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HITACHI ZX 160LC-5A HYDRAULIC EXCAVATOR WORKSHOP MANUAL + TROUBLESHOOTING + OPERATIONAL PRINCIPLE + ELECTRICAL-HYDRAULIC CIRCUIT DIAGRAM – DOWNLOAD
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HITACHI ZX 160LC-5A HYDRAULIC EXCAVATOR WORKSHOP MANUAL + TROUBLESHOOTING + OPERATIONAL PRINCIPLE + ELECTRICAL-HYDRAULIC CIRCUIT DIAGRAM – DOWNLOAD
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HITACHI ZX 160LC-5A HYDRAULIC EXCAVATOR WORKSHOP MANUAL + TROUBLESHOOTING + OPERATIONAL PRINCIPLE + ELECTRICAL-HYDRAULIC CIRCUIT DIAGRAM – DOWNLOAD
SCREENSHOTS FROM THE MANUAL:
WORKSHOP MANUAL TABLE OF CONTENTS :
HITACHI ZX 160LC-5A HYDRAULIC EXCAVATOR WORKSHOP MANUAL + TROUBLESHOOTING + OPERATIONAL PRINCIPLE + ELECTRICAL-HYDRAULIC CIRCUIT DIAGRAM – DOWNLOAD
WDBL90-EN-00......................................................... 1
INTRODUCTION......................................................... 3
SYMBOL AND ABBREVIATION.............................................. 5
SAFETY............................................................... 7
SECTION AND GROUP CONTENTS........................................... 47
SECTION 1 GENERAL.................................................... 49
Group 1 Precautions for Disassembling and Assembling............. 51
Precautions for Disassembling and Assembling................. 51
Group 2 Tightening............................................... 57
Tightening Bolts and Nuts.................................... 57
Piping Joint................................................. 60
Group 3 Painting................................................. 65
Painting..................................................... 65
Group 4 Bleeding Air............................................. 67
Bleeding Air from Hydraulic Oil Tank......................... 67
Bleeding Air from Hydraulic System........................... 68
Bleeding Air from Fuel System................................ 69
Bleeding Air from Radiator................................... 71
Group 5 Pressure Release Procedure............................... 73
Hydraulic Circuit Pressure Release Procedure................. 73
Group 6 Preparation.............................................. 75
Preparation before Inspection and Maintenance................ 75
SECTION 2 MAINTENANCE STANDARD....................................... 79
Group 1 Upperstructure........................................... 81
Pump Device.................................................. 81
Swing Motor.................................................. 85
Group 2 Undercarriage............................................ 89
Travel Motor................................................. 89
Sprocket..................................................... 91
Front Idler.................................................. 93
Upper Roller................................................. 95
Lower Roller................................................. 96
Track........................................................ 97
Group 3 Front Attachment.........................................101
Pin and Bushing..............................................101
Side Cutter (2015428, 2015429)...............................103
Point (963228)...............................................104
Standard Dimensions for Arm and Bucket Connection............105
Standard Dimensions for Arm and Boom Connection..............106
Cylinder.....................................................107
SECTION 3 UPPERSTRUCTURE.............................................111
Group 1 Cab......................................................113
Removal and Installation of Cab..............................113
Dimensions of Cab Glass......................................141
Group 2 Counterweight............................................161
Removal and Installation of Counterweight....................161
Group 3 Main Frame...............................................163
Removal and Installation of Main Frame.......................163
Group 4 Engine...................................................173
Removal and Installation of Engine...........................173
Group 8 Pump Device..............................................199
Removal and Installation of Pump Device......................199
Removal and Installation of Coupling.........................209
Disassembly of Pump Device...................................211
Assembly of Pump Device......................................218
Disassembly of Regulator.....................................229
Assembly of Regulator........................................231
Disassembly of Solenoid Valve................................233
Assembly of Solenoid Valve...................................235
Structure of Pilot Pump......................................237
Group 9 Control Valve............................................239
Removal and Installation of Control Valve....................239
Disassembly of Housing.......................................259
Assembly of Housing..........................................261
Disassembly of Control Valve (4-Spool Side)..................263
Assembly of Control Valve (4-Spool Side).....................270
Disassembly of Control Valve (5-Spool Side)..................281
Assembly of Control Valve (5-Spool Side).....................288
Group 10 Swing Device............................................297
Removal and Installation of Swing Device.....................297
Disassembly of Swing Device..................................301
Assembly of Swing Device.....................................306
Disassembly of Swing Motor...................................313
Assembly of Swing Motor......................................316
Group 11 Pilot Valve.............................................319
Removal and Installation of Pilot Valve (Left)...............319
Removal and Installation of Pilot Valve(Right)...............325
Removal and Installation of Travel Pilot Valve...............333
Disassembly of Pilot Valves (Right and Left).................337
Assembly of Pilot Valves (Right and Left)....................340
Disassembly of Travel Pilot Valve............................343
Assembly of Travel Pilot Valve...............................347
Group 12 Solenoid Valve..........................................353
Removal and Installation of Pilot Shut-Off Solenoid Valve....353
Removal and Installation of 3-Spool Solenoid Valve Unit......357
Disassembly of Pilot Shut-Off Solenoid Valve.................361
Assembly of Pilot Shut-Off Solenoid Valve....................363
Structure of 3-Spool Solenoid Valve Unit.....................365
Group 13 Signal Control Valve....................................367
Removal and Installation of Signal Control Valve.............367
Structure of Signal Control Valve............................373
SECTION 4 UNDERCARRIAGE..............................................377
Group 1 Swing Bearing............................................379
Removal and Installation of Swing Bearing....................379
Disassembly of Swing Bearing.................................383
Assembly of Swing Bearing....................................386
Group 2 Travel Device............................................389
Removal and Installation of Travel Device....................389
Disassembly of Travel Device.................................393
Assembly of Travel Device....................................397
Disassembly of Travel Motor..................................405
Assembly of Travel Motor.....................................408
Disassembly of Brake Valve...................................413
Assembly of Brake Valve......................................415
Precautions for Using Floating Seal..........................417
Group 3 Center Joint.............................................419
Removal and Installation of Center Joint.....................419
Disassembly of Center Joint..................................423
Assembly of Center Joint.....................................425
Replacement of Body and Spindle..............................428
Group 4 Track Adjuster...........................................429
Removal and Installation of Track Adjuster...................429
Disassembly of Front Idler...................................433
Assembly of Front Idler......................................436
Disassembly of Track Adjuster................................439
Assembly of Track Adjuster...................................443
Precautions for Using Floating Seal..........................447
Group 5 Upper and Lower Rollers..................................449
Removal and Installation of Upper Roller.....................449
Removal and Installation of Lower Roller.....................453
Disassembly of Lower Roller..................................459
Assembly of Lower Roller.....................................461
Precautions for Using Floating Seal..........................463
Group 6 Track....................................................465
Removal and Installation of Track............................465
SECTION 5 FRONT ATTACHMENT...........................................473
Group 1 Front Attachment.........................................475
Removal and Installation of Front Attachment.................475
Group 2 Cylinder.................................................483
Removal and Installation of Boom Cylinder....................483
Removal and Installation of Arm Cylinder.....................487
Removal and Installation of Bucket Cylinder..................493
Disassembly of Boom, Arm, and Bucket Cylinders...............497
Assembly of Boom, Arm, and Bucket Cylinders..................504
SERVICE MANUAL REVISION REQUEST FORM.................................511
OPERATORS MANUAL - TABLE OF CONTENTS:
TTDBL90-EN-00............................................................................................. 1 INTRODUCTION.............................................................................................. 3 SYMBOL AND ABBREVIATION................................................................................... 5 SAFETY.................................................................................................... 7 SECTION AND GROUP CONTENTS................................................................................ 47 SECTION 4 OPERATIONAL PERFORMANCE TEST.................................................................... 49 Group 1 Introduction.................................................................................. 51 Operational Performance Tests..................................................................... 51 Preparation for Performance Tests................................................................. 52 Group 2 Standard...................................................................................... 53 Operational Performance Standard Table............................................................ 53 Main Pump P-Q Diagram............................................................................. 61 Sensor Activating Range........................................................................... 63 MPDr. Monitor Indicating Values................................................................... 64 Group 3 Engine Test................................................................................... 77 Engine Speed...................................................................................... 77 Lubricant Consumption............................................................................. 80 Group 4 Machine Performance Test...................................................................... 81 Travel Speed...................................................................................... 81 Track Revolution Speed............................................................................ 82 Mistrack Check.................................................................................... 83 Travel Parking Leakage............................................................................ 84 Swing Speed....................................................................................... 85 Swing Function Drift Check........................................................................ 86 Swing Motor Leakage............................................................................... 88 Maximum Swingable Slant Angle..................................................................... 90 Swing Bearing Play................................................................................ 92 Hydraulic Cylinder Cycle Time..................................................................... 94 Dig Function Drift Check.......................................................................... 96 Control Lever Operating Force..................................................................... 99 Control Lever Stroke..............................................................................100 Combined Operation of Boom Raise/Swing Function Check.............................................101 Combined Operation of Boom Raise/Arm Roll-In Function Check.......................................102 Clearance of Front Attachment Connecting Part.....................................................103 Group 5 Component Test................................................................................105 Primary Pilot Pressure............................................................................105 Secondary Pilot Pressure..........................................................................107 3-Spool Solenoid Valve Set Pressure...............................................................108 Main Pump Delivery Pressure.......................................................................111 Main Relief Set Pressure..........................................................................112 Relief Pressure (when relieving swing)............................................................116 Overload Relief Valve Set Pressure................................................................118 Main Pump Flow Rate Measurement...................................................................120 Swing Motor Drainage..............................................................................128 Travel Motor Drainage.............................................................................130 SECTION 5 TROUBLESHOOTING.................................................................................135 Group 1 Diagnosing Procedure..........................................................................137 Introduction......................................................................................137 Diagnosis Procedure...............................................................................138 Electric System Inspection........................................................................141 Precautions for Inspection and Maintenance........................................................142 Instructions for Disconnecting Connectors.........................................................144 Fuse Inspection...................................................................................146 Fusible Link Inspection...........................................................................149 Battery Voltage Check.............................................................................150 Alternator Check..................................................................................151 Continuity Check..................................................................................152 Voltage and Current Measurement...................................................................154 Check by False Signal.............................................................................161 Test Harness......................................................................................162 Group 2 Monitor.......................................................................................165 Outline...........................................................................................165 Operating Procedures of Service Menu..............................................................166 Setting Menu......................................................................................203 Inspection of Engine Oil Level, Coolant Level, Hour Meter, and Fuel Gauge.........................206 Fuel Gauge and Coolant Temperature Gauge..........................................................207 Group 3 e-Service.....................................................................................209 Outline...........................................................................................209 List of Operation Data............................................................................210 Snapshot Data.....................................................................................214 Communication System..............................................................................215 Group 4 Component Layout..............................................................................217 Main Component....................................................................................217 Electrical System (Overview)......................................................................218 Electrical System (Rear Tray).....................................................................219 Electrical System (Switch Panel)..................................................................220 Electrical System (Around Air Cleaner)............................................................221 Electrical System (Relays, etc.)..................................................................222 Components Related with Engine....................................................................223 Components Related with Pump Device...............................................................224 Around Pump Device................................................................................225 Components Related with Control Valve.............................................................226 Components Related with Control Valve.............................................................226 Components Related with Swing Device..............................................................228 Travel Device.....................................................................................228 3-Spool Solenoid Valve Unit.......................................................................229 Layout of Attachment Spec. Parts..................................................................230 Boom Foot Part Lower Side.........................................................................231 Components in Control Valve.......................................................................234 Pilot Port........................................................................................254 Group 5 Troubleshooting A.............................................................................259 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure.........................259 MC Fault Code List................................................................................261 ECM Fault Code List...............................................................................272 Monitor Controller (Monitor) Fault Code List......................................................296 Monitor Controller (Information) Fault Code List..................................................297 Air Conditioner Controller Fault Code List........................................................300 Communication Terminal Fault Code List............................................................301 MC Fault Codes 11000 to 11002.....................................................................303 MC Fault Code 11003...............................................................................304 MC Fault Codes 11006, 11007,11009 Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005....306 CAN0 Harness Check................................................................................307 MC Fault Codes 11008, 11010 Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007..........311 CAN1 Harness Check................................................................................312 MC Fault Code 11100...............................................................................315 MC Fault Code 11101...............................................................................316 MC Fault Codes 11200, 11202.......................................................................317 MC Fault Codes 11206, 11208.......................................................................318 MC Fault Codes 11301 to 11303.....................................................................319 MC Fault Codes 11304, 11307.......................................................................320 MC Fault Codes 11325, 11997.......................................................................321 MC Fault Code 11410...............................................................................322 MC Fault Code 11400...............................................................................323 MC Fault Code 11401...............................................................................324 MC Fault Code 11402...............................................................................325 MC Fault Code 11403...............................................................................326 MC Fault Code 11407...............................................................................327 MC Fault Code 11436...............................................................................328 MC Fault Codes 11458, 11459.......................................................................329 MC Fault Code 11901...............................................................................330 MC Fault Code 20011...............................................................................331 MC Fault Code 20062...............................................................................332 Monitor Controller (Information) Fault Codes 13304, 13310.........................................333 Monitor Controller (Information) Fault Code 13311.................................................334 Air Conditioner Controller Fault Codes 11 to 22...................................................335 Air Conditioner Controller Fault Codes 43 to 92...................................................336 Monitor Controller (Information) Fault Codes 20100 to 20114.......................................337 Monitor Controller (Information) Fault Codes 20109 to 20149.......................................338 Group 6 Troubleshooting B.............................................................................339 Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure..................339 Relationship between Machine Trouble Symptoms and Related Parts...................................341 Correlation between Trouble Symptoms and Part Failures............................................361 Engine System Troubleshooting.....................................................................375 All Actuator System Troubleshooting...............................................................383 Front Attachment System Troubleshooting...........................................................390 Swing System Troubleshooting......................................................................402 Travel System Troubleshooting.....................................................................404 Other System Troubleshooting......................................................................409 Exchange Inspection...............................................................................414 How to Lowering Boom in Case of Emergency and When Engine Stops...................................417 Group 7 Air Conditioner...............................................................................419 Outline...........................................................................................419 Functions of Main Parts...........................................................................422 Troubleshooting...................................................................................427 Air Conditioner Controller Fault Code List........................................................428 Air Conditioner Controller Fault Codes 11 to 22...................................................429 Air Conditioner Controller Fault Codes 43 to 92...................................................430 Work after Replacing Components...................................................................452 Refill Compressor Oil.............................................................................453 Charge Air Conditioner with Refrigerant...........................................................454 Hose and Pipe Tightening Torque...................................................................462 SERVICE MANUAL REVISION REQUEST FORM......................................................................465 The Attached Diagram List.................................................................................466
TODBL90-EN-00.............................................................................................................................................................. 1 INTRODUCTION............................................................................................................................................................... 3 SYMBOL AND ABBREVIATION.................................................................................................................................................... 5 SECTION AND GROUP CONTENTS................................................................................................................................................. 7 SECTION 1 GENERAL.......................................................................................................................................................... 9 Group 1 Specifications................................................................................................................................................. 11 Specifications..................................................................................................................................................... 11 Working Ranges (Grouser shoe)...................................................................................................................................... 12 Group 2 Component Layout............................................................................................................................................... 13 Main Component..................................................................................................................................................... 13 Electrical System (Overview)....................................................................................................................................... 14 Electrical System (Rear Tray)...................................................................................................................................... 15 Electrical System (Switch Panel)................................................................................................................................... 16 Electrical System (Around Air Cleaner)............................................................................................................................. 17 Electrical System (Relays, etc.)................................................................................................................................... 18 Components Related with Engine..................................................................................................................................... 19 Components Related with Pump Device................................................................................................................................ 20 Around Pump Device................................................................................................................................................. 21 Components Related with Control Valve.............................................................................................................................. 22 Components Related with Control Valve.............................................................................................................................. 22 Components Related with Swing Device............................................................................................................................... 24 Travel Device...................................................................................................................................................... 24 3-Spool Solenoid Valve Unit........................................................................................................................................ 25 Layout of Attachment Spec. Parts................................................................................................................................... 26 Boom Foot Part Lower Side.......................................................................................................................................... 27 Group 3 Component Specifications....................................................................................................................................... 29 Engine............................................................................................................................................................. 29 Engine Accessories................................................................................................................................................. 33 Hydraulic Component................................................................................................................................................ 34 Electrical Component............................................................................................................................................... 38 SECTION 2 SYSTEM........................................................................................................................................................... 41 Group 1 Controller..................................................................................................................................................... 43 Outline............................................................................................................................................................ 43 CAN Circuit........................................................................................................................................................ 44 Group 2 Control System................................................................................................................................................. 47 Outline............................................................................................................................................................ 47 Engine Control..................................................................................................................................................... 50 Pump Control....................................................................................................................................................... 82 Valve Control (Standard)........................................................................................................................................... 96 Valve Control (Optional)...........................................................................................................................................108 Other Control......................................................................................................................................................116 Group 3 ECM System.....................................................................................................................................................125 Outline............................................................................................................................................................125 Fuel Injection Control.............................................................................................................................................126 Fuel Injection Amount Correction Control...........................................................................................................................134 EGR Control........................................................................................................................................................136 Preheating Control.................................................................................................................................................138 Alarm Control......................................................................................................................................................139 Group 4 Hydraulic System...............................................................................................................................................141 Outline............................................................................................................................................................141 Pilot Circuit......................................................................................................................................................142 Main Circuit.......................................................................................................................................................152 Breaker/Pulverizer/Crusher Circuit (Optional)......................................................................................................................168 Group 5 Electrical System..............................................................................................................................................177 Outline............................................................................................................................................................177 Main Circuit.......................................................................................................................................................178 Electric Power Circuit (Key Switch: OFF)...........................................................................................................................180 CAN Circuit........................................................................................................................................................182 Accessory Circuit..................................................................................................................................................184 Starting Circuit (Key Switch: START)...............................................................................................................................186 Charging Circuit (Key Switch: ON)..................................................................................................................................188 Surge Voltage Prevention Circuit...................................................................................................................................192 Pilot Shut-Off Circuit (Key switch: ON)............................................................................................................................194 Auto Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature............................................................................................196 Engine Stop Circuit................................................................................................................................................198 Monitor Circuit....................................................................................................................................................201 Security Circuit...................................................................................................................................................202 Radio Circuit......................................................................................................................................................204 Air Conditioner Circuit............................................................................................................................................204 Accessory Circuit..................................................................................................................................................207 Work Light Circuit.................................................................................................................................................208 Wiper/Washer Circuit...............................................................................................................................................210 Cab Light Circuit..................................................................................................................................................212 SECTION 3 COMPONENT OPERATION..............................................................................................................................................217 Group 1 Pump Device....................................................................................................................................................219 Outline............................................................................................................................................................219 Main Pump..........................................................................................................................................................220 Regulator..........................................................................................................................................................224 Solenoid Valve.....................................................................................................................................................242 Pilot Pump.........................................................................................................................................................244 Pump Delivery Pressure Sensor......................................................................................................................................244 Pump Control Pressure Sensor.......................................................................................................................................244 Group 2 Swing Device...................................................................................................................................................245 Outline............................................................................................................................................................245 Swing Reduction Gear...............................................................................................................................................246 Swing Motor........................................................................................................................................................247 Swing Parking Brake................................................................................................................................................248 Valve Unit.........................................................................................................................................................250 Group 3 Control Valve..................................................................................................................................................253 Outline............................................................................................................................................................253 Hydraulic Circuit..................................................................................................................................................274 Flow Combiner Valve................................................................................................................................................280 Main Relief Valve..................................................................................................................................................282 Overload Relief Valve (with Make-Up Function)......................................................................................................................286 Regenerative Valve.................................................................................................................................................290 Anti-Drift Valve...................................................................................................................................................294 Flow Rate Control Valve............................................................................................................................................298 Digging Regenerative Valve.........................................................................................................................................302 Boom Lower Meter-In Cut Valve......................................................................................................................................304 Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve............................................................................................................306 Group 4 Pilot Valve....................................................................................................................................................311 Outline............................................................................................................................................................311 Operation (Front Attachment / Swing and Travel Pilot Valves).......................................................................................................313 Operation (Auxiliary Pilot Valve)..................................................................................................................................321 Shockless Function (Only for Travel Pilot Valve)...................................................................................................................326 Group 5 Travel Device..................................................................................................................................................327 Outline............................................................................................................................................................327 Travel Reduction Gear..............................................................................................................................................328 Travel Motor.......................................................................................................................................................330 Parking Brake......................................................................................................................................................332 Travel Brake Valve.................................................................................................................................................334 Overload Relief Valve..............................................................................................................................................338 Travel Mode Control................................................................................................................................................340 Group 6 Signal Control Valve...........................................................................................................................................345 Outline............................................................................................................................................................345 Pilot Port.........................................................................................................................................................346 Shuttle Valve......................................................................................................................................................351 Shockless Valve....................................................................................................................................................354 Pump 1 and 2 Flow Rate Control Valve...............................................................................................................................358 Bucket Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool, Arm 1 Flow Rate Control Valve Control Spool....360 Group 7 Others (Upperstructure)........................................................................................................................................363 Pilot Shut-Off Solenoid Valve......................................................................................................................................363 Solenoid Valve.....................................................................................................................................................365 Pilot Relief Valve.................................................................................................................................................369 Recirculation Valve (Option).......................................................................................................................................370 Group 8 Others (Undercarriage).........................................................................................................................................371 Swing Bearing......................................................................................................................................................371 Center Joint.......................................................................................................................................................372 Track Adjuster (Front Idler Integrated Type).......................................................................................................................373 SERVICE MANUAL REVISION REQUEST FORM.......................................................................................................................................377
ELECTRICAL CIRCUIT DIAGRAM - TABLE OF CONTENTS:
ELECTRICAL CIRCUIT DIAGRAM..................... 1
CONNECTORS..................................... 2
CAB HARNESS.................................... 3
ENGINE HARNESS................................. 4
PUMP HARNESS................................... 5
MONITOR HARNESS................................ 6
GSM (MOBILE COMMUNICATION TERMINAL) HARNESS.... 7
SATELLITE COMMUNICATION HARNESS................ 8
KEY SWITCH HARNESS............................. 9
PILOT SHUT-OFF SOLENOID VALVE HARNESS..........10
REARVIEW CAMERA HARNESS........................11
HYDRAULIC CIRCUIT DIAGRAM (STANDARD)...........12
HYDRAULIC CIRCUIT DIAGRAM (OPTIONAL)...........13
AIR CONDITIONER CIRCUIT DIAGRAM................14
AIR CONDITIONER HARNESS........................15
TROUBLESHOOTING MANUAL - TABLE OF CONTENTS:
TODBL90-EN-00.............................................................................................................................................................. 1 INTRODUCTION............................................................................................................................................................... 3 SYMBOL AND ABBREVIATION.................................................................................................................................................... 5 SECTION AND GROUP CONTENTS................................................................................................................................................. 7 SECTION 1 GENERAL.......................................................................................................................................................... 9 Group 1 Specifications................................................................................................................................................. 11 Specifications..................................................................................................................................................... 11 Working Ranges (Grouser shoe)...................................................................................................................................... 12 Group 2 Component Layout............................................................................................................................................... 13 Main Component..................................................................................................................................................... 13 Electrical System (Overview)....................................................................................................................................... 14 Electrical System (Rear Tray)...................................................................................................................................... 15 Electrical System (Switch Panel)................................................................................................................................... 16 Electrical System (Around Air Cleaner)............................................................................................................................. 17 Electrical System (Relays, etc.)................................................................................................................................... 18 Components Related with Engine..................................................................................................................................... 19 Components Related with Pump Device................................................................................................................................ 20 Around Pump Device................................................................................................................................................. 21 Components Related with Control Valve.............................................................................................................................. 22 Components Related with Control Valve.............................................................................................................................. 22 Components Related with Swing Device............................................................................................................................... 24 Travel Device...................................................................................................................................................... 24 3-Spool Solenoid Valve Unit........................................................................................................................................ 25 Layout of Attachment Spec. Parts................................................................................................................................... 26 Boom Foot Part Lower Side.......................................................................................................................................... 27 Group 3 Component Specifications....................................................................................................................................... 29 Engine............................................................................................................................................................. 29 Engine Accessories................................................................................................................................................. 33 Hydraulic Component................................................................................................................................................ 34 Electrical Component............................................................................................................................................... 38 SECTION 2 SYSTEM........................................................................................................................................................... 41 Group 1 Controller..................................................................................................................................................... 43 Outline............................................................................................................................................................ 43 CAN Circuit........................................................................................................................................................ 44 Group 2 Control System................................................................................................................................................. 47 Outline............................................................................................................................................................ 47 Engine Control..................................................................................................................................................... 50 Pump Control....................................................................................................................................................... 82 Valve Control (Standard)........................................................................................................................................... 96 Valve Control (Optional)...........................................................................................................................................108 Other Control......................................................................................................................................................116 Group 3 ECM System.....................................................................................................................................................125 Outline............................................................................................................................................................125 Fuel Injection Control.............................................................................................................................................126 Fuel Injection Amount Correction Control...........................................................................................................................134 EGR Control........................................................................................................................................................136 Preheating Control.................................................................................................................................................138 Alarm Control......................................................................................................................................................139 Group 4 Hydraulic System...............................................................................................................................................141 Outline............................................................................................................................................................141 Pilot Circuit......................................................................................................................................................142 Main Circuit.......................................................................................................................................................152 Breaker/Pulverizer/Crusher Circuit (Optional)......................................................................................................................168 Group 5 Electrical System..............................................................................................................................................177 Outline............................................................................................................................................................177 Main Circuit.......................................................................................................................................................178 Electric Power Circuit (Key Switch: OFF)...........................................................................................................................180 CAN Circuit........................................................................................................................................................182 Accessory Circuit..................................................................................................................................................184 Starting Circuit (Key Switch: START)...............................................................................................................................186 Charging Circuit (Key Switch: ON)..................................................................................................................................188 Surge Voltage Prevention Circuit...................................................................................................................................192 Pilot Shut-Off Circuit (Key switch: ON)............................................................................................................................194 Auto Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature............................................................................................196 Engine Stop Circuit................................................................................................................................................198 Monitor Circuit....................................................................................................................................................201 Security Circuit...................................................................................................................................................202 Radio Circuit......................................................................................................................................................204 Air Conditioner Circuit............................................................................................................................................204 Accessory Circuit..................................................................................................................................................207 Work Light Circuit.................................................................................................................................................208 Wiper/Washer Circuit...............................................................................................................................................210 Cab Light Circuit..................................................................................................................................................212 SECTION 3 COMPONENT OPERATION..............................................................................................................................................217 Group 1 Pump Device....................................................................................................................................................219 Outline............................................................................................................................................................219 Main Pump..........................................................................................................................................................220 Regulator..........................................................................................................................................................224 Solenoid Valve.....................................................................................................................................................242 Pilot Pump.........................................................................................................................................................244 Pump Delivery Pressure Sensor......................................................................................................................................244 Pump Control Pressure Sensor.......................................................................................................................................244 Group 2 Swing Device...................................................................................................................................................245 Outline............................................................................................................................................................245 Swing Reduction Gear...............................................................................................................................................246 Swing Motor........................................................................................................................................................247 Swing Parking Brake................................................................................................................................................248 Valve Unit.........................................................................................................................................................250 Group 3 Control Valve..................................................................................................................................................253 Outline............................................................................................................................................................253 Hydraulic Circuit..................................................................................................................................................274 Flow Combiner Valve................................................................................................................................................280 Main Relief Valve..................................................................................................................................................282 Overload Relief Valve (with Make-Up Function)......................................................................................................................286 Regenerative Valve.................................................................................................................................................290 Anti-Drift Valve...................................................................................................................................................294 Flow Rate Control Valve............................................................................................................................................298 Digging Regenerative Valve.........................................................................................................................................302 Boom Lower Meter-In Cut Valve......................................................................................................................................304 Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve............................................................................................................306 Group 4 Pilot Valve....................................................................................................................................................311 Outline............................................................................................................................................................311 Operation (Front Attachment / Swing and Travel Pilot Valves).......................................................................................................313 Operation (Auxiliary Pilot Valve)..................................................................................................................................321 Shockless Function (Only for Travel Pilot Valve)...................................................................................................................326 Group 5 Travel Device..................................................................................................................................................327 Outline............................................................................................................................................................327 Travel Reduction Gear..............................................................................................................................................328 Travel Motor.......................................................................................................................................................330 Parking Brake......................................................................................................................................................332 Travel Brake Valve.................................................................................................................................................334 Overload Relief Valve..............................................................................................................................................338 Travel Mode Control................................................................................................................................................340 Group 6 Signal Control Valve...........................................................................................................................................345 Outline............................................................................................................................................................345 Pilot Port.........................................................................................................................................................346 Shuttle Valve......................................................................................................................................................351 Shockless Valve....................................................................................................................................................354 Pump 1 and 2 Flow Rate Control Valve...............................................................................................................................358 Bucket Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool, Arm 1 Flow Rate Control Valve Control Spool....360 Group 7 Others (Upperstructure)........................................................................................................................................363 Pilot Shut-Off Solenoid Valve......................................................................................................................................363 Solenoid Valve.....................................................................................................................................................365 Pilot Relief Valve.................................................................................................................................................369 Recirculation Valve (Option).......................................................................................................................................370 Group 8 Others (Undercarriage).........................................................................................................................................371 Swing Bearing......................................................................................................................................................371 Center Joint.......................................................................................................................................................372 Track Adjuster (Front Idler Integrated Type).......................................................................................................................373 SERVICE MANUAL REVISION REQUEST FORM.......................................................................................................................................377 PLEASE NOTE: This is the same manual used by the dealers to diagnose and troubleshoot your vehicle You will be directed to the download page as soon as the purchase is completed. 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