clearance gauge from inside case,
measure clearance a between retainer and
tip of housing.
5) Select shim with a thickness of 0.3 mm
greater than measured dimension.

3. Bearing
Install bearing (51).

PC1800-6 30-33
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

6) Insert shim and install retainer (42). 7. Carrier assembly (large)

3 Mounting bolt: 1) Assemble carrier assembly as follows.
279.5 ± 29.4 Nm {28.5 ± 3 kgm} i) Install button (37) to carrier.

7) Set dial gauge 1 on ring gear, then lever up ii) Assemble bearing (35) and spacer (36)
case, and measure end play. to gear (34).
★ End play: 0 – 0.1 mm ★ The bearing and spacer form a set,
★ If the end play is not within the standard so be careful not to change the com-
value, adjust the shim thickness and re- binations.
peat Steps 6) and 7) to measure again. iii) Fit thrust washers (33) to both faces of
gear (34), then set on carrier.
★ Align the inside diameter of the
spacer with the inside diameter of
the bearing.

6. Shaft
Raise shaft (41) with wire and install.
★ Set a block between the shaft and the retain-
er, and pull out the wire.

30-34 PC1800-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

iv) Expand fit shaft (32). 8. Carrier assembly (small)

★ Fit lock plate (31) to shaft (32), use a 1) Assemble carrier assembly as follows.
guide bolt to align the bolt hole, then i) Install snap ring (28) to gear (24).
install. ii) Fit spacer (27), and install outer race
★ If the shaft is stiff, press fit it with a (26) (outside diameter: 150 mm).
press. ★ The outer race and bearing form a
v) Install lock plate (31). set, so make match marks.
2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
112.8 ± 9.8 Nm {11.5 ± 1 kgm}

iii) Assemble bearing (25) and spacer (23)

to gear (24), then set on carrier.
★ Align the inside diameter of spacer
(23) with the inside diameter of the
2) Apply gasket sealant, and align gear with bearing.
shaft, then install carrier assembly (29). iv) Expand fit shaft (22).
2 Carrier mounting surface: ★ Fit lock plate (21) to shaft, use a
Gasket sealant (LG-6) guide bolt to align the bolt hole, then
2 Mounting bolt: install.
Thread tightener (LT-2) ★ If the shaft is stiff, press fit it with a
3 Mounting bolt: press.
931.6 ± 98.1 Nm {95 ± 10 kgm}

PC1800-6 30-35
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

v) Install lock plate (21). 10. Case, gear assembly

2 Mounting bolt: 1) Assemble case and gear assembly as fol-
Thread tightener (LT-2) lows.
3 Mounting bolt: i) Install bearings (13) (inside diameter:
112.8 ± 9.8 Nm {11.5 ± 1 kgm} 105 mm) to gear (11).
ii) Install bearings (12) (inside diameter: 45
mm) to gear (10).

2) Raise carrier assembly (19), then align with

shaft and install.
iii) Align with dowel pin, and install thrust
washer (18) to case (17).
iv) Install lubrication tube (16).
2 Tube: Thread tightener (LT-2)
v) Install outer races (15) (outside diame-
ter: 190 mm) and (14) (outside diame-
ter: 85 mm).

9. Ring gear (small)

Apply gasket sealant, and install ring gear (18).

vi) Install gears (10) and (11) to case.

30-36 PC1800-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

vii) Fit spacer (9) to shaft (8), then install to 11. Case assembly
gear (10). 1) Install outer races (3) (outside diameter: 190
mm) and (2) (outside diameter: 85 mm) to
case (4).

viii) Fit holder (7), and tighten bolts (6).

2 Mounting bolt:
Thread tightener (LT-2) 2) Apply gasket sealant, and install case
3 Mounting bolt: assembly (1).
279.5 ± 29.4 Nm {28.5 ± 3 kgm} 2 Case: Gasket sealant (LG-6)

2) Apply gasket sealant, and install case and

gear assembly (5).

PC1800-6 30-37
DISASSEMBLY AND ASSEMBLY SWING MOTOR

REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY

REMOVAL INSTALLATION
k Lower the work equipment completely to the • Carry out installation in the reverse order to
ground and stop the engine. removal.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
★ When installing the motor from the rear, if the
1. Remove top cover (1) (rear only). mounting bolt holes cannot be aligned, re-
lease the brake. Remove plug 1 (Thread
dia. = 14 mm, Pitch = 2.0 mm) and apply hy-
draulic pressure.

2. Disconnect hoses (2), (3), (4), and (5).

3. Lift off swing motor assembly (6).

4
• Refilling with oil
Swing motor assembly: 120 kg ★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
★ Add oil to replace the oil that leaked out
when the motor assembly was removed.

30-38 PC1800-6
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

REMOVAL AND INSTALLATION OF REVOLVING FRAME

ASSEMBLY
REMOVAL 7. Pull out pin (7), and move link (8) towards frame.
1. Remove work equipment assembly from chas-
sis.
For details, see REMOVAL OF BOOM ASSEM-
BLY.

2. Remove counterweight assembly.

For details, see REMOVAL OF COUNTER-
WEIGHT ASSEMBLY.

3. Disconnect 4 grease tubes (1).

4. Leave 3 or 4 mounting bolts (2) each at front

and rear of revolving frame, and remove other
mounting bolts.
8. Revolving frame assembly
★ Start the engine and swing the revolving
1) Fit wires to counterweight mounting frame
frame while removing the bolts.
and boom mount, then sling revolving frame
★ If you do not start the engine, remove the
assembly.
swing motor and use a crane to swing the re-
2) Remove remaining mounting bolts and lift
volving frame.
off revolving frame assembly.

4 Revolving frame assembly:

Approx. 46,230 kg

5. Disconnect swivel joint top pipes (3), (4), and

(5).

6. Disconnect clamp (6) of swing motor hose

between front and rear.
INSTALLATION
• Carry out installation in the reverse order to
removal.

2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt:
2746 ± 294 Nm {280 ± 30 kgm}

2 Swing circle top surface:

Gasket sealant (LG-6)

PC1800-6 30-39
DISASSEMBLY AND ASSEMBLY SWING CIRCLE

REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY

REMOVAL INSTALLATION
1. Remove revolving frame assembly. • Carry out installation in the reverse order to
For details, see REMOVAL OF REVOLVING removal.
FRAME ASSEMBLY.

2. Remove mounting bolts (1). 2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt:
2746 ± 294 Nm {280 ± 30 kgm}

2 Swing circle mounting surface

: Gasket sealant (LG-6)

Approx. 170 l
★ Amount of grease (G2-LI) in oil bath:

500 l)
(Amount to top surface of inside teeth:

★ Coat inside teeth with grease (G2-LI).

★ Fill groove of seal with grease (G2-LI).
★ Set the S (Soft zone) marks facing to the
3. Pass round bar through revolving frame mount- side.
ing bolt holes, fit wire, then lift off swing circle
assembly (2).

4 Swing circle assembly: 3,610 kg

30-40 PC1800-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

REMOVAL AND INSTALLATION OF SWING MACHINERY

ASSEMBLY
REMOVAL 5. Using eyebolts 1, sling swing machinery
1. Remove swing motor assembly. assembly (3), screw in forcing screws, pull out
For details, see REMOVAL OF SWING MOTOR pilot portion, then remove.
ASSEMBLY.
4 Swing machinery assembly: 1050 kg
2. Drain oil.

6 Swing machinery case: Approx. 30 l

3. Disconnect drain hose (1).

INSTALLATION
• Carry out installation in the reverse order to
removal.

4. Remove step (2). (for removal of front swing

machinery) 3 Mounting bolt:
1715 ± 196 Nm {175 ± 20 kgm}

• Refilling with oil

★ Add oil through oil filler to the specified level.

5
Approx. 30 l
Swing machinery case:

Remove ladder (2). (for removal of rear swing

machinery)

PC1800-6 30-41
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY

ASSEMBLY
DISASSEMBLY 5. No. 1 carrier assembly
1. Oil filler 1) Fit wires to gear at three places, sling at
Disconnect breather hose, then remove oil filler three points, then lift off No. 1 carrier assem-
(1). bly (5).

2. Cover
Using eyebolts 1, lift off cover (2).

2) Disassemble No. 1 carrier assembly as fol-

lows.
i) Remove thrust washer (6).
3. No. 1 sun gear ii) Knock pin (7) into shaft (8).
Remove No. 1 sun gear (3). iii) Knock shaft (8) upwards to remove.
★ Pull out pin (7) from shaft (8).
4. No. 1 ring gear
Remove No. 1 ring gear (4).

30-42 PC1800-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

iv) Pull out gear (9) from carrier (10), then 9. No. 2 carrier assembly
remove thrust washer (11) and bearing 1) Fit wires at 2 places at gears, then lift off No.
(12). 2 carrier assembly (18).

6. No. 2 sun gear 2) Disassemble No. 2 carrier assembly as fol-

Remove No. 2 sun gear (13). lows.
i) Knock pin (19) into shaft (20).
7. Cover ii) Knock shaft (20) downwards to remove.
Remove 28 bolts, and using eyebolts 5, ★ Pull out pin (19) from shaft (20).
remove cover (16).

iii) Pull out gear (21) from carrier (22), then

8. No. 2 ring gear remove thrust washer (23) and bearing
Using eyebolts 2, remove No. 2 ring gear (17). (24).

PC1800-6 30-43
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

iv) Remove thrust washer (25).

10. Hub
1) Remove bolt (26).
2) Remove plate (27).
3) Remove hub (28).

5) Support position of bolt hole of cover

assembly (29) with block 4, and set in
press.
★ Set the block height so that there is a
clearance of approx. 150 mm between
11. Pinion shaft assembly the pinion and the press stand.
• When removing the outer race, do as fol- 6) Push pinion shaft (32) and pull out from
lows. bearing (36).
1) Remove mounting bolts of cover assembly ★ The shaft will go at an angle, so push
(29). perpendicularly.
7) Remove cover assembly (29) from pinion
shaft (32).

2) Put block 3 in contact with case (31), then

set in press.
★ Set the block height so that there is a 8) Remove oil seal (30) from cover (35).
clearance of approx. 150 mm between
the pinion and the press stand.
3) Push pinion shaft (32) from top to remove
pinion shaft.
★ The bearing will come out: bottom part
(36) is the outer race and top part (37) is
the inner race.
★ The bearing is a spherical type, so do
not press it continuously with the press.
Release the pressure at intervals, and
repeat the pushing operation.
4) Remove spacer (34).

30-44 PC1800-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

12. Bearing 4) Remove cover (29).

Remove bearing (37) from case (31). 5) Remove bearings (37), (36) from case (31).

• When removing the inner race, do as fol-

lows.
1) Put block 6 in contact with cover assembly
(29), then set in press.
★ Set the block height so that there is a
clearance of approx. 150 mm between
the pinion and the press stand.
2) Push pinion shaft (32) from top to remove
pinion shaft.
★ The inner races of both bearing (36) and
(37) will come out.
3) Remove spacer (34).

PC1800-6 30-45
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

ASSEMBLY 3) Align oil groove of cover assembly (29) with

★ Clean all parts, and check for dirt or damage. drill hole (drain port) of case (31), then
Coat the sliding surfaces of all parts with engine install cover assembly (29).
oil before installing. 2 Cover mounting surface:
Gasket sealant (LG-6)
1. Bearing 3 Bolt:
1) Expand fit bearing (36) to case (31), or use 66.5 ± 7.5 Nm {6.75 ± 0.75 kgm}
a press to install.

2. Pinion shaft assembly

2) Using tool F1, press fit oil seal (30) to cover 1) Set spacer (34) on push tool 7, and set
(35). case (31) in position.
2 Outside circumference of oil seal: ★ Clearance a between the case and the
Gasket sealant (LG-6) press stand is 1 – 2 mm.
2 Lip of oil seal: Grease (G2-LI) 2) Check that spacer (4) is in correct position,
then set pinion shaft (32) and press fit to
bearing (36).
★ When setting pinion shaft (32) to case
assembly (31), be careful not to damage
the oil seal.

30-46 PC1800-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

3. Bearing ★ There are the remains of the caulking when

Using tool F2, install bearing (37). the pin is inserted at the end face of hole h at
★ Press the bearing inner race and outer race the side of the carrier, so remove the caulked
at the same time when press fitting. Do not metal from the inside diameter of the hole
push only the inner race when press fitting. before starting to assemble.
★ After press fitting the bearing, check that the ii) Assemble bearing (24) to gear (21), put
case rotates smoothly. thrust washer (23) in contact with both
ends, then set gear assembly to carrier
(22).

4. Hub
1) Install hub (28).
2) Install plate (27). iii) Align position of pin holes of carrier and
3) Tighten bolt (26). shaft, then tap with a plastic hammer to
2 Bolt: Thread tightener (LT-2) install shaft (20).
3 Bolt: ★ When installing the shaft, rotate the
385 ± 42 Nm {39.25 ± 4.25 kgm} planetary gear, and be careful not to
damage the thrust washer.
iv) Insert pin (19).
★ Check that the pin groove and pro-
truding part of the pin are not fa-
tigued. If the pin is defective, replace
it with a new part.
★ When assembling the pin again,
avoid the position previously used
for caulking.
★ After inserting the pin, caulk the pin
portion (marked by arrows) of the
carrier.
★ After assembling the carrier assem-
bly, check that gear (21) rotates
5. No. 2 carrier assembly smoothly.
1) Assemble No. 2 carrier assembly as follows.
i) Install thrust washer (25).

PC1800-6 30-47
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

2) Fit wires at 2 places at gears, raise No. 2 8. No. 2 sun gear

carrier assembly (18), align hub gear, then 1) Install collar (15) and button (14) to sun gear
install. (13).
2) Install No. 2 sun gear (13).

6. No. 2 ring gear

Using eyebolts 2, install No. 2 ring gear (17). 9. No. 1 carrier assembly
2 Mounting surface with case: Assemble No. 1 carrier assembly as follows.
Gasket sealant (LG-6) ★ There are the remains of the caulking when
the pin is inserted at the end face of hole h at
the side of the carrier, so remove the caulked
metal from the inside diameter of the hole
before starting to assemble.
1) Assemble bearing (12) to gear (9), put thrust
washer (11) in contact with both ends, then
set to carrier (10).

7. Cover
1) Align oil groove of oil filler port with protru-
sion of case, and install cover (16).
2 Mounting surface with No. 2 ring
gear: Gasket sealant (LG-6)
2) Tighten mounting bolts.
2 Bolt:
385 ± 42 Nm {39.25 ± 4.25 kgm} 2) Align position of pin holes of carrier and
shaft, then tap with a plastic hammer to
install shaft (8).
★ When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
3) Insert pin (7).
★ Check that the pin groove and protruding
part of the pin are not fatigued. If the pin
is defective, replace it with a new part.
★ When assembling the pin again, avoid
the position previously used for caulking.

30-48 PC1800-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY

4) Install thrust washer (6). 10. No. 1 ring gear

★ After inserting the pin, caulk the pin por- Align drill hole at oil filler port and install No. 1
tion (marked by arrows) of the carrier. ring gear (4).
(See Step 5., 1), iv).) 2 Mounting surface:
★ After assembling the carrier assembly, Gasket sealant (LG-6)
check that gear (9) rotates smoothly.
11. No. 1 sun gear
Install No. 1 sun gear (3).

12. Cover
Using eyebolts 1, raise cover (2), then align oil
filler and install.
2 Mounting surface:
Gasket sealant (LG-6)
3 Bolt: 277 ± 32 Nm {28.25 ± 3.25 kgm}

13. Install oil filler (1), and connect breather hose.

2 Mounting portion:
Gasket sealant (LG-5)
3 Oil filler:
56.35 ± 14.25 Nm {5.75 ± 1.45 kgm}
5) Fit wires at 3 places at gears, align with No.
1 carrier assembly (5), then install.

PC1800-6 30-49
DISASSEMBLY AND ASSEMBLY IDLER CUSHION CYLINDER

REMOVAL AND INSTALLATION OF IDLER CUSHION CYLINDER

ASSEMBLY
REMOVAL 5. Pull out idler cushion cylinder assembly (4), then
k Lower the work equipment completely to the remove.
ground and stop the engine. Then loosen the oil
filler cap slowly to release the pressure inside 4 Idler cushion cylinder assembly:
the hydraulic tank. 885 kg
k Release the pressure from the circuit.
For details, see TESTING AND ADJUSTING,
Remaining pressure relief from HIC circuit.

1. Remove track shoe assembly

For details, see REMOVAL OF TRACK SHOE
ASSEMBLY

2. Sling idler and adjustment cylinder, then remove

front idler assembly (1).
★ Use a lever block at the adjustment cylinder
end to make the load horizontal.

4 Front idler assembly: 1,110 kg

INSTALLATION
• Carry out installation in the reverse order to
removal.

• Bleeding air
(Bleeding air from idler cushion circuit)
For details, see TESTING AND ADJUSTING,
Bleeding air from and filling pressurized oil in
HIC circuit.

3. Disconnect tube (2).

4. Remove 8 mounting bolts (3).

30-50 PC1800-6
DISASSEMBLY AND ASSEMBLY IDLER CUSHION CYLINDER

DISASSEMBLY AND ASSEMBLY OF IDLER CUSHION CYLINDER

ASSEMBLY
DISASSEMBLY ASSEMBLY
1. Remove gland (1). 1. Install bushing (10) (O.D.: 144 mm) on cylinder.

2. Remove plunger assembly (2) from cylinder (3).

2. Press fit dust seal (9) (O.D.: 160 mm), then

install snap ring (8).
3. Remove snap ring (4), then remove packing (5)
and wear ring (6) from plunger (7). 3. Assemble wear ring (6) and packing (5) on
plunger (7), then install snap ring (4).

4. Coat with grease (G2-LI) and assemble plunger

assembly (2) in cylinder (3).

5. Fit O-ring and install gland (1).

★ If the tip of the bolt protrudes from the gland,
remove the tip to make it level with the sur-
face.
★ Install the gland so that the mounting hole of
the tube is parallel to the bracket mounting
plate of the cylinder.

4. Remove snap ring (8), then remove dust seal

(9).

PC1800-6 30-51
DISASSEMBLY AND ASSEMBLY IDLER ADJUSTMENT CYLINDER

DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT

CYLINDER ASSEMBLY
DISASSEMBLY 4. Remove dust seal (6).
1. Remove cylinder assembly (7) from front idler
assembly.

ASSEMBLY
2. Remove plunger assembly (2) from yoke (1). 1. Assemble wear ring (5) and packing (4) on
k Remove the lubricator and pump in air to plunger, then install snap ring (3).
push out the plunger. Be careful when
pumping in air as the plunger will come out 2. Fill plunger with grease (G2-LI).
suddenly. ★ Standard amount: 4600 cc
★ After the plunger is assembled, it is impossi-
ble to bleed the air completely, so always put
in grease first.

3. Coat with grease, then raise yoke (1) and lower

on plunger (2) side to install.

4. Install dust seal (6).

3. Remove snap ring (3), then remove packing (4)

and wear ring (5) from plunger.

30-52 PC1800-6
DISASSEMBLY AND ASSEMBLY TRACK SHOE

REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY

REMOVAL 5. Pull out master pin with tool A.
1. Loosen plug (1) 1 turn slowly to relieve track
shoe tension.
k The adjustment cylinder is under extremely
high pressure. Never loosen the plug more
than one turn. If the track shoe tension is not
relieved, move the machine backwards and
forwards.

6. Pull block or hydraulic jack 1 (980 kN {10 ton})

under track shoe at idler, then pull out guide pin
2.

7. Support front of track shoe with crane, and

move machine slowly in reverse to separate
track shoe assembly (3).
2. Relieve the remaining pressure from the circuit
referring to the section Remaining pressure
relief from HIC circuit.

3. Move machine so that master pin is located mid-

way between front idler and carrier roller.
★ Make sure that there is enough space to lay
out the track shoe behind the machine.

4. Remove snap ring (2).

INSTALLATION
1. Close stop valves (7) and (8).

2. Raise top of track shoe assembly with crane, fit

on sprocket, then move machine forward slowly,
and install track shoe.

PC1800-6 30-53
DISASSEMBLY AND ASSEMBLY TRACK SHOE

3. Fit block or hydraulic jack 1 (980 kN {10 ton}) to 6. Install snap ring (2).
shoe at idler end, and raise link at idler end.

7. Before pumping in grease, check that protrusion

4. Assemble spacer (4) and washer (5) to link, then S of hydraulic cushion cylinder plunger B is 135
connect to link at bottom and install guide pin. ± 5 mm on both left and right.
★ If protrusion S is not within the standard val-
ue, adjust the hydraulic cushion.
(For details, see INSTALLATION OF IDLER
CUSHION ASSEMBLY.)

5. Move guide pin to midway point between idler

and carrier roller, then use tool A to press fit
master pin.

8. Pump in grease (G2-LI) through lubricator (6),

and adjust tension of track shoe.
★ Adjust the track shoe tension.
For details, see TESTING AND ADJUST-
ING, Inspection and adjustment of track
shoe tension.

9. After pumping in grease, check again that pro-

trusion S of hydraulic cushion cylinder plunger B
is 135 ± 5 mm on both left and right.
k If the machine is used with the stroke im-
properly adjusted, it may lead to a serious
accident when the shoe tension is adjusted,
so always adjust the stroke properly.

30-54 PC1800-6
DISASSEMBLY AND ASSEMBLY FRONT IDLER

REMOVAL AND INSTALLATION OF FRONT IDLER ASSEMBLY

REMOVAL INSTALLATION
1. Remove the track shoe. For details, see 1. Install yoke (3) to the idler.
REMOVAL OF TRACK SHOE ASSEMBLY.
3 Idler mounting bolt:
2. Loosen mounting bolts (1) of the cushion cylin- 1720 ± 196 Nm {175 ± 20 kgm}
der, adjustment cylinder, and idler assembly.
2. Sling the idler and adjustment cylinder and
install front idler assembly (2) to the frame.
3 Mounting bolt:
927 ± 98 Nm {94.5 ± 10 kgm}
★ Use a lever block on the adjustment cylinder
side.

3. Install the track shoe. For details, see INSTAL-

LATION OF TRACK SHOE ASSEMBLY.

3. Sling the idler and adjustment cylinder and

remove front idler assembly (2).
★ Secure the level of the front idler assembly
by using a lever block on the adjustment cyl-
inder side.

4. Remove mounting bolts (4) of yoke (3) and

remove the idler from the adjustment cylinder.

4 Front idler assembly: 1,110 kg

PC1800-6 30-55
DISASSEMBLY AND ASSEMBLY IDLER

DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

DISASSEMBLY 8. Remove bushings (10) and (11) from the idler.
1. Remove plug (1) and drain the oil.

2. Pull out mounting bolt (3) of support (2) and

remove the support.

3. Remove O-ring (5) from shaft (4).

4. Remove spacer (6) and dowel pin (7).

ASSEMBLY
1. Press fit bushings (2) and (3) to idler (1).

5. Remove floating seal assembly (9) from support

and idler (8).

2. Install floating seals (4) to the idler.

6. Set the idler on blocks [1].

7. Pull shaft (4) out of the idler.

30-56 PC1800-6
DISASSEMBLY AND ASSEMBLY IDLER

3. Install floating seal (5) to the support.

• Install the shaft, spacer, and support in the

reverse order to removal.

• Refilling with oil

quantity (1.1 l).

★ Add oil through the oil filler by the specified

PC1800-6 30-57
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER

REMOVAL AND INSTALLATION OF CARRIER ROLLER

ASSEMBLY
REMOVAL
1. Loosen the track shoe. For details, see
REMOVAL OF TRACK SHOE ASSEMBLY.

2. Using hydraulic jack 1, push up track shoe

assembly.

INSTALLATION
• Carry out installation in the reverse order to
removal.

3. Sling carrier roller assembly (2) and loosen

mounting bolts (1). 2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
1,720 ± 196 Nm {175 ± 20 kgm}

4. Lift off the carrier roller assembly.

5. Remove shaft clamp bolt (3), open bracket (4)

with a screwdriver, and pull the roller out of the
bracket.

4 Carrier roller assembly (incl. bracket):

70 kg

30-58 PC1800-6
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER

DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER

ASSEMBLY
DISASSEMBLY 5. Pull floating seal (14) out of the shaft and
1. Remove plug (1) and drain the oil. remove spacers (12) and (13).

5 Carrier roller assembly: 1.05 – 1.15 l 6. Remove O-ring (16) and dowel pin (11) from
spacer (12).
2. Loosen cover mounting bolts (2) and remove
cover (3), spacer (4), dowel pin (5), and O-ring 7. Remove floating seal (15) from carrier roller (9).
(6).

3. Remove spacer mounting bolts (7) and spacer

(8).

8. Remove bushings (17) and (18) from carrier

roller (9).

4. Pull shaft (10) out of carrier roller (9).

PC1800-6 30-59
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER

ASSEMBLY
1. Press fit bushing (2) to roller (1).

2. Turn over the roller and press fit inside bushing

(3).

7. Apply the standard pressure to the roller oil filler

to check the seal for air leakage.
★ Standard pressure: 0.1 MPa {1 kg/cm2}

3. Fit O-ring (5) and floating seal (6) to spacer (4)

and install them to shaft (7).

4. Install floating seal (8) to roller (1).

8. Fill the carrier roller assembly with oil.

5 Quantity of oil: 1.05 – 1.15 l (GO140B)

9. Install plug (14).

5. Press fit spacer (9) to shaft (7) and install the
shaft to the roller.

6. Install spacer (10) and install O-ring (11) and

dowel pin (12) to cover (13), and then install
cover (13).

★ Play of carrier roller in axial direction:

0 – 0.18 mm

30-60 PC1800-6
DISASSEMBLY AND ASSEMBLY TRACK ROLLER

REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY

REMOVAL 4. Jack up the machine with the work equipment,
1. Loosen track tension. set tool A, and sling track roller assembly (3) to
For details, see REMOVAL OF TRACK SHOE remove.
ASSEMBLY.
4 Track roller assembly: 280 kg
2. Remove roller guard (1).

3. Loosen mounting bolts (2) of track roller. INSTALLATION

• Carry out installation in the reverse order to
removal.

2 Mounting bolt: Thread tightener (LT-2)

3 Mounting bolt:
1,720 ± 196 Nm {175 ± 20 kgm}

PC1800-6 30-61
DISASSEMBLY AND ASSEMBLY TRACK ROLLER

DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER

ASSEMBLY
DISASSEMBLY 5. Remove bushings (9) and (10) from roller (5).
1. Remove plug (1) and drain the oil.

5 Track roller assembly: 0.86 – 0.94 l

2. Remove bolt (2) and collar (3).

ASSEMBLY
1. Press fit bushing (2) to track roller (1).

2. Turn over the roller and press fit bushing (3).

3. Pull shaft (4) out of roller (5) and remove O-ring
(6).

3. Install floating seals (4) to track roller (1).

4. Remove floating seals (7) and (8) from roller (5) 4. Install floating seals (6) to collar (5).
and collar (3).

30-62 PC1800-6
DISASSEMBLY AND ASSEMBLY TRACK ROLLER

5. Fit O-rings (8) to shaft (7) and install shaft (7) to

the track roller.

6. Install collars (5) to shaft (7) and tighten bolts

(9).

7. Apply the standard pressure to the roller oil filler

to check the seal for air leakage.
★ Standard pressure: 0.1 MPa {1 kg/cm2}

8. Fill the track roller assembly with oil.

5 Quantity of oil: 0.86 – 0.94 l (GO140B)

9. Install plug (1).

★ Play of track roller in axial direction:
0 – 0.18 mm

PC1800-6 30-63
DISASSEMBLY AND ASSEMBLY CONTROL • PTO LUBRICATION PUMP

REMOVAL AND INSTALLATION OF CONTROL • PTO

LUBRICATION PUMP ASSEMBLY
REMOVAL 6. Disconnect pump inlet tubes (5) and (6).
k Lower the work equipment completely to the ★ When the inlet tube is disconnected, the oil
ground and stop the engine. Operate the control inside the piping will flow out, so catch it in an
levers several times to release the remaining oil pan.
pressure in the hydraulic piping. Then loosen the
oil filler cap slowly to release the pressure inside 7. Remove control and PTO lubrication pump
the hydraulic tank. assembly (7).
★ Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.

1. Remove cover, then remove strainer (1) from

tank.

2. Remove rod from strainer, install tool A, assem-

ble in tank, then fit spring and install cover.
★ When not using tool A, loosen the drain
valve at the bottom of the hydraulic tank and
drain the oil.

6 Hydraulic tank: Approx. 1500 l

INSTALLATION
• Carry out installation in the reverse order to
removal.

• Refilling with oil (hydraulic tank)

★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

• Bleeding air
Bleed air from pump.
For details, see TESTING AND ADJUSTING,
3. Disconnect tube (2) and sling. Air bleeding from each component.

4. Remove bracket (3) of hose clamp.

5. Disconnect hose (4).

30-64 PC1800-6
DISASSEMBLY AND ASSEMBLY SWING PUMP

REMOVAL AND INSTALLATION OF SWING PUMP ASSEMBLY

REMOVAL
k Lower the work equipment completely to the
ground and stop the engine. Operate the control
levers several times to release the remaining
pressure in the hydraulic piping. Then loosen the
oil filler cap slowly to release the pressure inside
the hydraulic tank.
★ Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering. Mark
with tags to prevent mistakes when connecting.

1. Remove cover, then remove strainer (1) from

tank.

2. Remove rod from strainer, install tool A, assem-

ble in tank, then fit spring and install cover.
★ When not using tool A, loosen the drain
valve at the bottom of the hydraulic tank and
drain a quarter of oil.

INSTALLATION
• Carry out installation in the reverse order to
removal.
3. Disconnect pump outlet hose (2) and branch
hose (3). • Refilling with oil (hydraulic tank)
★ Add oil through oil filler to the specified level.
4. Disconnect high pressure hose (4), drain hose Run the engine to circulate the oil through
(5) and control hose (6). the system. Then check the oil level again.

5. Disconnect hoses (7), (8) and (9). • Bleeding air

Bleed air from pump.
6. Disconnect pump inlet hose (10). For details, see TESTING AND ADJUSTING,
★ When the pump inlet hose is disconnected, Air bleeding from each component.
the oil inside the piping will flow out, so catch
it in an oil pan.

7. Sling swing pump assembly, and remove

mounting bolts, then remove swing pump
assembly (11).

4 Swing pump assembly: 140 kg

PC1800-6 30-65
DISASSEMBLY AND ASSEMBLY NO. 1, 3 PUMP

REMOVAL AND INSTALLATION OF NO. 1, 3 PUMP ASSEMBLY

REMOVAL
k Lower the work equipment completely to the
ground and stop the engine. Operate the control
levers several times to release the remaining
pressure in the hydraulic piping. Then loosen the
oil filler cap slowly to release the pressure inside
the hydraulic tank.
★ Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering. Mark
with tags to prevent mistakes when connecting.

1. Remove cover, then remove strainer (1) from

tank.

2. Remove rod from strainer, install tool A, assem-

ble in tank, then fit spring and install cover.
★ When not using tool A, loosen the drain
valve at the bottom of the hydraulic tank and
drain the oil.

6 Hydraulic tank: Approx. 1500 l

INSTALLATION
• Carry out installation in the reverse order to
removal.

• Refilling with oil (hydraulic tank)

3. Disconnect No. 2, 4 pump outlet hoses (2). ★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
4. Disconnect clamp (3) of No. 4 pump drain hose. the system. Then check the oil level again.
(only No. 3 pump)
• Bleeding air
5. Disconnect pump outlet hoses (4) and NC outlet Bleed air from pump.
hoses (5). For details, see TESTING AND ADJUSTING,
Air bleeding from each component.
6. Disconnect pump drain hose (6) and control
hose (7).

7. Disconnect pump inlet hose (8).

★ When the pump inlet hose is disconnected,
the oil inside the piping will flow out, so catch
it in an oil pan.

8. Sling pump assembly, and remove mounting

bolts, then remove pump assembly (9).

4 No. 1, 3 pump assembly: 150 kg

30-66 PC1800-6
DISASSEMBLY AND ASSEMBLY NO. 2, 4 PUMP

REMOVAL AND INSTALLATION OF NO. 2, 4 PUMP ASSEMBLY

REMOVAL 9. Sling pump assembly, and remove mounting
k Lower the work equipment completely to the bolts, then remove pump assembly (13).
ground and stop the engine. Operate the control
levers several times to release the remaining 4 No. 2, 4 pump assembly: 160 kg
pressure in the hydraulic piping. Then loosen the
oil filler cap slowly to release the pressure inside
the hydraulic tank.
★ After disconnecting the hoses, fit blind plugs to
prevent dust or dirt from entering, and fit tags to
prevent mistakes in the connections when install-
ing.

1. Remove cover, and take out strainer (1) from

inside of tank.
2. Remove strainer and install tool A on rod, then
assemble rod and tool A inside tank, fit spring,
and install cover.
★ When not using tool A, loosen the drain
valve at the bottom of the hydraulic tank and
drain the oil.

6 Hydraulic tank: Approx. 1500 l

INSTALLATION
• Carry out installation in the reverse order to
removal.
3. Disconnect wiring at connector (2).
• Refilling with oil (hydraulic tank)
4. Disconnect swing pump high pressure hose (3), ★ Add oil through oil filler to the specified level.
4 jet sensor hoses (4), and 2 NC output hoses Run the engine to circulate the oil through
(5). the system. Then check the oil level again.

5. Disconnect 2 hoses (6) for CO 2-stage cut and • Bleeding air

TVC output hose (7) for swing pump. Bleed air from pump.
For details, see TESTING AND ADJUSTING,
6. Disconnect pump drain hose (8) and control Air bleeding from each component.
hose (9).

7. Disconnect pump outlet hoses (10) and branch

hoses (11).

8. Disconnect pump inlet hose (12).

★ When the inlet tube is disconnected, the oil
inside the piping will flow out, so catch in an
oil pan.

PC1800-6 30-67
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

REMOVAL AND INSTALLATION OF HYDRAULIC TANK

ASSEMBLY
REMOVAL
k Swing the frame to bring the hydraulic tank to
between both track shoes.
k Lower the work equipment to the ground, stop
the engine, and loosen the hydraulic tank cap
slowly to release the internal pressure of the hy-
draulic tank.
★ Make match marks on the hoses before discon-
necting them.
★ Plug the disconnected tubes and hoses.

1. Drain the oil from the hydraulic tank.

6 Hydraulic tank: 1500 l

6. Disconnect hydraulic oil temperature sensor
2. Remove cover (1).
(10).

7. Disconnect drain filter hoses (11) and (12).

8. Disconnect hoses (13) and (14) between the

tank and block.

9. Disconnect drain hose (15).

3. Remove ladder (2), handrails (3) and (4), and

side cover assembly (5).

10. Disconnect suction tubes (16) and (17) under

the hydraulic tank.

4. Disconnect oil level sensor connector (6) and

remove clamps (7).

5. Disconnect 2 hoses (8) of the return filter com-

ing from the control valve and 2 hoses (9)
between the main filters.

30-68 PC1800-6
 HYDRAULIC TANK
DISASSEMBLY AND ASSEMBLY PILOT RELIEF VALVE

REMOVAL AND INSTALLA-

TION OF PILOT RELIEF
VALVE ASSEMBLY
11. Sling hydraulic tank assembly (18), remove REMOVAL
mounting bolts (19), and lift off the hydraulic k Lower the work equipment completely to the
tank assembly. ground and stop the engine. Then loosen the oil
filler cap slowly to release the pressure inside
4 Hydraulic tank assembly: 1,500 kg the hydraulic tank.
• Remove pilot relief valve assembly (1).

INSTALLATION
• Carry out installation in the reverse order to
removal. INSTALLATION
• Carry out installation in the reverse order to
removal.
2 Mounting bolt: Adhesive (LT-2)
3 Hydraulic tank mounting bolt:
549 ± 58 Nm {56 ± 6 kgm} 3 Pilot relief valve:
152 ± 25 Nm {15.5 ± 2.5 kgm}
• Refilling with oil
Circulate the oil through the system and check
the oil level again. ★ Check the relief pressure.
5 Hydraulic tank: 1500 l
For details, see TESTING AND ADJUST-
ING, Inspection and adjustment of control
circuit oil pressure.
• Bleeding air
Bleed air from the piping. For details, see
TESTING AND ADJUSTING, Air bleeding from
each component.

PC1800-6 30-69
DISASSEMBLY AND ASSEMBLY PILOT RELIEF VALVE

DISASSEMBLY AND ASSEMBLY OF PILOT RELIEF VALVE

ASSEMBLY
DISASSEMBLY ASSEMBLY
1. Loosen locknut (1) and remove holder (2). 1. Assemble valve (9) and spring (8) to sleeve
(12), fit O-ring and backup ring, then install seat
2. Remove retainer (3), spring (4), spacer (5), and (7).
poppet (6).
2. Assemble poppet (6), spacer (5), spring (4), and
3. Remove seat (7), spring (8), and valve (9). retainer (3).
★ Do not remove plug (10) as it cannot be sup-
plied as an individual part. 3. Fit O-ring and install holder (2), then tighten nut
★ Do not disassemble adjustment screw (11) (1).
except when replacing parts. ★ After installing the valve to the machine, ad-
just the relief pressure.
For details, see TESTING AND ADJUST-
ING, Inspection and adjustment of control
circuit oil pressure.

30-70 PC1800-6
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE (FOR SWING)

DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE

ASSEMBLY (FOR SWING)
DISASSEMBLY ASSEMBLY
1. Loosen locknut (3) and remove holder (4). 1. Assemble spring (13) and valve (12) in sleeve
(14), and secure with snap ring (11).
2. Remove seat (5). ★ Check that the snap ring is fitted securely in
the groove.
3. Loosen nut (6) and remove adjustment screw
(7), then remove retainer (8), spring (9), and 2. Assemble poppet (10), spring (9), and retainer
poppet (10). (8) to holder (4).
★ Before loosening nut (6), measure the pro-
trusion of the adjustment screw from the end 3. Adjust protrusion of the adjustment screw (7)
face of holder (4). from end face of holder (4) to same distance as
when disassembling, then tighten nut (6).
4. Remove snap ring (11), and pull out valve (12)
and spring (13) from sleeve (14). 4. Fit O-ring and backup ring, then assemble seat
(5) in sleeve (14).

5. Install holder (4) in sleeve (14), and tighten nut

(3).
★ After installing the valve to the machine, ad-
just the relief pressure.
For details, see TESTING AND ADJUST-
ING, Inspection and adjustment of work
equipment, swing and travel circuit oil pres-
sures.

PC1800-6 30-71
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE (FOR WORK EQUIPMENT, TRAVEL)

DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE

ASSEMBLY (FOR WORK EQUIPMENT, TRAVEL)
DISASSEMBLY ASSEMBLY
1. Loosen nut (1) and remove holder (2). 1. Assemble spring (9) and valve (8) in sleeve (13),
★ Before loosening nut (1), measure the di- then install snap ring (7).
mension from sleeve (13) to plug (10).
2. Fit O-ring and backup ring, then assemble seat
2. Remove spring (3) and poppet (4). (6), and install plug (5).

3. Remove plug (5), then remove seat (6). 3. Assemble poppet (4) and spring (3).

4. Remove snap ring (7), then remove valve (8) 4. Set the protrusion from sleeve (13) to end face
and spring (9). of plug (10) to same distance as when disas-
★ Do not disassemble plug (10), nut (11) and sembling, then install holder (2) and tighten nut
retainer (12) except when replacing parts. (1).
★ Parts (5), (6), (8), and (13) cannot be sup- ★ After installing the valve to the machine, ad-
plied as individual parts. just the relief pressure.
For details, see TESTING AND ADJUST-
ING, Inspection and adjustment of work
equipment, swing and travel circuit oil pres-
sures.

30-72 PC1800-6
DISASSEMBLY AND ASSEMBLY SWING CONTROL VALVE

REMOVAL AND INSTALLATION OF SWING CONTROL VALVE

ASSEMBLY
REMOVAL INSTALLATION
k Lower the work equipment completely to the • Carry out installation in the reverse order to
ground and stop the engine. removal.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. • Refilling with oil
★ Add oil through oil filler to the specified level.
1. Disconnect 2 jet sensor hoses (1). Run the engine to circulate the oil through
the system. Then check the oil level again.
2. Disconnect left and right pilot hoses (2). ★ Add oil to replace the oil that leaked out
when the control valve assembly was re-
3. Disconnect tube (3), and hoses (4) and (5). moved.

4. Disconnect 2 tubes (6) leading to swing motor.

5. Remove battery on top of control valve.

6. Sling swing control valve assembly (7) tempo-

rarily, remove mounting bolts, then remove.

4 Swing control valve assembly: 110 kg

★ Using the lifting holes under the battery
case, raise the valve assembly, then lower it
straight down. Sling it again from outside the
side cover, then lift it off.

PC1800-6 30-73
DISASSEMBLY AND ASSEMBLY SWING CONTROL VALVE

DISASSEMBLY AND ASSEMBLY OF SWING CONTROL VALVE

ASSEMBLY
DISASSEMBLY
1. Remove case (1), then remove springs (2) and
(3), and retainer (4), and pull out spool (5) from
valve body (6).

2. Remove plate (7), then remove spring (8) and

valve (9).

3. Remove jet sensor assembly (11), then pull out

flange (12).

4. Remove relief valve assembly (13).

5. Disassemble jet sensor assembly as follows.

1) Remove orifice (14).
2) Remove relief valve assembly (15).
3) Disassemble relief valve assembly as fol-
lows.
i) Loosen locknut (16), and remove holder
(17).
★ Before disassembling, measure the
dimension from sleeve (18) to screw
(19).
ii) Remove spring (20), poppet (21), seat
(22), spring (23), and piston (24).
★ Do not disassemble sleeve (19) except
when replacing parts.

ASSEMBLY
1. Assemble jet sensor assembly as follows.
1) Assemble relief valve assembly as follows.
i) Assemble piston (24), spring (23), seat
(22), poppet (21), and spring (20) in
sleeve (18).
ii) Set the protrusion from sleeve (18) to
screw (19) to same distance as when
disassembling, then install holder (17)
and tighten locknut (16).
2) Fit O-ring and backup ring, and install relief
valve assembly (15).
3) Fit O-ring and install orifice (14).

2. Fit O-ring and install relief valve assembly (13).

3 Relief valve:
321 ± 46.6 Nm {32.75 ± 4.75 kgm}

30-74 PC1800-6
DISASSEMBLY AND ASSEMBLY SWING CONTROL VALVE

3. Fit O-ring and assemble flange (12), then install

jet sensor assembly (11).

4. Assemble valve (9) and spring (8), then fit O-

ring and install plate (7).

5. Assemble spool (5) in valve body (6), then install

retainer (4) and springs (3) and (2).

6. Fit O-ring and install case (1).

PC1800-6 30-75
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE

ASSEMBLY
DISASSEMBLY
★ The operation for the L.H. 4-spool control valve
(with straight-travel valve) is basically the same
as for the R.H. 4-spool control valve and 5-spool
control valve.

1. Remove mounting bolts (1), then remove

straight-travel valve assembly (2).

2. Disassemble straight-travel valve assembly as

follows.
1) Remove cover (3).
2) Pull out plug (4), and remove backup ring
(5).
3) Remove sleeve (6), then pull out piston (7),
spool (8), and spring (9).
4) Remove plug (10), then pull out spring (11)
and check valve (12).
5) Loosen nut (13), and remove sleeve (14).

3. Remove spring (15) and check valve (16).

4. Remove seat (17), spring (18), and check valve

(19).

5. Pull out spool from valve body as follows.

1) Remove case (20), then remove springs
(21) and (22), and retainer (23).
2) Pull out spool (24) from valve body.

6. Pull out spool from valve body as follows.

1) Remove case (25), then remove tube (26)
and retainer (27).
2) Pull out spool (28) from valve body.
★ Only L.H. 4-spool control valve.

7. Remove jet sensor orifice (29) and jet sensor

relief valve (30).

8. Remove safety-suction valves (31) and (32).

9. Remove suction valve (33).

10. Remove main relief valve (34).

30-76 PC1800-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

PC1800-6 30-77
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

ASSEMBLY 10. Fit O-ring and straight-travel valve assembly (2),

★ The operation for the L.H. 4-spool control valve then tighten mounting bolts (1).
(with straight-travel valve) is basically the same ★ Tighten in the numerical order as indicated.
as for the R.H. 4-spool control valve and 5-spool 3 Bolt 1, 3, 5 – D:
control valve. 88.3 ± 9.8 Nm {9 ± 1 kgm}
★ Coat the sliding surfaces of all parts with engine 3 Bolt 2, 4:
oil before installing. 166.7 ± 9.8 Nm {17 ± 1 kgm}

1. Fit O-ring and install main relief valve (34).

3 Main relief valve:
318.7 ± 44.1 Nm {32.5 ± 4.5 kgm}

2. Fit O-ring and install suction valve (33).

3 Suction valve:
225.5 ± 9.8 Nm {23 ± 1 kgm}

3. Fit O-ring and install safety-suction valves (32)

and (31).
3 Safety-suction valve:
225.5 ± 9.8 Nm {23 ± 1 kgm}

4. Fit O-ring and install jet sensor relief valve (30)

and jet sensor orifice (29).
3 Jet sensor relief valve:
186.3 ± 9.8 Nm {19 ± 1.0 kgm}
3 Jet sensor orifice:
152 ± 24.5 Nm {15.5 ± 2.5 kgm}

5. Install spool to valve body as follows.

i) Assemble spool (28) in valve body.
ii) Assemble retainer (27) and tube (26), then
fit O-ring and install case (25).
★ Only L.H. 4-spool control valve.

6. Install spool to valve body as follows.

i) Assemble spool (24) in valve body.
ii) Assemble retainer (23) and springs (22) and
(21), then fit O-ring and install case (20).

7. Assemble check valve (19), spring (18), and

seat (17) in valve body.

8. Install check valve (16) and spring (15).

9. Assemble straight-travel valve as follows.

i) Fit O-ring and backup ring (35), install
sleeve (14), then tighten nut (13).
ii) Assemble check valve (12) and spring (11),
then fit O-ring and backup ring (36) and
install plug (10).
iii) Assemble spring (9), spool (8), and piston
(7) in valve body, then fit O-ring and install
sleeve (6).
iv) Fit backup ring (5) and install plug (4).
v) Install cover (3).

30-78 PC1800-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

PC1800-6 30-79
DISASSEMBLY AND ASSEMBLY CO, NC VALVE

REMOVAL AND INSTALLATION OF CO, NC VALVE ASSEMBLY

REMOVAL 3. For swing pump
★ Open door of pump room. 1) Disconnect jet sensor hoses (1) and (2).
2) Disconnect TVC output pressure hose (3).
1. For No. 2, 4 front pump 3) Remove CO, NC valve assembly (4).
1) Disconnect TVC valve wiring connector (1).
2) Disconnect jet sensor hoses (2) and (3).
3) Disconnect CO cancel hose (4).
4) Disconnect swing pump discharge pressure
hose (5).
5) Disconnect TVC output pressure F-R con-
nection tube (6).
6) Remove CO, NC valve assembly (7)
together with TVC valve.
★ After removing as an assembly, discon-
nect the TVC valve.

INSTALLATION
• Carry out installation in the reverse order to
removal.

3 Mounting bolt:
31.36 ± 2.94 Nm {3.2 ± 0.3 kgm}

2. For No. 2, 4 rear pump

1) Disconnect jet sensor hoses (1) and (2).
2) Disconnect CO cancel hoses (3).
3) Disconnect TVC output pressure hose (4).
4) Disconnect TVC output pressure F-R con-
nection tube (5).
5) Remove CO, NC valve assembly (6).

30-80 PC1800-6
DISASSEMBLY AND ASSEMBLY SERVO VALVE

REMOVAL AND INSTALLATION OF SERVO VALVE ASSEMBLY

REMOVAL 3. For swing pump
1. For No. 1, 3 pump 1) Remove CO•NC valve assembly.
1) Disconnect CO•NC output pressure hoses For details, see REMOVAL OF CO, NC
(1). VALVE ASSEMBLY.
2) Remove servo valve assemblies (2). 2) Remove servo valve assembly (1).

2. For No. 2, 4 pump

1) Remove CO•NC valve assembly. INSTALLATION
For details, see REMOVAL OF CO, NC • Carry out installation in the reverse order to
VALVE ASSEMBLY. removal.
2) Disconnect CO•NC output pressure hoses
(1).
3) Remove servo valve assembly (2). ★ Push in by hand until the dowel pin is fully in-
serted, then tighten the mounting bolts.
3 Mounting bolt:
31.36 ± 2.94 Nm {3.2 ± 0.3 kgm}

PC1800-6 30-81
DISASSEMBLY AND ASSEMBLY TVC VALVE

REMOVAL AND INSTALLATION OF TVC VALVE ASSEMBLY

REMOVAL INSTALLATION
1. Open door of pump room. • Carry out installation in the reverse order to
removal.
2. Disconnect TVC valve wiring connector (1) (P03
or P04).
3 Mounting bolt:
3. Disconnect swing pump discharge pressure 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
hose (2).

4. Remove TVC valve assembly (3).

30-82 PC1800-6
DISASSEMBLY AND ASSEMBLY PPC VALVE (FOR TRAVEL)

REMOVAL AND INSTALLATION OF PPC VALVE ASSEMBLY

(FOR TRAVEL)
REMOVAL INSTALLATION
k Lower the work equipment completely to the • Carry out installation in the reverse order to
ground and stop the engine. Then loosen the oil removal.
filler cap slowly to release the pressure inside
the hydraulic tank.
3 Sleeve nut (02):
1. Disconnect 4 linkages (1). 29.4 ± 4.9 Nm {3 ± 0.5 kgm}
3 Sleeve nut (03):
78.5 ± 19.6 Nm {8 ± 2 kgm}

2. Disconnect inlet hose (2), outlet hose (3), and 4

control valve hoses (4).

3. Remove PPC valve assembly (5).

PC1800-6 30-83
DISASSEMBLY AND ASSEMBLY PPC VALVE (FOR TRAVEL)

DISASSEMBLY AND ASSEMBLY OF PPC VALVE ASSEMBLY

(FOR TRAVEL)
DISASSEMBLY
1. Remove bolt (1).

2. Remove plate (2).

3. Remove seals (3), then remove collar (4).

4. Remove pistons (5).

5. Remove valve assemblies (12) from valve body

(9).

6. Remove collars (10), then remove retainers (6),

shims (11) and springs (7) from pistons (8).

7. Remove rings (13), then remove retainers (14),

springs (15) and valves (16) from valve body (9).

ASSEMBLY
1. Assemble valves (16) and springs (15) in valve
body (9), then push down retainers (14), and
install rings (13).

2. Assemble shims (11) and springs (7) on pistons

(8), then push down retainers (6), and install col-
lars (10).

3. Install valve assemblies (12) in valve body (9).

4. Install pistons (5).

5. Fit O-rings, and install collars (4).

6. Install seals (3).

7. Install plate (2), then tighten bolt (1).

3 Bolt: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}

30-84 PC1800-6
DISASSEMBLY AND ASSEMBLY PPC VALVE (FOR WORK EQUIPMENT, SWING)

REMOVAL AND INSTALLATION OF PPC VALVE ASSEMBLY

(FOR WORK EQUIPMENT, SWING)
REMOVAL INSTALLATION
k Lower the work equipment completely to the • Carry out installation in the reverse order to
ground and stop the engine. Then loosen the oil removal.
filler cap slowly to release the pressure inside
the hydraulic tank.
3 Sleeve nut (02):
1. Remove operator’s seat assembly. 29.4 ± 4.9 Nm {3 ± 0.5 kgm}
3 Sleeve nut (03):
2. Remove covers (1), (2) and boot (3). 78.5 ± 19.6 Nm {8 ± 2 kgm}

★ If there is excessive play in the control le-

vers, adjust the PPC valve.
For details, see TESTING AND ADJUST-
ING, Adjustment of work equipment and
swing PPC valve.

3. Disconnect inlet hose (4), outlet hose (5), and 4

control valve hoses (6).

4. Remove PPC valve assembly (7).

PC1800-6 30-85
DISASSEMBLY AND ASSEMBLY PPC VALVE (FOR WORK EQUIPMENT, SWING)

DISASSEMBLY AND ASSEMBLY OF PPC VALVE ASSEMBLY

(FOR WORK EQUIPMENT, SWING)
DISASSEMBLY
1. Remove nut (1), then remove disc (2).

2. Remove joint (3), then remove plate (4).

3. Pull out pistons (7), and remove together with

collars (6) and seals (5).

4. Remove valve assemblies (15) and springs

[large] (9).

5. Push retainers (8) to remove collars (13), then

remove retainers (8), springs (10), and shims
(14) from pistons (11).

6. Remove rings (16), then remove retainers (17),

springs (18) and valves (19) from valve body
(12).

ASSEMBLY
1. Assemble valves (19) and springs (18) in valve
body (12), then push down retainers (17), and
install rings (16).

2. Assemble shims (14) and springs (10) on pis-

tons (11), then push down retainers (8), and
install collars (13).

3. Assemble springs [large] (9) in valve body (12),

then install valve assemblies (15).

4. Fit pistons (7), seals (5), and O-ring to collars

(6), and install to valve body (12).

5. Fit plate (4), then install joint (3).

3 Joint: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}

6. Screw in disc (2) until it contacts 3 pistons (7).

★ Check that the clearance is within 0.05 – 0.3
mm for the piston that the disc does not con-
tact.
★ If the clearance is more than 0.3 mm, change
the position of the disc, or change the mount-
ing position of the piston, and check again.

7. Tighten nut (1).

3 Nut: 34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}

30-86 PC1800-6
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

REMOVAL AND INSTALLATION OF BOOM CYLINDER

ASSEMBLY
9. Using forcing screw, pull out bottom pin (7).
BACK HOE
REMOVAL
k Retract the arm and bucket cylinder piston rods
fully, lower the work equipment completely to the
ground, then put the safety lock lever in the
LOCK position.
★ Fit blind plugs in the hoses to prevent dust or dirt
from entering.

1. Disconnect grease hose (1).

2. Remove plate (2).

10. Remove boom cylinder assembly (8).

4 Boom cylinder assembly: 2000 kg

3. Sling boom cylinder assembly.

4. Using bolt or eyebolt 1, pull out head pin (3),

then disconnect piston rod from boom.

5. Start engine, and retract piston rod, then tie pis-

ton rod with wire to prevent it from coming out.

6. Lower boom cylinder assembly on stand, then

disconnect hoses (4).

7. Disconnect grease hose (5).

8. Sling boom cylinder assembly and remove lock

plate (6).

PC1800-6 30-87
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

INSTALLATION • Bleeding air

• Carry out installation in the reverse order to ★ Bleed the air.
removal. For details, see TESTING AND ADJUST-
ING, Air bleeding from each component.

2 Inside surface of bushing when assem- • Refilling with oil (hydraulic tank)
bling pin: ★ Add oil through oil filler to the specified level.
Anti-friction compound (LM-P) Run the engine to circulate the oil through
2 Grease after assembling pin: the system. Then check the oil level again.
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
★ Sling at 2 places (pin and piston rod portion)
and align the position of the pin hole.

2 Inside surface of bushing when assem-

bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
★ Adjust with shims (10) so that the clearance
a between bracket (9) and the bottom end
face of boom cylinder (8) is less than 1 mm.
• Shim thickness: 1.0, 1.5 mm

30-88 PC1800-6
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

REMOVAL AND INSTALLATION OF BOOM CYLINDER

ASSEMBLY
LOADING SHOVEL 4. Sling boom cylinder assembly, and remove lock
REMOVAL plate, then using forcing screws (Thread dia. =
k Extend the arm and bucket fully, lower the work 24 mm, Pitch = 3.0 mm), pull out foot pin (4).

4
equipment completely to the ground and stop
the engine. Operate the control levers several Pin: 87 kg
times to release the remaining pressure in the
hydraulic piping.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
★ Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.

1. Sling boom cylinder assembly and remove lock

plate, then using forcing screws (Thread dia. =
24 mm, Pitch = 3.0 mm), pull out rod pin (1).

4 Pin: 61 kg

5. Remove boom cylinder assembly (5).

4 Boom cylinder assembly: 2,330 kg

2. Start engine and retract piston rod fully.

k Tie the rod with wire to prevent it from com-
ing out.

3. Lower boom cylinder assembly onto stand, then

disconnect grease hose (2) and hoses (3).

PC1800-6 30-89
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

INSTALLATION
• Carry out installation in the reverse order to
removal.

2 Inside surface of bushing when assem-

bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.

2 Inside surface of bushing when assem-

bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
★ Adjust with shims (7) so that the clearance a
between bracket (6) and the bottom end face
of boom cylinder (5) is less than 1 mm.
• Shim thickness: 1.0, 1.5 mm

• Bleeding air
★ For details, see TESTING AND ADJUST-
ING, Air bleeding from each component.

• Refilling with oil (hydraulic tank)

★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

30-90 PC1800-6
DISASSEMBLY AND ASSEMBLY ARM CYLINDER

REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY

BACK HOE 7. Remove arm cylinder assembly (8).
REMOVAL
k Extend the arm cylinder piston rod to a point ap- 4 Arm cylinder assembly: 1300 kg
prox. 200 mm before the end of the IN stroke,
lower the work equipment completely to the
ground, then set the safety lock lever to the
LOCK position.
★ Fit blind plugs in the hoses to prevent dust or dirt
from entering.

1. Set block 1 between arm cylinder and boom.

2. Disconnect grease hose (1).

3. Remove plate (2), and pull out head pin (3).

★ If the pin does not come out, use bolt or eye-

bolt and remove the pin from the head end.

INSTALLATION
• Carry out installation in the reverse order to
removal.

2 Inside surface of bushing when assem-

bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.

• Bleeding air
4. Start engine, and retract piston rod, then tie pis- ★ For details, see TESTING AND ADJUST-
ton rod with wire to prevent it from coming out. ING, Air bleeding from each component.

5. Disconnect hose (4) and grease hose (5). • Refilling with oil (hydraulic tank)
★ Add oil through oil filler to the specified level.
6. Sling arm cylinder assembly, then remove plate Run the engine to circulate the oil through
(6) and pull out bottom pin (7). the system. Then check the oil level again.
★ If the pin does not come out, use bolt or eye-
bolt and remove the pin from the bottom end.

PC1800-6 30-91
DISASSEMBLY AND ASSEMBLY ARM CYLINDER

REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY

LOADING SHOVEL
REMOVAL
k Retract boom cylinder fully, and extend arm cyl-
inder, then set the bottom of the bucket horizon-
tal, lower the work equipment completely to the
ground and stop the engine. Operate the control
levers several times to release the remaining
pressure in the hydraulic piping.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
★ Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.

1. Sling arm cylinder assembly, and remove lock

plate, then using forcing screws (Thread dia. =
5. Lift off arm cylinder assembly (4) carefully.
24 mm, Pitch = 3.0 mm), pull out pin (1).
4
★ Pull out the pin to a position where the piston
Arm cylinder assembly: 1,100 kg
rod can be disconnected.

4 Pin: 28 kg

INSTALLATION
• Carry out installation in the reverse order to
2. Start engine and retract piston rod fully.
k Tie the rod with wire to prevent it from com-
removal.
ing out.

3. Disconnect hoses (2). 2 Inside surface of bushing when assem-

bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
4. Sling piston rod end and bottom end, and
remove lock plate, then using forcing screws
Grease (LM-G)
k When aligning the position of the pin hole,
(Thread dia. = 24 mm, Pitch = 3.0 mm), pull out
pin (3).
★ Pull out the pin to a position where the cylin- never insert your fingers in the hole.
der bottom can be disconnected.
• Bleeding air
4 Pin: 28 kg ★ For details, see TESTING AND ADJUST-
ING, Air bleeding from each component.

• Refilling with oil (hydraulic tank)

★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

30-92 PC1800-6
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

REMOVAL AND INSTALLATION OF BUCKET CYLINDER

ASSEMBLY
BACK HOE 5. Sling bucket cylinder assembly, then remove
REMOVAL plate (6) and pull out bottom pin (7).
k Retract the arm and bucket cylinder piston rods, ★ If the pin does not come out, use bolt or eye-
lower the work equipment completely to the bolt and remove the pin from the bottom end.
ground, then set the safety lock lever to the
LOCK position. 6. Remove bucket cylinder assembly (8).
★ Fit blind plugs in the hoses to prevent dust or dirt
from entering. 4 Bucket cylinder assembly: 920 kg

1. Set block 1 between bucket cylinder and arm,

and block 2 between link and arm.

2. Remove 3 pin lock bolts (1) of link inside and

stopper (2), then using forcing screws, pull out
head pin (3).

INSTALLATION
• Carry out installation in the reverse order to
removal.

2 Inside surface of bushing when assem-

3. Start engine, and retract piston rod, then tie pis- bling pin:
ton rod with wire to prevent it from coming out. Anti-friction compound (LM-P)
2 Grease after assembling pin:
4. Disconnect hose (4) and grease hose (5). Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.

• Bleeding air
★ For details, see TESTING AND ADJUST-
ING, Air bleeding from each component.

• Refilling with oil (hydraulic tank)

★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

PC1800-6 30-93
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

REMOVAL AND INSTALLATION OF BUCKET CYLINDER

ASSEMBLY
LOADING SHOVEL 5. Lower bucket cylinder assembly onto stand 1.
REMOVAL
k Extend the arm cylinder fully, set the bottom of
the bucket horizontal, lower the work equipment
completely to the ground and stop the engine.
Operate the control levers several times to re-
lease the remaining pressure in the hydraulic
piping.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
★ Fit blind plugs in the hoses after disconnecting
them, to prevent dirt or dust from entering.

1. Sling bucket cylinder assembly, and remove

lock plate, then using forcing screws (Thread
6. Remove plate (4) and lock plate (5), then pull
dia. = 24 mm, Pitch = 3.0 mm), remove rod pin
out bottom pin (6).
(1).
★ Pull out the pin to a position where the cylin-
4
der bottom can be disconnected.
Pin: 51 kg
4 Pin: 68 kg
2. Start engine and retract piston rod fully.
7. Raise bucket cylinder assembly (7) carefully and
3. Disconnect grease tube (2).
remove.

4
4. Disconnect hose (3).
Bucket cylinder assembly: 1,500 kg

30-94 PC1800-6
 BUCKET CYLINDER
DISASSEMBLY AND ASSEMBLY BOTTOM DUMP CYLINDER

REMOVAL AND INSTALLA-

TION OF BOTTOM DUMP CYL-
INDER ASSEMBLY
INSTALLATION LOADING SHOVEL
• Carry out installation in the reverse order to REMOVAL
removal. k Set the bottom of the bucket horizontal, and re-
tract the rod to a position where the rod connect-
ing pin of the bottom dump cylinder can be
2 Inside surface of bushing when assem- removed. Then fit a block under the bucket, low-
bling pin: er the work equipment completely to the ground
Anti-friction compound (LM-P) and stop the engine.
2 Grease after assembling pin: ★ Fit blind plugs in the hoses after disconnecting
Grease (LM-G) them, to prevent dirt or dust from entering.
k When aligning the position of the pin hole, never
insert your fingers in the hole. 1. Disconnect grease tube (1).

• Bleeding air 2. Sling bottom dump cylinder assembly, and

★ For details, see TESTING AND ADJUST- remove plate (2) and lock plate (3), then pull out
ING, Air bleeding from each component. rod pin (4).

• Refilling with oil (hydraulic tank) 4 Pin: 41 kg

★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

3. Start engine and retract piston rod fully.

4. Remove hoses (5).

PC1800-6 30-95
DISASSEMBLY AND ASSEMBLY BOTTOM DUMP CYLINDER

5. Remove plate (6), then using forcing screws INSTALLATION

(Thread dia. = 16 mm, Pitch = 2.0 mm), pull out • Carry out installation in the reverse order to
bottom pin (7). removal.

4 Pin: 26 kg
2 Inside surface of bushing when assem-
bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.

• Bleeding air
★ For details, see TESTING AND ADJUST-
ING, Air bleeding from each component.

• Refilling with oil (hydraulic tank)

6. Lift off bottom dump cylinder assembly (8). ★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
4 Bottom dump cylinder assembly: the system. Then check the oil level again.
310 kg

30-96 PC1800-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER

ASSEMBLY
BACK HOE 2. Piston assembly and head assembly
DISASSEMBLY • Boom cylinder
1. Piston rod assembly 1) Fix the head side of piston rod assembly (3)
1) Fix the bottom side of cylinder assembly (1) with tool U1 or a press.
with tool U1 or a press, remove the mount- 2) Remove bolts (7), piston assembly (9), and
ing bolts and disconnect head assembly (2). spacer (8).
★ Width across flats of head bolt (hexagon 3) Remove the O-ring and backup ring (10).
socket head bolt) Unit: mm 4) Remove plunger (11).
Cylinder
Boom Arm Bucket
Specification
Backhoe 27 50 41

2) Pull out piston rod assembly (3).

★ Put a container under the cylinder to re-
ceive oil flowing out of the cylinder.

2 5) Disassembly of piston assembly

3 i) Remove rings (12).
ii) Remove wear rings (13).
iii) Remove piston ring (14).

CEP00001

1 3

3
U1

6) Remove collar assembly (15) and head

assembly (2) from piston rod (3).

15 2 3
CEP00002

CEP00005

PC1800-6 30-97
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

7) Remove ring (18) from collar (17). • Arm cylinder

1) Fix the head side of piston rod assembly (3)
with tool U1 or a press.
2) Remove bolts (7), piston assembly 1 (26),
and spacer (8).
3) Remove pin (27), 10 balls (5), and plunger
(6).
4) Remove piston assembly 2 (9), O-ring, and
backup ring (10).
5) Remove plunger (11).

8) Disassembly of head assembly

i) Remove the O-ring and backup ring
(20).
ii) Remove snap ring (21) and dust seal
(22).
iii) Remove rod packing (23).
iv) Remove backup ring (24).
v) Remove bushing (25).

25 6) Disassembly of piston assembly 1

20 i) Remove ring (12).
ii) Remove wear ring (13).
24

22
23

21
CEP00006

7) Disassembly of piston assembly 2

i) Remove ring (12).
ii) Remove wearing rings (13).
iii) Remove piston ring (14).

30-98 PC1800-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

8) Remove collar assembly (15) and head • Bucket cylinder

assembly (2) from piston rod (3). 1) Fix the head side of piston rod assembly (3)
with tool U1 or a press.
15 2 3 2) Remove bolts (7), piston assembly (9), and
spacer (8).
3) Remove screw (4), 12 balls (5), and plunger
(6).
4) Remove the O-ring and backup ring (10).
5) Remove plunger (11).

CEP00005

9) Remove ring (18) from collar (17).

6) Disassembly of piston assembly

i) Remove rings (12).
ii) Remove wear rings (13).
iii) Remove piston ring (14).

10) Disassembly of head assembly

i) Remove the O-ring and backup ring
(20).
ii) Remove snap ring (21) and dust seal
(22).
iii) Remove rod packing (23).
iv) Remove backup ring (24).
v) Remove bushing (25).

25
20 7) Remove collar assembly (15) and head
assembly (2) from piston rod (3).
24 15 2 3

22
23

21
CEP00006

CEP00005

PC1800-6 30-99
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

8) Disassembly of collar assembly ASSEMBLY

i) Remove the O-ring and backup ring ★ Take care not to damage the packings, dust
(16). seals, O-rings, etc.
ii) Remove ring (18) and collar (19) from ★ Do not fit the backup rings forcibly. Warm them
collar (17). in water of about 50 – 60°C before fitting them.

1. Assembly of head assembly

1) Using tool U4, press fit bushing (25).
2) Fit backup ring (24).
3) Fit rod packing (23).
4) Using tool U5, fit dust seal (22) and fix it with
snap ring (21).
5) Fit the O-ring and backup ring (20).

9) Disassembly of head assembly

i) Remove the O-ring and backup ring
(20).
ii) Remove snap ring (21) and dust seal
(22).
iii) Remove rod packing (23).
iv) Remove backup ring (24).
v) Remove bushing (25).

25
20

24

22
23

21
CEP00006

30-100 PC1800-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

2. Assembly of collar assembly 4) Fit wear rings (13).

1) Fit rings (19) and (18) to collar (17). 5) Fit rings (12).
★ Fit ring (19) to only the bucket cylinder. ★ Fit only 1 ring to the arm cylinder.
2) Fit the O-ring and backup ring (16). ★ Take care not to open the closed gap too
★ Fit the O-ring and backup ring (16) to much.
only the bucket cylinder. 2 Ring groove: Grease (G2-LI)
For bucket

4. Piston rod assembly

For boom and arm 1) Fix the head side of the piston rod to tool U1
or a press.
2) Install head assembly (2) and collar assem-
bly (15) to the rod.

15

2
3. Assembly of piston assembly CEP00010
1) Using tool U2, expand piston ring (14).
★ Set the piston ring to tool U2 and rotate
the handle 8 – 10 turns to expand the
piston ring.
2) Fit piston ring (14) to the piston.
3) Set tool U3 and tighten piston ring (14).

PC1800-6 30-101
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

5. Assembly of piston assembly • Bucket cylinder

• Boom cylinder 1) Install plunger (11), O-ring, and backup ring
1) Install plunger (11), O-ring, and backup ring (10).
(10). 2) Set plunger (6) to the piston rod, install balls
2) Install piston assembly (9) and spacer (8) (5), and tighten screw (4).
and tighten bolts (7). ★ When installing 12 balls, count them.
★ Clean and degrease the bolts and bolt ★ Clean and degrease the screw and
holes and apply "hardening accelerator" screw holes and apply "hardening accel-
to them. erator" to them.
2 Bolt: LOCTITE 262 2 Screw: LOCTITE 262
3 Bolt: 3 Screw:
277 ± 32 Nm {28.25 ± 3.25 kgm} 66.5 ± 7.5 Nm {6.75 ± 0.75 kgm}
3) Install piston assembly (9) and spacer (8)
and tighten bolts (7).
★ Clean and degrease the bolts and bolt
holes and apply "hardening accelerator"
to them.
2 Bolt: LOCTITE 262
3 Bolt: 177 ± 20 Nm {18 ± 2 kgm}

• Arm cylinder
1) Install plunger (11), O-ring, and backup ring
(10).
2) Set plunger (6) to the piston rod and install
balls (5) and pin (27).
★ When installing 10 balls (5), count them.
★ After installing the pin, check that the
plunger end has play.
3) Install piston assembly 2 (9), spacer (8), and
piston assembly 1 (26) and tighten bolts (7).
★ Clean and degrease the bolts and bolt
holes and apply "hardening accelerator"
to them.
2 Bolt: LOCTITE 262
3 Bolt:
277 ± 32 Nm {28.25 ± 3.25 kgm}

30-102 PC1800-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

6. Cylinder assembly
1) Fix the bottom side of cylinder assembly (1)
with tool U1 or a press.
2) Install the piston rod assembly.
2 Sealing part: Grease (G2-LI)
★ When inserting the piston rod assembly,
set the closed gaps of the rings horizon-
tally (to the sides of the piston rod as-
sembly) and align the piston rod with the
cylinder tube.
★ After inserting the piston rod assembly,
check that the rings are not broken or re-
moved, and then push in the piston rod
assembly to the end.

1 3

3
U1

CEP00002

3) Secure head assembly (2) with the mount-

ing bolts.
3 Mounting bolt:
Cylinder Tightening torque
Boom 1.67 ± 0.25 kNm {170 ± 25 kgm}
Arm 2.11 ± 0.34 kNm {215 ± 35 kgm}
Bucket 529.7 ± 78.5 Nm {54 ± 8 kgm}

2
3

CEP00001

PC1800-6 30-103
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER

ASSEMBLY
2. Piston assembly and head assembly
LOADING SHOVEL 1) Fix the head side of piston rod assembly (3)
DISASSEMBLY with tool U1 or a press.
1. Piston rod assembly 2) Remove screws (7) to remove piston
1) Fix the bottom side of cylinder assembly (1) assembly 1 (8).
with tool U1 or a press and remove the 3) Remove pin (4) and balls (5), then remove
mounting bolt to disconnect head assembly plunger (6).
(2). 4) Remove O-ring and backup ring (9) from
★ Width across flats of hexagon socket plunger (6).
head bolt Unit: mm 5) Remove piston assembly 2 (10).
Cylinder
Bottom
Boom Arm Bucket
dump
Specification
Backhoe 27 19 21 19

2) Pull out piston rod assembly (3).

★ Set an oil receiving pan under the cylin-
der to receive oil flowing out of the cylin-
der.

2
3

CEP00001

1 3 6) Disassembly of piston assembly 2.

i) Remove O-ring and backup ring (11).
3 ii) Remove rings (12).
U1 iii) Remove wear rings (13).
iv) Remove piston ring (14).

CEP00002

30-104 PC1800-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

7) Remove head assembly (2) from piston rod ASSEMBLY

(3). ★ Take care not to damage the packing, dust seal,
O-ring, etc.
★ Do not fit the backup ring forcibly. Warm it in wa-
ter at 50 – 60°C before fitting it.

1. Assembly of head assembly

1) Fit ring (21) and wear ring (20).
2) Fit buffer ring (19).
3) Fit rod packing (18).

8) Disassembly of head assembly

i) Remove O-ring and backup ring (15).
ii) Remove snap ring (16) and dust seal
(17).
iii) Remove rod packing (18).
iv) Remove buffer ring (19).
v) Remove wear rings (20).
vi) Remove ring (21).

PC1800-6 30-105
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

4) Using tool U5, fit dust seal (17) and secure it 2. Assembly of piston assembly 2
with snap ring (16). 1) Using tool U2, expand piston ring (14).
5) Fit O-ring and backup ring (15). ★ Set the piston ring to tool U2 and revolve
the handle by 8 – 10 turns to expand the
piston ring.
2) Fit piston ring (14) to the piston.
3) Set tool U3 and contract piston ring (14).

4) Fit wear rings (13).

5) Fit rings (12).
★ Take care not to increase the gap of the
piston ring too much.
2 Ring groove: Grease (G2-LI)
6) Fit O-ring and backup ring (11).

3. Piston rod assembly

1) Fix the head side of the piston rod with tool
U1 or a press.
2) Install the rod to head assembly (2).

30-106 PC1800-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

3) Fit O-ring and backup ring (9) to plunger (6). 4. Cylinder assembly
★ This work is not necessary for the boom 1) Fix the bottom side of cylinder assembly (1)
cylinder. with tool U1 or a press.
4) Set plunger (6) to the piston rod, then set 2) Install piston rod assembly (3).
balls (5) and install pin (4). 2 Sealed part: Grease (G2-LI)
★ This work is not necessary for the boom ★ Bring the gap of the ring in the horizontal
cylinder. position (on the side of the piston rod),
★ Check the number of the balls. then insert the piston rod, aligning it with
★ After installing the pin, check that there the cylinder tube.
is play at the end of the plunger. ★ After inserting the piston rod, check that
5) Install piston assembly 2 (10) and piston the ring is not damaged or removed,
assembly 1 (8), then secure them with then push in the piston rod to the end.
screws (7).
★ Clean the threads of the screws. After
tightening the screws, caulk them.
1 3

3
U1

CEP00002

3) Tighten the mounting bolt of head assembly

(2).
3 Mounting bolt:
Tightening torque
Boom 1,770 Nm {180.5 kgm}
Arm 510 Nm {52 kgm}
Bucket 890 Nm {90.8 kgm}
Bottom dump 510 Nm {52 kgm}

2
3

CEP00001

PC1800-6 30-107
DISASSEMBLY AND ASSEMBLY BUCKET

REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY

BACK HOE
REMOVAL
k Set the back of the bucket facing down, lower
the work equipment completely to the ground,
then set the safety lock lever to the LOCK posi-
tion.

1. Remove 3 pin lock bolts (1), then remove stop-

per (2).

2. Using forcing screws, remove connecting pin (3)

of link and bucket.

3. Start engine, and retract piston rod, then tie link

to arm with wire to prevent piston rod from com-
ing out.

4. Remove 3 pin lock bolts (4), then remove stop-

per (5).

5. Remove collar (6), covers (7) and (8), then

remove shims (9).

6. Remove arm connecting pin (10).

7. Start engine and raise work equipment, discon-

nect arm from bucket, then remove bucket
assembly.

4 Bucket assembly: 10,000 kg

30-108 PC1800-6
DISASSEMBLY AND ASSEMBLY BUCKET

REMOVAL AND INSTALLA-

TION OF BUCKET ASSEMBLY
INSTALLATION LOADING SHOVEL
• Carry out installation in the reverse order to REMOVAL
removal. k Set the bottom of the bucket horizontal, lower
the work equipment completely to the ground
and stop the engine. Operate the control levers
2 Inside surface of bushing when assem- several times to release the remaining pressure
bling pin: in the hydraulic piping.
Anti-friction compound (LM-P) k Loosen the oil filler cap slowly to release the
2 Grease after assembling pin: pressure inside the hydraulic tank.
Grease (LM-G) ★ Fit blind plugs in the hoses after disconnecting
k When aligning the position of the pin hole, them, to prevent dirt or dust from entering.
never insert your fingers in the hole.
1. Disconnect grease tubes (1).

2 Inside surface of bushing when assem- 2. Disconnect bottom dump cylinder hoses (2).
bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
★ Insert the O-ring at the end face of the bucket
boss securely.
★ Adjusting of bucket clearance
1) Measure clearance a between arm (11)
and bushing (12).
★ It is easier to measure if the bucket
is moved to one side so that all the
play is in one place. 3. Sling bucket cylinder assembly, and remove
2) Select shims so that clearance a is 0.5 – plate (3) and lock plate (4), then pull out bottom
1.0 mm. pin (5).
• Shim thickness b: 0.5, 1.0 mm ★ Remove the pin on the other side in the
same way.

4 Pin: 68 kg

3) Install selected shims, then install cover

and collar.

PC1800-6 30-109
DISASSEMBLY AND ASSEMBLY BUCKET

4. Sling bucket assembly, and remove plate (6) INSTALLATION

and lock plate (7), then pull out arm top pin (8). • Carry out installation in the reverse order to
removal.
★ Remove the pin on the other side in the
same way.
2 Inside surface of bushing when assem-
4 Pin: 105 kg bling pin:
Anti-friction compound (LM-P)
5. Lift off bucket assembly (9). 2 Grease after assembling pin:
Grease (LM-G)
4 Bucket assembly: 14,315 kg k When aligning the position of the pin hole,
never insert your fingers in the hole.

• Insert one pin without being locked, after insert-

ing another pin, lock them.

• Bleeding air
★ Bleed the air.
For details, see TESTING AND ADJUST-
ING, Air bleeding from each component.

• Refilling with oil (hydraulic tank)

★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

30-110 PC1800-6
DISASSEMBLY AND ASSEMBLY ARM

REMOVAL AND INSTALLATION OF ARM ASSEMBLY

BACK HOE 6. Start engine, and retract piston rod, then tie pis-
REMOVAL ton rod with wire to prevent it from coming out.
1. Remove bucket assembly.
F o r d e t a i l , s e e R E M O VA L O F B U C K E T 7. Disconnect 2 bucket cylinder hoses (4).
ASSEMBLY.
8. Disconnect grease hose (5).
2. Secure link to arm with wire.
k Extend the arm cylinder piston rod to a point 9. Remove plate (6), then using tool V, pull out
approx. 200 mm before the end of the IN boom top pin (7).
stroke, then lower the arm on to block 1
and stand 2, and set the safety lock lever
to the LOCK position. Then, stop the en-
gine.

3. Set block 3 between arm cylinder and boom.

4. Disconnect grease hose (1).

5. Remove plate (2), and pull out head pin (3) of

arm cylinder.
★ If the pin does not come out, use bolt or eye-
bolt and remove the pin from the head end.

10. Start engine, then raise boom and remove arm

assembly (8).

4 Arm assembly (including bucket cylin-

der, link): 11,300 kg

PC1800-6 30-111
DISASSEMBLY AND ASSEMBLY ARM

REMOVAL AND INSTALLA-

TION OF ARM ASSEMBLY
INSTALLATION LOADING SHOVEL
• Carry out installation in the reverse order to REMOVAL
removal. 1. Remove bucket assembly.
F or de ta il s , s ee R EM O VA L O F B UCK E T
ASSEMBLY.
2 Inside surface of bushing when assem-
bling pin: 2. Start engine, and set work equipment so that
Anti-friction compound (LM-P) bucket cylinder is perpendicular.
2 Grease after assembling pin:
Grease (LM-G) 3. Disconnect grease hose (1).
k When aligning the position of the pin hole,
never insert your fingers in the hole. 4. Disconnect cylinder hoses (2).
★ Disconnect 6 hoses between boom and arm,
• Bleeding air and 6 hoses between arm and cylinder.
★ Bleed the air.
For details, see TESTING AND ADJUST-
ING, Air bleeding from each component.

• Refilling with oil (hydraulic tank)

★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

5. Remove cover (3), and disconnect wiring (4) of

potentiometer.

6. Remove 3 mounting bolts (5), then remove

potentiometer (6) together with bracket (7).

30-112 PC1800-6
DISASSEMBLY AND ASSEMBLY ARM

9. Lift off arm assembly (9).

4 Arm assembly: 6,850 kg

7. Disconnect arm cylinder from arm.

For details, see REMOVAL OF ARM CYLINDER
ASSEMBLY.
★ Secure the arm cylinder assembly to the INSTALLATION
boom with lever block 1. • Carry out installation in the reverse order to
removal.

2 Inside surface of bushing when assem-

bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.

• Bleeding air
★ For details, see TESTING AND ADJUST-
8. Sling arm assembly, and remove lock plate, then ING, Air bleeding from each component.
using forcing screws (Thread dia. = 24 mm,
Pitch = 3.0 mm), pull out boom top pin (8). • Refilling with oil (hydraulic tank)
★ Pull out the pin on the other side in the same ★ Add oil through oil filler to the specified level.
way to a position where the arm can be dis- Run the engine to circulate the oil through
connected from the boom. the system. Then check the oil level again.

4 Pin: 99 kg

PC1800-6 30-113
DISASSEMBLY AND ASSEMBLY BOOM

REMOVAL AND INSTALLATION OF BOOM ASSEMBLY

BACK HOE 7. Remove lock plate (6) and using forcing screw,
REMOVAL remove 2 boom foot pins (7), then remove boom
1. Remove arm assembly. assembly.

4
For details, see REMOVAL OF ARM ASSEM-
BLY. Boom assembly (including arm cylin-
k Lower the boom assembly completely to the der): 19,170 kg
ground, then set the safety lock lever to
LOCK position.

2. Disconnect boom cylinder assembly from boom.

For details, see REMOVAL OF BOOM CYLIN-
DER ASSEMBLY.

3. Disconnect front lamp wiring (1).

4. Disconnect grease hose (2).

5. Disconnect bucket cylinder hoses (3) and arm

cylinder hoses (4).

6. Sling boom assembly (5).

30-114 PC1800-6
DISASSEMBLY AND ASSEMBLY BOOM

INSTALLATION
• Carry out installation in the reverse order to
removal.

2 Inside surface of bushing when assem-

bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
★ Adjust with shims (9) so that clearance a be-
tween bracket (8) and the end face of the
foot of boom (5) is less than 1 mm.
• Shim thickness : 1.0, 1.5 mm

• Bleeding air
★ For details, see TESTING AND ADJUST-
ING, Air bleeding from each component.

• Refilling with oil (hydraulic tank)

★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

PC1800-6 30-115
DISASSEMBLY AND ASSEMBLY BOOM

REMOVAL AND INSTALLATION OF BOOM ASSEMBLY

LOADING SHOVEL 5. Disconnect bottom dump cylinder hoses (3),
REMOVAL bucket cylinder hoses (4), and arm cylinder
1. Remove arm assembly. hoses (5).
For details, see REMOVAL OF ARM ASSEM- ★ When the hoses are disconnected, oil may
BLY. spurt out, so loosen the hose flanges slowly
before disconnecting.
2. Sling bucket cylinder assembly (1), remove lock
plate, then using forcing screws, pull out rod pin
(2), and remove bucket cylinder assembly.

4 Pin: 51 kg

4 Bucket cylinder assembly: 1,500 kg

★ Remove the bucket cylinder on the other
side in the same way.

3. Sling boom, set stand 1 at tip of boom to sup-

port boom.

6. Disconnect grease hose and head lamp wiring.

7. Remove clamp, and disconnect cable (6).

8. Remove cover (7), and disconnect wiring (8) of

potentiometer.

4. Disconnect boom cylinder from boom.

For details, see REMOVAL OF BOOM CYLIN-
DER ASSEMBLY.
★ Disconnect the boom cylinder on the other
side from the boom in the same way.

30-116 PC1800-6
DISASSEMBLY AND ASSEMBLY BOOM

9. Remove 3 mounting bolts (9), then remove INSTALLATION

potentiometer assembly (10) together with • Carry out installation in the reverse order to
bracket (11). removal.

2 Inside surface of bushing when assem-

bling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.

★ Adjust with shims (15) so that the clearance

a between bracket (14) and the end face of
10. Remove lock plate, and using forcing screws the foot of boom (13) is less than 1 mm.
(Thread dia. = 24 mm, Pitch = 3.0 mm), pull out • Shim thickness : 1.0, 1.5 mm
left and right boom foot pins (12), then lift off
boom (13).
★ Check the number and thickness of the
shims, and keep in a safe place.

4 Boom: 13,200 kg

• Bleeding air
For details, see TESTING AND ADJUSTING,
Air bleeding from each component.

• Refilling with oil (hydraulic tank)

★ Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.

PC1800-6 30-117
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

REMOVAL AND INSTALLATION OF COUNTERWEIGHT

ASSEMBLY
REMOVAL INSTALLATION
k Stop the machine on level ground, and lower the • Carry out installation in the reverse order to
work equipment completely to the ground. removal.

1. Sling counterweight assembly.

★ Install so that the clearance between the
2. Disconnect upper brackets (1). counterweight and the fuel tank is uniform on
the left and right.
3 Counterweight mounting bolt:
3923 ± 490 Nm {400 ± 50 kgm}

3. Disconnect left and right brackets (2).

4. Remove mounting bolts (3).

5. Lift off counterweight assembly (4).

4 Counterweight assembly: 22,000 kg

30-118 PC1800-6
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB

REMOVAL AND INSTALLATION OF OPERATOR’S CAB

ASSEMBLY
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Remove floor mat.

2. Remove wiper motor covers (1).

★ Be careful not to damage the cover.

3. Disconnect hose (2) for window washer.

6. Disconnect air conditioner hoses (3).

4. Disconnect wiring connectors (CN-D01, D02,

H10, H20) of wiper motor and work equipment
lamp.

5. Disconnect speaker wiring connectors (CN-C08,

C09).

PC1800-6 30-119
DISASSEMBLY AND ASSEMBLY VHMS CONTROLLER

REMOVAL AND INSTALLA-

TION OF VHMS CONTROLLER
7. Remove 16 mounting bolts, then lift off opera- REMOVAL
tor’s cab assembly (4). ★ Before removing the VHMS controller, download
the remaining data of the controller to be re-
4 Operator’s cab assembly: 1,230 kg moved and check the set information, referring to
TESTING AND ADJUSTING, Setting proce-
dures for replacing VHMS controller.

INSTALLATION

★ After installing the VHMS controller, reset it, re-

ferring to TESTING AND ADJUSTING, Setting
procedures for replacing VHMS controller.

INSTALLATION
• Carry out installation in the reverse order to
removal.

3 Mounting nut:
176.5 ± 19.6 Nm {18 ± 2 kgm}

30-120 PC1800-6
 90 OTHERS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 1/12).................................................................90-2- 1

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 2/12).................................................................90-2- 2
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 3/12).................................................................90-2- 3
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 4/12).................................................................90-2- 4
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 5/12).................................................................90-2- 5
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 6/12).................................................................90-2- 6
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 7/12).................................................................90-2- 7
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 8/12).................................................................90-2- 8
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 9/12).................................................................90-2- 9
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 10/12) ...............................................................90-2- 10
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 11/12) ...............................................................90-2- 11
LOCATIONS OF CONNECTORS (WHOLE MACHINE – 12/12) ...............................................................90-2- 12
LOCATIONS OF CONNECTORS (AROUND CONTROL) ........................................................................90-2- 13
LOCATIONS OF CONNECTORS (OPERATOR’S CAB – 1/2) ..................................................................90-2- 14
LOCATIONS OF CONNECTORS (OPERATOR’S CAB – 2/2) ..................................................................90-2- 15
LOCATIONS OF CONNECTORS (AROUND LADDER) ...........................................................................90-2- 16
LOCATIONS OF CONNECTORS (RELATED TO AUTO GREASE SYSTEM)..........................................90-2- 17
LOCATIONS OF CONNECTORS (FRONT ENGINE) ...............................................................................90-2- 18
LOCATIONS OF CONNECTORS (REAR ENGINE) ..................................................................................90-2- 19
HYDRAULIC CIRCUIT DIAGRAM (BACK HOE) ..........................................................................................90- 3
HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL).............................................................................90- 5
ELECTRICAL CIRCUIT DIAGRAM (1/7) ......................................................................................................90- 7
ELECTRICAL CIRCUIT DIAGRAM (2/7) ......................................................................................................90- 9
ELECTRICAL CIRCUIT DIAGRAM (3/7) ......................................................................................................90- 11
ELECTRICAL CIRCUIT DIAGRAM (4/7) ......................................................................................................90- 13
ELECTRICAL CIRCUIT DIAGRAM (5/7) ......................................................................................................90- 15
ELECTRICAL CIRCUIT DIAGRAM (6/7) ......................................................................................................90- 17
ELECTRICAL CIRCUIT DIAGRAM (7/7) ......................................................................................................90- 19

PC1800-6 90-1
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 1/12)

PC1800-6 90-2-1
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 2/12)

90-2-2 PC1800-6
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 3/12)

PC1800-6 90-2-3
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 4/12)

90-2-4 PC1800-6
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 5/12)

PC1800-6 90-2-5
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 6/12)

90-2-6 PC1800-6
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 7/12)

PC1800-6 90-2-7
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 8/12)

90-2-8 PC1800-6
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 9/12)

PC1800-6 90-2-9
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 10/12)

90-2-10 PC1800-6
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 11/12)

PC1800-6 90-2-11
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (WHOLE MACHINE – 12/12)

90-2-12 PC1800-6
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (AROUND CONTROL)

PC1800-6 90-2-13
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (OPERATOR’S CAB – 1/2)

90-2-14 PC1800-6
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (OPERATOR’S CAB – 2/2)

PC1800-6 90-2-15
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (AROUND LADDER)

90-2-16 PC1800-6
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (RELATED TO AUTO GREASE SYSTEM)

PC1800-6 90-2-17
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (FRONT ENGINE)

90-2-18 PC1800-6
(6)
OTHERS LOCATIONS OF CONNECTORS

LOCATIONS OF CONNECTORS (REAR ENGINE)

PC1800-6 90-2-19
(6)
OTHERS HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM (BACK HOE)

PC1800-6 90-3
OTHERS HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)

PC1800-6 90-5
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM (1/7)

PC1800-6 90-7
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM (2/7)

PC1800-6 90-9
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM (3/7)

PC1800-6 90-11
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM (4/7)

PC1800-6 90-13
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM (5/7)

PC1800-6 90-15
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM (6/7)

PC1800-6 90-17
OTHERS ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM (7/7)

PC1800-6 90-19