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MECHANICAL SYSTEM
(H MODE)
Failure mode
Work equipment, travel, swing system
H- 1 Speeds of work equipment, travel, swing are all slow ................... . 20-182
H- 2 There is excessive drop in engine speed, or engine stalls ................ 20-184
H- 3 Work equipment, travel, swing do not move, or speed is extremely slow . 20-186
H- 4 Work equipment, travel, swing lack power ............................. 20-188
H- 5 Power mode selection system does not switch ........................ . 20-188
H- 6 Abnormal noise generated (from around pump) ........................ 20-189
H- 7 Auto-deceleration does not work ..................................... 20-189
Work equipment system
H- 8 Boom, arm speed is extremely slow ................................... 20- 190
H- 9 Work equipment (boom, arm, bucket) speed is slow .................... .. 20- 192
H-l 0 When boom and arm are operated simultaneously, boom is slow ........ . 20- 194
H-l 1 Work equipment (boom, arm, bucket) lacks power ..................... . 20- 194
H-l 2 Excessive hydraul,ic drift ............................................. .. 20- 194
H-13 Excessivetimelag .................................................. . 20-I 96
H-l 4 Does not enter finishing operation mode .............................. 20-I 96
H-l 5 When arm and swing are operated simultaneously, arm is slow .......... 20- 196
Travel system
H-16 When machine is traveling, it deviates naturally to one side
al Deviates in same direction both in forward and reverse . .. 20-I 98
b1 Deviates in different direction in forward and reverse . . 20-200
H-17 Excessive deviation during compound operations .. .... . 20-20 1
H-18 Excessive deviation when starting ...... .... ... .... . 20-202
H-19 Travel lacks power or speed is slow ... .. . ....... . 20-204
H-20 Travel speed does not switch .. . .... . .... ... .... . 20-204
H-21 Machine does not move (one side only) ... ........ .. . 20-205
Swing system
H-22 Doesnotswing ............................................ ....... . . 20-206
H-23 Swing speed is slow or acceleration is poor. .................. ...... 20-208
H-24 Excessive overrun when stopping swing ..................... ...... . 20-209
H-25 Excessive shock when stopping swing ....................... ...... . 20-209
H-26 Excessive abnormal noise when stopping swing .............. ...... . 20-210
H-27 Excessive hydraulic drift of swing ........................... ...... . 20-210
H-28 When operated simultaneously with arm, swing speed is slow . . ...... . 20-210
TABLE OF FAILURE MODES AND CAUSES ............................. ...... . 20-211
20-181
H-l Speeds of work equipment, travel, swing are all slow
* If there are other problems, such as travel deviation or low bucket or swing speed, go to H-l 6.
% 1. If the pressure is not at least 27 kg/cm2, the spool of the acceleration (Hi) end is not fully actuated.
x2. The discharge pressure of the pump has an effect on the TVC valve set pressure, so check it
before adjusting the TVC valve set pressure.
4 YES
v
Is engine speed . When normal relieved:
YES normal when PC200 2150 * 60 rpm
- pump is relieved - PC220 2300 * 60 rpm
with CO canceled?
3
. When CO canceled: NO
PC200 2050 ? 60 rpm PC220 2200 + 60 rpm
YES IS set pressure
* H.0 + H mode
- at Tvcvalve -
. Engine at high idling
normal?
. Arm relief
5 YES
. 30 TE kg/cm2
*1
20-182
0
I CalKX Remedy
Adjust
4djus.t
20-183
H-2 There is excessive drop in engine speed, or engine stalls
YES
I
2
When pump is
I
Y, relieved, is Y,
OUtpUt pressure Of
co valve normal?
3
a At normal relief: Does output f Output pres-
Max. 5.5 kg/cm’ pres$ure become sure becomes
a When CO canceled: _ normal when CO normal
Same pressure at NO valve is * Condition also -
TVC press”re adjusted? becomes
* Engine at high idling normal J
. H.0 + H mode * output pres-
suredoes not -
become
normal I
* PCZOO: 16
+1
-2
. set pressure
becomes
YES
.r
kg/cm’ normal
. PC220: 17
+1
_2
. Problem does
4 I L not cnange
kg/cm2
Does condition . Set pressure
* l-pump relief becomes
become normal
* H.0 + H mode
“orma’
* Engine at high 1v”L when TVCvalve --
. Condition also
.
set pressure is
idling adjusted? becomes
i normal 1
Set pressure
does not
become
normal
20-184
0
Cause Remedy
Defective adjustment of
Adjust
TVC valve
YES
3-
Block circuit (1) -
YES (6) in Fig. 1. Is
-charging pump -
relief pressure 4 YES
I
n normal?
_ Is any foreign
material found in
* 30 ‘E kg/cm2 _ oil drained from -
NO charging pump
* Engine at high outlet strainer?
idling
NO
motor.
- Disconnect
gcwernor “lOtOr
Do not move, or connector, and set h
speed is extremely governor lever
to NO INJECTION.
YES
L To I tern 3 above
5
Solenoid valve 4
_Y 9tJ+
205FO5300
20-186
0
Remedy
Defective charging
Wplace relief
ralve
. Defectwe damper
iPT0)
_ - Defective mm pump
(broken shaft, etc 1
20-187
0
H-4 Work equipment, travel, swing lack power
CaUSe Remedy
3 YE
Defective CO valve
correct or
reDlace
YI Outlet Port Of
solenoid valve’
When digging
2 * See conditions for N
Defective
solenoid
CO cancel
valve
ReplaCe
Y ES Item 4 below.
force is
maximized
4 YE Drop in set pressure of Adjust or
* At travel relief: main relief valve ,ep1ace
335 - 365 kg/cm*
1 . Engine at high ,
idling solenoid valve
Does the problem
cxcur when Defective 2.stage
digging force is Replace
- At travel relief and N relief solenoid valve
maximized, or when digging force
during normal is maximized:
25 - 35 kg/cm’
. During normal
operation: 0 kg/cm’
Cause Remedy
1
When TVC valve 1 YES
solenoid is remov- Defective TVC valve ReplaCe
I) Turn starting
switch ON.
20-188
0
H-6 Abnormal noise generated (from around pump)
CaUSe Remedy
Add hydraulic
Lack of oil
oil
CaUSe Remedy
t-
1 YES Defective travel shuttle Repair or
Valve reDlaCe
Is hydraulic
pressure at inlet
port of travel -
shuttle valve
normal? Defective PPC shuttle Repair or
valve replace
- 25 - 35 kg/cm’ ND
20-189
H-8 Boom, arm speed is extremely slow
C.WSl2 Remedy
20- 190
0
H-9 Work equipment (boom, arm, bucket) speed is slow
3 YES
Is operation of
- boom holding -
valve normal?
NO
. Check movement of
valve with your hand.
4 YES
Is hydraulic
pressure at Outlet
Arm only ] - port of arm half -
I
flow solenoid
valve normal? NO
. F.0 or L.0 mode: 0 kg/cm2
. Normal operation: 25 - 36 kg/cm2
l It is also possible to hold the solenoid valve outlet
hose by hand to judge.
[ Bucket only
J
1
* ;li~b/c-’ 1
* Engine at high
Is hydraulic drift NO
of slow cylinder _
within standard
ValUe?
5
Does hydraulic
drift become
faster when YES
lever is
operated? NO 6
20-192
0
I Cause Remedy
Repair or
Defective operation of replaCe
control valve spool control valve
(boom) assembly
Repair or
Defective operation of
replace
control valve spool (arm)
Control valve
assembly
Defective oil-tightness
of control valve spool
20-193
H-10 When boom and arm are operated simultaneously,
boom is slow.
F-i-i
Defective
valve
arm throttle Repair
replaCe
or
2 YES
H
i I I
1
r
-w I
NO
I-
. Engine at high idling
Does this problem
occur when digging
force is maximized, 4 YES
or during normal I 1 I
operation?
YES
3r
power at both
j_ ( During normal head end and
~0 i operation bottom end, or
Table 1 mm
+I Go to H-9, Item 5.
20-l 94
a
Cause Remedy
Defective operation of
1 CO cancel solenoid ReplaCe
valve
Defective OperatiOn Of
*-stage relief solenoid ReplaCe
Valve
Defective safety
Replace
(suction) valve
20-195
H-13 Excessive time lag
* If the work equipment speed is normal (if the speed is slow, go first to H-9, Item 2).
CaUSi? Remedy
Defective operation
Replace
of suction valve
Time lag set
CaUSe Remedy
Defective operation
of arm half flow ReplaCe
solenoid valve
C.NSe Remedy
20-196
0
H-l 6 When machine is traveling, it deviates naturally to one
side
Direction of 41L
YES
deviation . For details, see NO
changes TESTING AND
YES Is OUtpUt preSS”re
ADJUSTING.
- of NC valve
* Fordetails, see normal?
YES
TESTING AND
ADJUSTING. 6-
* When track is rota-
ted freely or during
normal travel, Is differential
-
sensor norma!?
1
When pump outle t
hoses are changed
between F and R,
does direction of
deviation change?
10
Are metal particles
YES found in oil
_ drained from final _ YES
drive on side
which deviates? 11 r
p DoesdirectionOf
deviario"
change when
_ leftand
rigil*tmres _
9 NO betwee"
C0"tr.d "he
andIWi".I
joint are
i”tsrchsnged7
YES Does control valve
spool move
smoothly? NO
I I
Direction of
Is output preswre
L deviation does
of PPC valve
NO not change
NO
. 30 ‘g kg/cm2
Note: When the track is rotated freely, if the output pressure of the NC valve is the same as the
output pressure of the TVC valve, both the jet sensor and NC valve are normal.
20-:98
CCV_lSC? Remedy
Leakage of inside
ReplaCe
pump
Defective operation
Replace
of servo valve
Defective control
Replace
valve body
Defective swivel
Replace
joint
Defective Operation Of
Replace
COntrOl valve spool
20- 199
b) Deviates in different direction in forward and reverse (See Fig. 1 I
20-200
0
H-l 7 Excessive deviation during compound operations
CS_lSC? Remedy
Does spool of
YES travel shuttle
1 - valve mclve
smoothly?
Defective operation of Repair or
Is oil pressure at
- travel shuttle valve repIS
inlet port of travel NO
shuttle valve
normal?
* If the pressure in Item 1 is lost, the auto-deceleration also will not work.
*O-$O’
H-l 8 Excessive deviation when starting
\IES 4 YES
Deviates at
full stroke
NO
El
Does machine
deviate at lever
full stroke, or
during fine
control?
. 220mm/20m 6 YES
7
is OUtpUt
YES_ pressure at NC
valve at fast end
normal?
5
Machine deviates Is differential - Control lever at NO
when starting, pressure of jet neutral: Max.5.5 kg/cm=
I regardless of N - - sensor at fast - * Traqk rotating freely: Min. 18 kg/cm*
NO fine control, or side (outside of a Engine at high idling
_ N - Full stroke turn) normal? 7 YES
- ,s”,::99’ lever at
13 - 19 kg/cm2
- Control lever at
full stroke problem reversed?
Max. 2 kg/cm= NO
a Engine at high idling
20-202
0
Remedy
Defective OperatiOn
of servo valve
Defective control
valve
Defective operation of
servo valve
Defective adjustment of
NC valve
20-203
H-19 Travel lacks power (or speed is slow)
Cause Remedy
2 YES Repair or
Defective CO valve
Is hydraulic replace
YES preSS”re at Outlet
- port of co cancel -
solenoid valve
1 Il0rlllal? Defective CO cancel Replace
* See conditions for NO solenoid valve
Is main relief Item 3 below.
pressure at travel -
relief normal?
3 YES Drop in set pressure of 4djust or
At travel relief: Is hydraulic main relief valve replace
335 - 365 kg/cm* pressure at Outlet
Engine at high N& port of 2.stage -
idling relief solenoid
valve normal?
I I I Defective 2.stage relief
1:
replace
. At travel relief and NO solenoid valve
with power
maximized:
25 - 35 kg/cm’
. During normal
operation: 0 kg/cm’
Remedy
20-204
0
H-21 Machine does not move (one side only)
CaUSe
I Remedy
2 YES Repair 0,
Defective final drive
replace
Is any foreign
YES material found in _
I
oil drained from
final drive?
I Travel motcar brake Replace motor
dragging assern b I y
NO
Is main relief
pressure at motor -’
relief normal? .
3 YES Defective travel I Replace safety
. At travel relief: mtxclr safety valve valve
Is hydraulic pressure
325 - 365 kg/cm’ normal at motor
* Engine at high - relief when safety -
idling NO va,ves are
interchanged?
Defective travel Replace motor
. For standard value, NO motor assembly
see Item 1.
H-22 Does not swing
YES
4
Is any foreign
YES material found in
oil drained from
swing machinery? 5 YES
3-
Does control
Is hydraulic L valve spool move
NO
YES_ pressure et left smoothly?
and right relief
normal?
2 _ NO
-1Is hydraulic
* .285 - 300 kg/cm2
r H
Does not swing pressure et swing Engine at high
YES
in either brake solenoid NO
idling
direction valve Outlet port
normal?
I
. Lever operated:
25 - 36 kg/cm2 NO
Does not swing in
- Lever at neutral:
either direction, or 0 ka/cm’
in one direction l It is a?so possible to hold the solenoid valve outlet hose by hand to judge.
6 YES
When left and
o”
Does not swing right safety valves
~0 are interchanged, -
I in one direction l- 0”
is problem
reVet?Xd? z
NO
l IS possible to measure
also
20-206
0
CaLI% Remedy
Repair or
Defective swing machinery rep,ace
Replace motor
Defective motor brake assembly
Defective operation of
control valve spool
Defective operation Of
swing brake solenoid Replace
valve
20-207
H-23 Swing speed is slow or acceleration is poor
+ When other work equipment and travel speeds are normal. (If there is also deviation (to right)
during normal travel, go first to “H-l 6 When machine is traveling, it deviates naturally to one side”.)
* Mode selection is H.0 and H mode.
CaUSe Remedy
2 Defective operation of
NC control Valve spool
F[
safety Valve
swing (set) (90’) :
PCZOO: Max. 3.4
sec.
PC220: Max. 3.8
* Time taken for
Defective safety valve qeplace
swing (secK5 turns)
One direction . For standard value, NC
Both PC200 and
only see Item 5.
220: Max. 30 NO
* Engine at high idling
* Is also possible to NO
Defective PPC valve GDlaCe
measure the hydraL c
pressure to judge.
.285- 300 kg/cm2
-Engine at high idling
20-208
0
H-24 Excessive overrun when stopping swing
Cause Remedy
0”
t3 H-25 Excessive shock when stopping swing
S+
* When the swing speed is normal.
C&US= Remedy
Defective Swing
Repair
machinery
i One direction
OlllY
1 Defective safety valve ReDlaCe
NO J
20-209
0
H-26 Excessive abnormal noise when stopping swing
CaUSe Remedy
H
YES Both left and material found in
right
1
oil drained from
swing machinery?
1
NO
Defective
Valve
lift check 3ePlXe
L
One direction become normal 1
I
O”lV when safetv
NO
interchanged?
3efective suction valve 3eplace
NO
CaUSe Remedy
CCdUSe Remedy
20-210
0