Case Excavator Crawler Cx330 Tier3 Training-21113C370193.pdf -Bookmark created by https://wimanual.com EXCAVATORS CX330 TIER3 10 Main CX330 GB.pdf Fluids and Lubricants Lubricants must have the correct properties for each application. Hydraulic fluid CASE Temperate climates: -20C to +40C (-4 to 104 F) CASE Hot climates: 0�C to +50�C (32 to 122 F) CASE Cold climates: -25�C to +20�C (-13 to 68 F) CASE Biodegradable fluid: -30�C to +40�C (-22 to 104 F) This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit completely before refilling with this fluid. CASE Transmission component oil Extreme pressure oil used for enclosed transmission components. CASE Grease CASE "Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide. CASE "Extreme Pressure" multipurpose grease with lithium soap and calcium. CASE "Extreme Pressure" multipurpose grease with lithium soap. Hydraulic breakers CASE Engine Oil Oil viscosity 1) With mineral base (2) With semi-synthetic base (3) With synthetic base Fuel Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard. Use grade No. 2-D fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption. In cold weather (below -7C), it is provisionally approved to use a mixture of fuels No. 1-D and No. 2-D. If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting. Required conditions for diesel fuel The following specific conditions are required for diesel fuel: - Must be free from minute dust particles. - Must have adequate viscosity. - Must have high cetane value. - Must have high fluidity at low temperature. - Must have low sulphur content. - Must have little residual carbon. Diesel fuel recommendation - JIS (Japanese Industrial Standard) : No. 2 - DIN (Deutsche Industrie Normen) : DIN 51601 - SAE (Society of Automotive Engineers) Based on SAE-J-313C: No. 2-D - BS (British Standard) Based on BS Using fuels other than those recommended can damage the fuel injection pump, the injector and other parts of the fuel supply sys... Fuel storage Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel. The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly. Anti-freeze Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. CASE For areas where the temperature goes down to -38C, mix 50 Environment Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles. Contact your local ecological recycling centre to obtain information on the correct method of disposing of these lubricants. Plastic and resin parts When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint solvents etc... Use only water, soap and a soft cloth. The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts. MAINTENANCE - PERIODICITY CONTENTS Tightening of cap screws, nuts Special torque settings NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*). 330-5-05-01-17c_1 Machine overall dimensions cs00K520 (CX330LC) (CX330NLC) cs00K520 (CX350) Component weight Major component weight 330-3-01-00-46a Other component weight Engine Approximately 640 kg (1410 lbs) Air cleaner 13.6 kg (30 lbs) Hydraulic pump 130 kg (287 lbs) Control valve 192 kg (432 lbs) Swing motor and reduction gear assembly 435 kg (959 lbs) Travel motor and reduction gear assembly (2) 399 kg (880 lbs) Rotary joint 56 kg (123 lbs) 6 solenoid valve bank 6 kg (13.2 lbs) Hand control valve 1.8 kg (4 lbs) Foot control valve 10.5 kg (23 lbs) Cab 255 kg (562 lbs) Muffler 20 kg (44 lbs) Radiator total weight 140 kg (309 lbs Oil cooler 34 kg (75 lbs) Radiator 21.1 kg (47 lbs) Air cooler 19.9 kg (44 lbs) Fuel cooler 1.2 kg (2.65 lbs) Idler wheel 165 kg (364 lbs) Upper roller 43 kg (95 lbs) Lower roller 60 kg (132 lbs) Tension damper assembly 254 kg (560 lbs) Recoil spring assembly 119.4 kg (263 lbs) Grease cylinder assembly 41.3 kg (91 lbs) Yoke 39.8 kg (88 lbs) Threaded rod 50.3 kg (111 lbs) Track chains 600 mm (23.62 in) (48 shoe) 2217 kg (4888 lbs) 700 mm (26.56 in) (48 shoe) 2473 kg (5452 lbs) 800 mm (31.5 in) (48 shoe) 2618 kg (5772 lbs) 850 mm (33.5 in) (48 shoe) 2735 kg (6030 lbs) 900 mm (35.5 in) (48 shoe) 2817 kg (6210 lbs) Boom (without cylinders) CX330, CX330NLC 2417 kg (5329 lbs) CX350 2709 kg (5972 lbs) Arm (without cylinders) CX330, CX330NLC CX350 Boom cylinder 279 kg (615 lbs) Arm (dipper) cylinder 462 kg (1019 lbs) Bucket cylinder 276 kg (608 lbs) Machine code Changing the language code Specifications Main data Model name CX330 Hydraulic Excavator CX330NLC Hydraulic Excavator CX350 Hydraulic Excavator Operating weight CX330 34100 kg (75178 lbs) CX330NLC 34000 kg (74957 lbs) CX350 36100kg (79587 lbs) Engine output 202 kW Performance Standard weight 18.0 kN (4047 lbf) Swing speed 9.6 Tr Travel speed Low Speed 3.2 km High Speed 5.5 km Maximum drawbar pull 278 kN (62497 lbf) Grade ability 70% (35) Ground pressure 64 kPa (600 mm (23.6 in) grouser shoe) Complete machine dimensions CX330, CX330NLC CX350 Main body dimensions Main body length 5910 mm (19 ft 5 in) Main body width 3200 mm (10 ft 6 in) Upper swing body width 3040 mm (10 ft 0 in) Cab width 1000 mm (39.36 in) Main body height 3130 mm (10 ft 26 in) Tail swing radius 3450 mm (11 ft 2 in) Distance of rear swing body 3420 mm (11 ft 2.5 in) Ground clearance for upperstructure 1210 mm (4 ft 0.5 in) Center-to-center of wheels 4040 mm (13 ft 3 in) Overall track length 4980 mm (16 ft 2.5 in) Maximum track width CX330, CX350 3200 mm (10 ft 6 in) CX330NLC 2990 mm (9 ft 9 in) Center-to-center for track CX330, CX350 2600 mm (8 ft 6 in) CX330NLC 2390 mm (7 ft 9.5 in) Width of track shoe 600 mm (23.6 in) Minimum ground clearance 480 mm (19 in) (To bottom of lower frame) Engine Name ISUZU, AH-6HK1XYSS Type: 4-cycle, water-cooled, overhead camshaft, common rail injection (electric control), with air-cooling type inter-cooler turbo with air-cooling. No. of cylinders - bore x stroke 6-dia. 115 mm x 125 mm (4.53 x 4.92 in) Displacement 7790 cc (475 cu.in) Compression ratio 17.5 Rated output 202� 3.0 kW Maximum torque 1080Nm (797 lb-ft) Engine dimensions (LxWxH) 1357 x 995.4 x1141 mm ( 53.42 x 39.19 x 44.92 in) Oil pan All direction 35, inclinable Starter, reduction type .24 V, 5 kW Alternator, AC type 24 V, 50 A Battery 2x 12V Cooling system Fan type diameter 850 mm (33.5 in), suction type-6blades resin & steel Pulley ratio .80 (reduction) Direction of rotation Right (viewed from fan side); compliant with Radiator capacity 96.0 kW Fin type wavy Fin space 2.0 mm (0.08 in) Oil cooler capacity 66.6 kW Fin type Wavy Fin space 1.75 mm (0.07 in) Inter-cooler capacity 29.9 kW Fin type triangular straight Fin space 2.0 mm (0.08 in) Fuel cooler capacity 1.7 kW Fin type wavy Fin space 2.0 mm (0.08 in) Capacity of coolant and lubricants Coolant 30 L (7.92 gal) Fuel 580 L (153 gal) Lubricant for engine 38 L (10 gal) Lubricant for travel reduction gear (per side) 9.5 L (2.5 gal) Lubricant for swing reduction gear (per side) 6 L (1.59 gal) Hydraulic oil 350 L (92.5 gal) Capacity of hydraulic oil tank 175 L (46.2 gal) Hydraulic oil filter Suction filter (inside tank) 150 mesh Return filter (inside tank) 10 m m Nephron filter (inside housing) 1 m m Pilot line filter (inside housing) 10 m m Operating devices Operator's seat Location; left side Structure; low frequency air suspension with helical springs and double acting hydraulic damper. Cab Smooth and round shape design cab, fabricated by press work Safety glass for all windows. Levers and pedals For travel use; levers and pedals (hydraulic pilot type) (2) For operating machine use; levers (hydraulic pilot type) (2) Instruments and switches Work mode switchover; 4 modes (heavy digging, standard, finishing and auto) Travel speed switchover; Low Speed One-touch idle; Knob switch type Monitor device Machine status display (full-dot liquid crystal) Travel speed selection status; Low Speed Work mode selection status; H Auto idle selection status; ON Instruments (full-dot liquid crystal, except for hour meter) Fuel gauge; bar graph indicator Engine coolant temperature gauge; bar graph indicator Hydraulic oil temperature gauge; bar graph indicator Hour meter; digital type Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm Over heat* Battery charge* Faulty electrical system* Refill fuel* Engine oil pressure* Refill coolant* Engine preheat Auto warm-up Air cleaner* Idling Service interval Lighting Working light Upper: 24V, 70W (1) Boom: 24V, 70W (1) Cab: 24V, 70W (1) Interior light 24V, 10W (1) Horn; electric horn (2) Other Hydraulic system Hydraulic pump drive system, directly coupled to the engine (no transmission) Main pump Pilot pump Control characteristics; simultaneous output control of overall, negative control, electric horse power control Control Valve Model; 4-spool section: integrated (1) or 5-spool section: integrated (1) Operation method; hydraulic pilot method: travel, swing and operating machine Maximum flow 284 L Set pressure of main relief valve standard; 34.3 MPa (4975 psi), power boost 37.3 MPa (5410 psi) Set pressure of overload relief valve when boom down; 27.4 MPa (3974 psi) at 20 L other: 39.2 MPa (5685 psi) at 20 L Set pressure of foot relief valve 2.89 MPa (420 psi) at 53 L Functions Hydraulic Cylinders Boom cylinder (2) Arm (dipper) cylinder Bucket cylinder Rotating Joint Operating pressure Hydrostatic test pressure Flow Number of revolutions 15 min-1 Torque, when pressurizing 2 ports 196 Nm (145 lb-ft) Port A; forward right G1-A Class Port B; forward left G1-A Class Port C; backward right G1-A Class Port D; backward left G1-A Class Port T; drain port G1 Port P; pilot port G1 Solenoid Valve Maximum flow P -> B: 20 L Rated pressure 4.41 MPa (640 psi) Operating voltage DC 20 to 32 V Current 13.0 W (at 24 V, 20� C) Hand control valve Manufacturer Kawasaki Operating pressure 3.92 MPa (569 psi) Secondary pressure, primary short type 0.64 � 0.1 to 2.45 � 0.14 MPa Operating angle Operating torque Foot control valve Manufacturer Nishina Operating pressure 3.92 MPa (569 psi) Secondary pressure; primary short type 0.64 � 0.1 to 2.45: 0.14 MPa Operating angle 12.4 � 0.3� Operating torque Digging force (New JIS) Bucket digging force Standard pressure 229 kN (51481 lbf) Power boost pressure 248 kN (55753 lbf) Arm (dipper) digging force Standard pressure Power boost pressure Swing unit Swing circle; swing bearing type (with internal gears) Swing hydraulic motor (1); fixed displacement piston motor with parking brake and reversal prevention valve Displacement 186.7 cm3 (11.39 cu in) Operating pressure 29.4 MPa (4264 psi) Operating flow 284 L Brake torque 961.6 Nm (709.24 lb-ft) or over Brake off pressure 2.9 MPa (421 psi) less than Relief set pressure 28.9 to 29.7 MPa (4192 to 4308 psi) at 100 L Reduction gears, planetary gear 2-stage reduction system Reduction ratio 27.143 Swing parking brake; mechanical lock (operational lever linkage type) Swing lock; mechanical lock (swing lock switch linkage type) Travel lower body Travel hydraulic motor (2); variable displacement piston motor, automatic 2-speed switch-over with parking brake Displacement 290.7 Operating pressure 34.3 MPa (4975 psi) Operating flow 284.2 L Brake torque 4738 Nm (3495 Ib-ft) or over (excluding reduction gear) Relief set pressure 35.8 MPa (5112 psi) at 5 L 2-speed control pressure 26.5 � 1 MPa (3443 psi) Reduction gears; planetary gear 2-stage reduction system Reduction ratio 40.467 Travel brake; hydraulic lock Parking brake; mechanical lock (travel lever linkage type) Track shoe Model; assembly-type double grouser shoe Number of shoes (per side) 48 Shoe width Grouser height 36 mm (1.42 in) Link pitch 216 mm (8.5 in) Roller Number of upper rollers (per side) 2 Number of lower rollers (per side) 8 Track belt tension adjuster; grease cylinder type (with cushion spring) mounting length of spring 779 mm (30.67 in) Work Unit Model; backhoe attachment Capacity Boom length 6450 mm 30 Components 330 GB.pdf TABLE OF CONTENTS Proportional soleno�d Hand remote controls How it work Foot control Auxiliary foot control Cushion valve Safety valves (HBCV) Swing reduction gear 6 soleno�ds bloc Cylinder 40 Diag_330 GB.pdf Machine history 1. Screen HR1 ENG : Hour meter (alternator generation time) WRK : Machine operation time (attachment ON or travel ON) U : Attachment operation time T : Travel operation time S : Swing operation time PU : Boost time BRK : Breaker usage time 2. Screen HR2 H : H mode usage time S : S mode usage time L : L mode usage time A : A mode usage time WT : Maximum coolant temperature OT : Maximum hydraulic oil temperature FT : Maximum fuel temperature 3. Screen HR3 1 : Controller power supply ON time 2 : 1-speed mode usage time 3 : 2-speed mode usage time 4 : Travel hydraulic only time 5 : Maintenance time 6 : ***** 7 : ***** 4. Screen HR4 [P1 pressure distribution] 1 : Time P1 10 MPa or less 2 : Time P1 10 to 15 MPa 3 : Time P1 15 to 20 MPa 4 : Time P1 20 to 25 MPa 5 : Time P1 25 to 30 MPa 6 : Time P1 30 to 25 MPa 7 : Time P1 35 MPa 5. Screen HR5 [P2 pressure distribution] 1 : Time P2 10 MPa or less 2 : Time P2 10 to 15 MPa 3 : Time P2 15 to 20 MPa 4 : Time P2 20 to 25 MPa 5 : Time P2 25 to 30 MPa 6 : Time P2 30 to 35 MPa 7 : Time P2-35 MPa 6. Screen HR6 [Engine speed distribution] 1 : Time N 1175 min-1 or less 2 : Time N 1175 to 1375 min-1 3 : Time N 1375 to 1575 min-1 4 : Time N 1575 to 1775 min-1 5 : Time N 1775 to 1975 min-1 6 : Time N 1975 to 2175 min-1 7 : Time N 2175 min-1 or more 7. Screen HR7 [Coolant temperature distribution] 1 : Time TW 77C or less (Marks 1 and 2 on the bar graph) 2 : Time TW 77 to 82C (Mark 3 on the bar graph) 3 : Time TW 82 to 97C (Mark 4 on the bar graph) 4 : Time TW 97 to 100C (Mark 5 on the bar graph) 5 : Time TW 100 to 103C (Mark 6 on the bar graph) 6 : Time TW 103 to 105C (Mark 7 on the bar graph) 7 : Time TW 105C or more (Mark 8 on the bar graph) 8. Screen HR8 [Hydraulic Oil temperature distribution] 1 : Time TO 45C or less (Marks 1 and 2 on the bar graph) 2 : Time TO 45 to 60C (Mark 3 on the bar graph) 3 : Time TO 60 to 80C (Mark 4 on the bar graph) 4 : Time TO 80 to 88C (Mark 5 on the bar graph) 5 : Time TO 88 to 95C (Mark 6 on the bar graph) 6 : Time TO 95 to 98C (Mark 7 on the bar graph) 7 : Time TO 98C or more (Mark 8 on the bar graph) 9. Screen HR9 [Fuel temperature distribution] 1 : Time TF 30�C or less 2 : Time TF 30 to 40�C 3 : Time TF 40 to 50�C 4 : Time TF 50 to 60�C 5 : Time TF 60 to 70�C 6 : Time TF 70 to 80�C 7 : Time TF 80�C or more 10. Screen HR10 [Load ratio distribution] 1 : Time R 30% or less 2 : Time R 30 to 40% 3 : Time R 40 to 50% 4 : Time R 50 to 60% 5 : Time R 60 to 70% 6 : Time R 70 to 80% 7 : Time R 80% or more 11. Screen HR11 [H mode high idle load ratio distribution] 1 : Time R 30% or less 2 : Time R 30 to 40% 3 : Time R 40 to 50% 4 : Time R 50 to 60% 5 : Time R 60 to 70% 6 : Time R 70 to 80% 7 : Time R 80% or more 12. Screen HR12 [S mode high idle load ratio distribution] 1 : Time R 30% or less 2 : Time R 30 to 40% 3 : Time R 40 to 50% 4 : Time R 50 to 60% 5 : Time R 60 to 70% 6 : Time R 70 to 80% 7 : Time R 80% or more Resetting Resetting (RST1, 2) MODE : Travel mode, work mode BRK : Breaker engine speed set L : Lifting magnet engine speed set AI : Auto idle time set (1 to 30 sec.) PA : Pump output adjustment AU : Automatic boost rise HLD : Previous data hold set OUT : Oil pressure drive fan inspection mode 1) Breaker speed set 1 Select the breaker speed set (BRK) with the Buzzer Stop switch. (The selected item switches from light- on-dark display to dark-on-light display.) 2 Now, set the breaker speed (BRK) to 1800 min-1. While watching the monitor, adjust the engine speed with the throttle volume. ... 3 Switch OFF the key switch. 4 To check, see the �CHK1� engine speed. 2) Lifting magnet speed set 1 Select the lifting magnet speed set (L 2 Now, set the lifting magnet speed (BRK) to 2000 min-1. While watching the monitor, adjust the engine speed with the throttle v... 3 Switch OFF the key switch. 4 To check, see the �CHK1� engine speed. 3) Auto idle time change 1 Select the auto idle time change (AI) with the buzzer stop switch. (The selected item switches from light- on-dark display to dark-on-light display.) 2 Now, set the auto idle time to 10 seconds. Turn ON the travel mode switch untl the number reaches 10. The number increases eac... 3 Turn OFF the key switch. 4) Pump output change 1 Select the pump output adjustment (PA) with the buzzer stop switch. (The selected item switches from light-on-dark display to dark-on-light display.) 2 Now, set the pump output to low-output mode. Turn ON the travel mode switch so that the number reaches 1, 2, or 3. Each time t... 3 Switch OFF the Key switch. 5) Automatic pressure rise release setting 1 Select the automatic boost rise release and engine protection function release (AU) with the buzzer stop switch. (The selected item switches from light-on-dark display to dark-on-light display.) 2 Now, set the automatic boost rise engine protection fanction to none. Turn ON the travel mode switch so that the number reache... 3 Turn OFF the key switch. 6) Previous data hold condition change 1 Select the previous data hold (HLD) with the buzzer stop switch. (The selected item switches from light- on-dark display to dark-on-light display.) 2 Now, set the work mode to previous data hold. Switch the travel mode switch ON so that the number reaches 1. Each time the switch is switched ON, the number displayed moves to the next step in the sequence: When the setting is complete, switch the work mode switch ON for 10 seconds. The buzzer buzzes to announce that the storing the setting into memory is complete. 3 Switch OFF the key switch. 8) Maintenance time setting 1 Move to RST2 with the buzzer stop switch and select (2). (The selected item switches from light-on-dark display to dark-on-light display.) 2 The number displayed shows the time for displaying �Maintenance time�. The display immediately after the selection is the defa... 3 Turn OFF the key switch. 9) Injector test mode 1 Move to RST2 with the buzzer stop switch and select (3). (The selected item switches from light-on-dark display to dark-on-light display.) 2 Now, after the engine has been started, injector test mode is to be set here. Turn ON the travel mode switch so that the numbe... 3 For the injector test mode, the previous time's data is reset. In other words, even if the key switch is turned OFF with a value set, the next time the Key switch is turned ON, the mode is normal mode. To confirm the excavator model selection MACHINE CODE RE-INITIALISATION machine information Setting of machine model 1. Key switch ON, the screen below appears and �?� for machine is selected: 2. Press the travel mode switch until the required machine code is displayed. SH0120 CX130 SH0150 CX160 SH0180 Not used SH0200 CX210 SH0220 CX240 SH0250 CX290 SH0300 CX330 SH0400 CX460 SH0700 CX700 SH0800 CX800 3. Press the work mode switch. The screen below appears and �?� for territory is selected. 4. Press the travel mode switch until the required destination code is displayed. 3 EUROPE MPa C 4 Rest of world KgF C 5. Press the work mode switch. The screen below appears and �?� for language is selected. 6. Press the travel mode switch to display the required language code: 7. After selecting the machine code, the destination code and the language code, press the auto mode switch and the screen below will appear: 8. If the machine code does not correspond to the engine controller installed, the error code: �E. CONT. ERROR� appears on the screen and the audible warning device sounds. 9. Check that the machine code corresponds to the engine controller installed on the excavator. 10. To confirm the excavator model selection, press the auto mode switch for 10 seconds: 11. Press the auto mode switch again and the work screen will appear: 12. Re-initialising the data Changing the language code Display of engine information 1 0 0 A B 2 C D E F 3 G H I J 4 0 0 K L 5 M N O P 7 0 Q R S Re-setting of engine information 4 e f g h 1 a b c d 5 m n o p 2 i j k l 6 u v 0 0 3 q r s t 7 w x 0 0 ab Engine code 4 Machine models 55 6HK1 5 CX330, CX350 5B 6UZ1 6 CX460 63 6WG1 7 CX700 Selection of injector 1 Select an injector number (RST11 ->RST12 . . . ->RST116) intending to check or enter with the buzzer stop switch. 2 The injector number on the fan side is assigned as 1 and the one on the pump side as 6 (refer to the figure below). Remarks: 1 Engine information re-setting screen will appear from any service support screen by turning the one- touch idle switch ON for more than 10 seconds. 2 Although the engine can be started while the engine information re-setting screen is being displayed, the ID code cannot be entered. Entering injector ID code (after injector has been replaced) 1 Select the replaced injector number 1 (RST11) with the buzzer stop switch. 2 Each time the auto mode switch is turned ON, 2 places of figure to be selected will shift in the order of "1Hi � 1Lo � 2Hi � 2... 3 Keep on entering the ID code and enter lower 2 places of figure on 2nd line here. (At this time, the 2nd line is indicated "li... 4 Check that any line does not indicate "light-on- dark " after completion of entering all ID codes by repeating steps 2) and 3)... 5 Turn OFF the key switch. 6 Access the engine information setting screen again to check that the data have been rewritten correctly. Entering sheet of ID code of injector Anti-theft DEVICE Changing the access code for the anti-theft system A. Hood A. Violet wire marked 469 female plug B. Black wire marked 621 male plug C. Radio connector Access and contents of monitor displays Access to monitor displays Machine condition 1. Machine condition CHK1 2. Machine condition CHK2 Transistor output: �0� = OFF; �1� = ON T R1 0 0 0 0 TR 2 0 0 0 0 TR 3 0 0 0 0 TR 4 0 0 0 0 X: Not used 3. Machine condition CHK3 Pressure switch electronic control box switch inputs: �0� = OFF; �1� = ON SW 1 0 0 0 0 SW 2 0 0 0 0 SW 3 0 0 0 0 SW 4 0 0 0 0 SW 5 0 0 0 0 SW 6 0 0 0 0 S W7 0 0 0 0 X = Not used 4. Machine condition CHK4 AC 0 0 0 4 TR5, SP1, SP2 Default When switched kPa kgf kgf kPa psi kPa kPa - kPa 5. Machine condition CHK5 1. While the travel mode switch is ON on the �CHK2� screen, the output status when over-current has been detected in the past is displayed. 2. Data is cleared by resetting the trouble code on the trouble diagnosis screen. 3. The example in the figure above shows that a travel alarm, swing braking, and battery relay output were being carried out when over-current was detected. 6. Machine condition CHK6 1. Shorts are automatically detected if the key switch is switched ON while the one-touch idle switch is ON.(* The engine must not be running.) 2. If you switch to the �CHK2� screen and switch the travel mode switch ON for 10 seconds, the automatic detection results are displayed. 3. The example in the figure above shows that the 2-speed travel line is currently shorted. 4. This data is cleared when the key switch is switched OFF. * For CHK1 to 6, the units can be switched with the work lamp switch. Status held as is when key OFF Diagnostic code 2. Detection of engine failures DIAG1 to 6 1) Trouble diagnosis (DIAG1), Engine system current trouble status (trouble code) 2) Trouble diagnosis (DIAG2), Engine system past trouble status (trouble code) 3) Trouble diagnosis (DIAG3), Engine system past trouble status (time of trouble: controller hour meter value) 1. Switching the work mode switch ON for longer than 10 seconds clears the data on past trouble codes and their times of occurrence. 2. The time displayed with �DIAG3� is the time at which the first trouble code occurred after the data was cleared. (The times for the second and subsequent trouble codes are not recorded.) 3. When the data is cleared, the �DIAG2� and �DIAG3� data is stored into EEPROM. 0087 O O O ELEC PROBLEM 1 0088 O O O ELEC PROBLEM 1 0089 O O O ELEC PROBLEM 1 0090 O O O ELEC PROBLEM 2 0092 -- -- O ELEC PROBLEM 1 0107 O O O ELEC PROBLEM 2 0108 O O O ELEC PROBLEM 2 0112* O O O ELEC PROBLEM 2 0113* O O O ELEC PROBLEM 2 0117* O O O ELEC PROBLEM 2 0118* O O O ELEC PROBLEM 2 0182* O O O -- 2 0183* O O O -- 2 0192 O O O ELEC PROBLEM 2 0193 O O O ELEC PROBLEM 2 0201 O O O ELEC PROBLEM 1 0202 O O O ELEC PROBLEM 1 0203 O O O ELEC PROBLEM 1 0204 O O O ELEC PROBLEM 1 0205 -- O O ELEC PROBLEM 1 0206 -- O O ELEC PROBLEM 1 0219 O O O ELEC PROBLEM 2 0237 O O O ELEC PROBLEM 2 0238 O O O ELEC PROBLEM 2 0335 O O O ELEC PROBLEM 1 0340 O O O ELEC PROBLEM 1 0380 O O O ELEC PROBLEM 1 0487 O O O ELEC PROBLEM 1 0488 O O O ELEC PROBLEM 2 0522 O O O ELEC PROBLEM 1 0523 O O O ELEC PROBLEM 2 0601 O O O ELEC PROBLEM 2 0603 O O O ELEC PROBLEM 2 0606 O O O ELEC PROBLEM 2 0611 O O O ELEC PROBLEM 2 0612 O O O ELEC PROBLEM 2 1093 -- -- O ELEC PROBLEM 1 1095 O O O ELEC PROBLEM 1 1112* O O O -- 2 1113* O O O -- 2 1173 O O O -- 2 1261 O O O ELEC PROBLEM 1 1262 O O O ELEC PROBLEM 1 1291 -- -- O ELEC PROBLEM 2 1292 -- -- O ELEC PROBLEM 1 1345 O O O ELEC PROBLEM 1 1625 O O O ELEC PROBLEM 2 1630 O O O ELEC PROBLEM 2 1631 O O O -- 2 1632 O O O ELEC PROBLEM 2 1633 O O O ELEC PROBLEM 2 1634 O O O ELEC PROBLEM 2 1635 O O O ELEC PROBLEM 2 2104 O O O ELEC PROBLEM 2 2106 O O O ELEC PROBLEM 2 1 Item marked with �O� in the table means that it can be applied. 2 Restoration from troubles. There are 2 ways as illustrated below to restore it from troubles. In order to clear an error code ... 3 For temperature sensors marked with �*� in the table however, hold the key switch for 3 minutes after it has been turned ON, then turned it OFF. 4) Trouble diagnosis (DIAG5), Machine main unit system Current trouble status (trouble code) 5) Trouble diagnosis (DIAG5), Machine main unit system Past trouble status (trouble code) 6) Trouble diagnosis (DIAG6), Machine main unit system Past trouble status (time of trouble: controller hour meter value) 1. Switching the work mode switch ON for longer than 10 seconds clears the data on past trouble codes and their times of occurrence. 2. The time displayed with �DIAG6� is the time at which the first trouble code occurred after the datawas cleared. (The times for the second and subsequent trouble codes are not recorded.) 3. When the data is cleared, the �DIAG5� and �DIAG6� data is stored into EEPROM. TABLE OF CONTENTS Operating Switches A. To be switched after the travel & work mode switch has been turned ON for more than 3 seconds. B. To be switched when the auto mode switch is turned ON. C. To be switched when the buzzer stop switch is turned ON. D. Data is to be cleared after the work mode switch has been turned ON for more than 10 seconds (buzzer sounds when the data have been cleared). E. Output with the protection circuit actuated is to be checked when the travel mode switch is turned ON. F. Automatic detection of short circuit is to be indicated after the travel mode switch has been turned ON for more than 10 seconds. G. To be switched after the one-touch idle switch has been turned ON for more than 10 seconds at anytime while the service support screen is being displayed. H. To be switched after the auto mode switch has been turned ON for more than 10 seconds. 50 Electricite_330 GB.pdf Engine Control Fuel Injection Control (Common rail type) Engine controller (ECM) gets information (signal from mounted sensors) such as engine speed and engine load. Based on the information, ECM sends electric signals to supply pump and to injector to make a proper control of fuel injection quantity and injection timing for each cylinder. 1) Injection quantity control 2) Injection pressure control 3) Injection timing control 4) Injection rate control Controller for the engine meeting Tier 3 emission control regulation (hardware is common to the vehicle). Quantity of pin is 121 as against 104 for the engine meeting Tier 2 emission control regulation. In area indicated by an arrow, ISUZU part number and TRANSTRON part number, and serial number are recorded. electric circuits operation explanation System Chart of Function ITEM FUNCTION METHOD 1 Engine control Electronic control (common-rail) 2 Work mode selection a) H Machine setting can be selected according to conditions such as of workload or fuel efficiency preference, and lifting operation. Maximum engine speed, pump current, and pressurizing solenoid valve are controlled according to the selected work mode. b) Auto-mode Suitable work mode is automatically selected. Selection of auto-mode allows the load to be calculated with pressure of negative control P1 and P2 which in turn work mode is switched. c) Load prefectch control Pump current is kept at 0 mA while machine is not being operated. Pump current and engine controller are controlled by signal from pressure switch. 3 Throttle control Engine can be controlled continuously from idling to high idling speed by operator's instruction. Engine speed is adjusted by control of throttle valve. 4 Idling control Engine speed can be switched to Pushing knob of switch on the right allows the engine to run idle and pushing it again to return it as it was. It makes engine to run idle while machine is not being operated. Selection of auto-idle allows the engine to run at idling speed automatically in 5 minutes after he lever is shifted to its neutral. Shifting lever makes the engine to return to its normal speed automatically. 5 Breaker mode Pressing the breaker pedal allows the engine to run at the set speed automatically and boosting pressure will be cut. Turning ON the pressure switch in breaker pilot line allows the engine to run at previously set speed. Also, pump current will be set as that in S-mode and boosting pressure is to be cut. 6 Auto preheat It helps the engine to start easily at a low temperature. Also, it stabilizes engine speed immediately after start of the engine to reduce exhausting smoke. Depending on cooling water temperature at the time when the key switch is turned ON, the glow plug is energized for a period of ... 7 Auto warm-up When coolant temperature is low, it allows the engine to start warming up automatically after it has been started. In case where no operation of the machine after the engine has been started is carried out when coolant temperature is low, it automatically increases engine speed gradually to warm it up. 8 Overheat protection When engine coolant temperature has been increased, reduce injection quantity to protect engine. When coolant temperature goes over 108C, reduce fuel injection quantity. Coolant temperature sensor to ECM. RelaYS and main fuses (battery compartment) 700.1.04.07.20a2 Fuse box cm00e005 Outils speciaux Specifications General location of the components (inside the cab) Switches and LCD: Left console (Switches) Work mode selection 1) Circuit configuration 700-1-04-01-23ap 2) Timing diagram 700-1-04-01-23 AQ 1. If the machine was in H 1) Alteration The current value of �I min� in mode H is set up between mode S and mode L. The engine speed sensing control is carried out even in mode S and �I maxi� is set to the current value equivalent in mode S and �I min� to the same as �I min� of mode H. The engine speed sensing control is carried out even in auto mode and control it within the range from �I maxi� to the current value �I min� to the same as �I min� of mode H for both Sa and La. 2) Purpose It lowers pump output automatically to cope with drop of engine power due to use of poor quality fuel and operation in highland. It applies optimum load with fuel cost and cycle time in mind when operated in automatic mode. 3) Circuit configuration 700-1-04-01-23ap 700.1.04.01.23aT2 Set value in each mode Mode Unit Set value H min-1 1950 min-1 2050 mA 470 mA 250 mA < 50 S min-1 1850 mA 410 mA 250 mA < 50 L min-1 1750 mA < 50 mA < 50 Mode Sa min-1 1850 mA 470 mA 250 Mode La min-1 1750 mA 470 mA 250 mA < 50 min-1 900 min-1 1200 min-1 1500 B) Load pre-fetch control 1) Purpose Pump current is controlled as measures against black smoke. 2) Circuit configuration 700.1.04.01.23au 3) Operation Throttle Control The analog voltage signal from throttle potentiometer is provided to the controller in the machine to transfer it to the engine controller (ECU) via CAN communication circuit together with work mode. Engine speed can be set by no dependence of the engine controllers on ISUZU side. 2) Circuit configuration 700.1.04.01.23aV 3) Operation 4. When CAN communication linking between the controller and the engine controller (ECM) is stopped, the engine speed is fixed t... 4) Throttle Control Relation Electric Circuit Diagram Idling Control (Auto 1) Circuit configuration 700.1.04.01.1.23ax 4) Timing diagram 1) Timing diagram for auto idle ON 700-1-04-01-23 AY2 2) Timing diagram when auto idle is ON 700-1-04-01-23 AZ2 700-1-04-01-23 BA2 Breaker mode 3) Circuit configuration 700.1.04.01.23bb 4) Operation Auto Prehead (Glow Control) 2) Circuit configuration 700.1.04.01.23bc 3) Operation 4) Water temperature control map 1) Glow lamp time (it transmits by CAN communication) 700-1-04-01-23 BD2 2) Pre-glow time 700-1-04-01-23 BE2 700-1-04-01-23 BF2 5) Timing chart 1) When in normal operation KEY SWITCH 700-1-04-01-23 BG2 2) When the engine has been started after pre-glow is completed KEY SWITCH 700-1-04-01-23 BH 3) When the engine has been started before glow lamp goes off KEY SWITCH 700-1-04-01-23 BI2 Auto Warm up 1) Circuit configuration 700.1.04.01.23bb 2) Operation 3) Auto warm-up control AUTO WARM-UP COMPLETE 700-1-04-01-23-BK2 Overheat Protection 2) Water temperature-fuel injection quantity 330.1.04.01.24bl2 Atmospheric Pressure Compensation 2) Map 330.1.04.01.24bm2 Control When Starting Engine 2. Time chart 700.1.04.01.23bn2 3) Starting control when number of effective cylinders is reduced 3. Number of cylinders-Correction factor Control When Stopping Engine 1. Operation Emergency Stop of the Engine 1. Alteration 2. Circuit configuration 700.1.04.01.23bo 3. Operation Function locking 1) Circuit configuration 700.1.04.01.23bp 2) Timing diagram 700-1-04-01-23 BQ2 3) Operation Power boost 1) Circuit configuration 700.1.04.01.23br 2) Increasing the pressure in each work mode Mode Auto Automatic power boost (*) (34.3 � 37.3 MPa) (4974 � 5410 psi) H mode (Pressure) Automatic power boost (*) (34.3 � 37.3 MPa) (4974 � 5410 psi) S mode (Pressure) Automatic power boost (*) (34.3 � 37.3 MPa) (4974 � 5410 psi) L mode (Pressure) Constant power boost (*) (34.3 � 37.3 MPa) (4974 � 5410 psi) * When the travel pilot pressure switch (B27) or the optional breaker pilot pressure switch (B25) is activated, power boost is deactivated. Swing brake 1) Circuit configuration 700.1.04.01.23bs 2) Operation of the swing brake control 700-1-04-01-23 BT2 3) Swing brake auto control Travel mode 1) Circuit configuration 700.1.04.01.23bu 2) Timing diagram 700-1-04-01-23 BV Power shut-off delay 1) Alteration 2) Circuit configuration 700.1.04.01.23by 3) Timing diagram 700-1-04-01-23bz Fuel Supply Pump Control (Automatic stop) Option 1) Control outline 2) Circuit configuration 700-1-04-01-23CK3 3) Operation Power Transistor Protection 700-1-04-01-23 CL Monitor Display cd00e007a2 Normal Display 1.Radiator coolant temperature 1) Circuit configuration 700-1-04-01-23CN2 2) Operation 2. Hydraulic oil temperature 1) Circuit configuration 700-1-04-01-23CO 2) Operation 3. Fuel level 1) Circuit configuration 700-1-04-01-23 CP2 2) Operation Message Display 700-1-04-01-23 CQ Troubleshooting Prior inspections --- --- --- --- --- --- --- - Add fuel Clean, drain Fill with fluid Drain, clean Fill with oil Fill with oil Fill with coolant --- --- --- Tighten or replace Tighten or replace Tighten or replace --- --- --- Repair Repair Bleed the air 23-26 V --- --- --- --- --- 27.5-29.5 V --- Replace Add or replace Replace Repair Disconnect and dry if damp Replace Replace Replace Reading the organisation charts Error code and description of problem The error code and the description of the problem are shown in the organisation charts. 1 2 B Black R Red W White Y Yellow Br Brown Lg Light green P Pink Sb Sky blue V Violet L Blue G Green Gr Grey O Orange Procedures 1. This is how one has to proceed to detect defects when the message is still displayed after all necessary measures have been taken to correct the error. Fuel 1 Low coolant 2 Low oil press. 3 Overheating 4 Alternator 5 Elect. problem 6 Fuel Description of problem No. 1 - The message is still displayed even after refilling the fuel tank. 700.1.04.06.11e Resistance between GL and BG Add coolant solution Description of problem No. 2 - The message is still displayed even after adding coolant solution. 700.1.04.06.11f2 Low engine oil pressure Description of problem No. 3 - The message is still displayed even when the engine oil level is satisfactory. 700.1.04.06.11g Overheating Description of problem No. 4 - The message is still displayed even when the actual temperature is lower than the following: Hydraulic oil temperature 98C (208F), engine coolant temperature 105C (221F). Prior check: 1. Make sure that 8 bars are displayed on the hydraulic oil and engine coolant temperature gauge bar-graphs. 700.1.04.06.11h 1. The 8 bars on the coolant temperature bar-graph are displayed. Overheating (continued) Coolant and hydraulic oil temperature sensor resistance NOTE: The resistance varies with temperature. 20C (68F) 2.50 kW 2.45 kW 30C (86F) 1.73 kW 1.66 kW 40C (104F) 1.20 kW 1.45 kW 50C (122F) 0.84 kW 0.81 kW 60C (140F) 0.61 kW 0.51 kW 70C (158F) 0.45 kW 0.43 kW 80C (176F) 0.31 kW 0.32 kW Defective battery charge circuit Description of problem No. 5 - The message is still displayed. 700.1.04.06.11j2 Electrical system troubleshooting Description of problem No. 6 - The message is still displayed 330.1.04.06.12k Electrical inspection of components Main pump proportional solenoid 6 solenoid valve bank Hydraulic oil temperature sensor Pressure sensor ITEM FUNCTION METHOD 9 Correction of atmospheric pressure It prevents black smoke and engine damage when intake air quantity is decreased such as operating in highland. Fuel is to be restricted by an atmospheric sensor when altitude is over 2000 meters. 1 0 Control on engine start It increases fuel injection according to coolant temperature to improve starting performance.It improves starting performance when sufficient fuel fails to be injected due to wear in the machine as it has been operated for a long time. It monitors coolant temperature when it is under 0C. It watches a lapse of time after cranking has been started. 1 1 Engine stop control Engine controller (ECM) recognizes engine key OFF by turning key switch OFF It stops fuel injection from injector.It insructs pressure control valve to opened fully. It makes EGR valve to be fully open. 1 2 Emergency engine stop Emergency stop switch is set up with no engine stop by key switch in mind. Signal of emergency stop switch is transferred to engine controller (ECM) to perform engine stop control. 1 3 Lever lock It allows the machine not to be operated by control of levers while cab is being moved Up When the lever is raised by control of the gate lever on the left console, the lever lock solenoid turns OFF which in turn pilot pressure is cut off. 1 4 Auto boost control Boost control It increases main relief pressure by approx. 10%. Whether boost of pressure is needed or not is judged by the input data on load factor of the engine and on pump discharge pressure. (Boosting for 8 seconds.) Boost -cut control It does not allow boosting according to a certain condition to protect machine and equipment. Boosting will not function when travelling and reserve pressure switches are turned OFF. 1 5 Swing lock It disables swing even when the swing lever is mistakenly controlled. Turning ON the swing lock switch allows the swing brake solenoid to be energized to actuate mechanical brake. 1 6 Swing brake control When swing lock is OFF, in order to protect swing device, it controls swing mechanical brake ON It controls swing brake solenoid valve by the data obtained from switches of swing, attachments, and travel pressure, and also from pump discharge pressure. 1 7 Travel speed switching-over It allows travel speed to switch to either one of 2 levels. It controls solenoid valve by the travel mode switch to switch over tilt angle of swash plate in the traction motor. 1 8 Travel alarm Alarm buzzer functions when travelling. Travel pressure switch controls the buzzer. 1 9 Power shut-off delay This ensures power supply for engine stop function. It allows a time-lag until main relay shuts off after key switch has been turned OFF. 2 0 (Option) Fuel supply pump control It makes an automatic stop when fuel tank becomes full on refueling. Enter signal of fuel sensor to turn OFF switch. Power transistor protection It protects controller in case where a circuit connected to transistor output is short-circuited. Over-current detection shuts off transistor output. Travel speed switching-over a) Normal display It displays current status of the machine. Temperature of hydraulic oil and of coolant temperature, and fuel level are displayed in bar graphs on LCD monitor and work b) Message display Warning. Functioning operation. When to service the machine Each information is to be displayed by letters on LCD monitor. 60 Fonction Hyd 330 GB.pdf Hydraulic functions List of functions Legend High Speed Travel Circuit With High Speed Travel, high speeds can be achieved by setting the two-level inclinatory angle of the travel motor to the smalle... Discharged oil from the hydraulic pump A1 enters the Port P1 of control valve while discharged oil from the hydraulic pump A2 en... By operating the travel mode switch, electric signals are sent to the controller, and from the controller, electric signals are ... Pa1 Pb1 Pa6 Pb6 10. Main hydraulic pump 15. Main control valve 21. Travel motors 25 52. 6 solenoid valve bank 108. Straight travel valve A1. Computer S2. Travel mode switch Y2. Pilot pressure solenoid valve (blue band) Y4. 2 stage travel solenoid valve (red band) 61 Fonction Hyd GB 330.pdf Low Speed Travel Circuit The two-level inclinatory angle in the travel motor is set to the larger angle side. When the travel status is set to high speed and the key switch is turned off and turned on again, the speed setting will always return to Low Speed. Discharged oil from the hydraulic pump A1 enters the Port P1 of control valve while discharged oil from the hydraulic pump A2 en... The solenoid valve for high speed travel is turned off and the oil in Port P of the travel motor enters the tank line and establishes a connection. As a result, the inclinatory angle of the travel motor is set to the larger angle side. Pa1 Pb1 Pa6 Pb6 10. Main hydraulic pump 15. Main control valve 21. Travel motors 25 52. 6 Solenoid valve bank 108. Straight travel valve A1. Computer S2. Travel mode switch Y2. Pilot pressure solenoid valve (blue band) Y4. 2 stage travel solenoid valve (red band) Straight Travel Circuit As an example, we describe the operation where travel and boom up are operated at the same time. The pilot oil pressure enters from Port PP of the control valve and communicates with the tank side via passages of travel spool... As the result of the switch over of the straight travel valve, the pressurized oil in the control valve P1 drives the right and ... Pa8 Pb8 Pa1 Pb1 Pa6 Pb6 Pb4. Boom 2 spool 10. Main hydraulic pump 15. Main control valve 21. Travel motors 25 52. 6 Solenoid valve bank 108. Straight travel valve A1. Computer S2. Travel mode switch Y2. Pilot pressure solenoid valve (blue band) Y4. 2 stage travel solenoid valve (red band) Swing Parking Circuit (Lever in Neutral When the engine is started and the swing lever is in neutral, the swing brake solenoid valve becomes turned on (24 V input) and the swing parking brake is activated. When the swing lock switch is on, even if the swing pressure switch or attachment pressure switch is turned on, the swing lock s... Pa3 Pb3 10. Main hydraulic pump 15. Main control valve 22. Swing motor 27. Dipper cylinder 52. 6 Solenoid valve bank 54. Swing dipper control lever 81. Swing shuttle block A1. Computer B22. Swing pilot pressure switch B26. Upper pilot pressure switch B42. Pump pressure sensor P1 B44. Pump pressure sensor P2 S2. Travel mode switch Y2. Pilot pressure solenoid valve (blue band) Y3. Swing brake solenoid valve (pink band) Swing Parking Circuit (Brake Released) When the swing pressure switch is turned on by operating the lever, output to the swing brake solenoid valve from the controller... When the pressure switch for attachments is kept off for more than 5 seconds, the swing pressure switch will be turned off. Then... Pa3 Pb3 10. Main hydraulic pump 15. Main control valve 22. Swing motor 27. Dipper cylinder 52. 6 Solenoid valve bank 54. Swing dipper control lever 81. Swing shuttle block A1. Computer B22. Swing pilot pressure switch B26. Upper pilot pressure switch B42. Pump pressure sensor P1 B44. Pump pressure sensor P2 S2. Travel mode switch Y2. Pilot pressure solenoid valve (blue band) Y3. Swing brake solenoid valve (pink band) Swing Push Digging The swing pilot pressure is supplied port Pc3 via shuttle valve and enable the swing priority variable restriction to be held to... Pa3 Pb3 10. Main hydraulic pump 15. Main control valve 22. Swing motor 27. Dipper cylinder 52. 6 Solenoid valve bank 54. Swing dipper control lever 81. Swing shuttle block A1. Computer B22. Swing pilot pressure switch B26. Upper pilot pressure switch B42. Pump pressure sensor P1 B44. Pump pressure sensor P2 S2. travel mode switch Y2. Pilot pressure solenoid valve (blue band) Y3. Swing brake solenoid valve (pink band) Arm-Out Circuit Oil discharged from hydraulic pump A1 is supplied to the arm (1) spool through the center bypass oil passage in the control valv... Pa5 Pb5 Pa9 15. Main control valve 25 27. Arm (Dipper) cylinder 54. Arm (Dipper) control lever 56. Dipper control shock absorber 57. Boom and arm (dipper) control shock absorber Arm-In Load Holding When the arm is in neutral, oil on the arm cylinder rod side is sealed by the load holding valve check. This mechanism reduces internal leakage from the main spool. When the arm-in is operated, the pilot pressure enters Port 5pb5 of the control valve and moves arm (1) spool to the arm-in side... Pa5 Pb5 Pa9 10. Main hydraulic pump 15. Main control valve 25 27. Arm (Dipper) cylinder 31. Dipper load holding valve 54. Arm (Dipper) control lever 56. Dipper control shock absorber 57. Boom and arm (dipper) control shock absorber Arm-In Circuit For arm-in operation, pilot pressure is supplied to Port 5pb5 and Pb9 of the control valve and the arm spool moves to the arm-in side. At the same time, the arm load holding valve is released by the pilot pressure, and the discharged oil on the cylinder rod side ... Pa5 Pb5 Pa9 10. Main hydraulic pump 15. Main control valve 25 27. Arm (Dipper) cylinder 54. Arm (Dipper) control lever 56. Dipper control shock absorber 57. Boom and arm (dipper) control shock absorber 110. Arm regeneration valve Boom-Up Circuit (Single) Oil discharged from hydraulic pump A1 is supplied to the boom (2) spool from the parallel oil passage via the control valve and ... P1. Outlet flow A1 P2. Outlet flow A2 Pa8 Pb8B8. Lowering the boom 10. Main hydraulic pump 15. Main control valve 25 27. Arm (Dipper) cylinder 54. Arm (Dipper) control lever 56. Dipper control shock absorber Boom-Up Circuit (Combined) When floor digging operation is performed, the boom-up pilot pressure, which is supplied to port Pbu, releases the restriction on flow to the arm by moving the swing priority variable restriction to the left. This makes the arm move smoothly. P1. Outlet flow A1 P2. Outlet flow A2 Pc2. Lowering load holding Pa8 10. Main hydraulic pump 15. Main control valve 25 27. Arm (Dipper) cylinder 54. Arm (Dipper) control lever 56. Dipper control shock absorber 57. Boom and arm (dipper) control shock absorber Boom-Down Load Holding When the boom is in neutral, oil on the boom cylinder bottom side is sealed by the load holding valve check. This mechanism redu... Pb8 Pa8 Pc2. Boom load holding 1. Load holding valve spool 10. Main hydraulic pump 15. Main control valve 25 27. Arm (Dipper) cylinder 32. Boom load holding valve 54. Arm (Dipper) control lever 56. Dipper control shock absorber 57. Boom and arm (dipper) control shock absorber Boom-Down Circuit For boom-down operation, pilot pressure is supplied at Port 4pb3 and 5pa4 of the control valve, and the boom spool moves to the ... Although the boom (2) spool is changed over, oil will not be supplied to the cylinder as it is center-bypassed. Pb8 Pa8 Pc2. Boom load holding 2. Non-return check valve 3. Jet 4. Jet 10. Main hydraulic pump 15. Main control valve 25 27. Arm (Dipper) cylinder 28. Bucket cylinder 32. Boom load holding valve 53. Boom control lever 57. Boom and arm (dipper) control shock absorber Combined Circuit (Breaker Circuit) Through remote control operation, the pilot pressure that is supplied to Port Pa2 of the control valve switches the backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the breaker. The pilot pressure operates the pressure switch at the same time. Through signals, the control gives an instruction to engine co... Pa2 Pb2 10. Main hydraulic pump 15. Main control valve 72. Control pedal 75. Flow re injection block 76. 3-way selector 78. Return filter 79. Control shuttle block 83. Shut-off valve 84. T-shuttle block 85. Hand A1. Computer B25 B23. Breaker pilot pressure switch Y9. Breaker Combined Circuit (High Speed Confluence Circuit) Through remote control operation, the pilot pressure that is supplied to Port Pa2 (or Pb2) of the control valve switches the backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the end attachment. The pilot pressure operates the pressure switch at the same time, and its signals switch over the solenoid valve. Through the sw... The pilot pressure from the solenoid valve acts on port P of the holding valve at the same time and moves the release spool as r... Pa2 Pb2 10. Main hydraulic pump 15. Main control valve 72. Control pedal 75. Flow re injection block 76. 3-way selector 78. Return filter 79. Control shuttle block 83. Shut-off valve 84. T-shuttle block 85. Hand A1. Computer B25 B23. Breaker pilot pressure switch Y9. Breaker 70 Settings CX330 GB.pdf SPECIFICATIONS Travel lower body Reference Values special tools Tester 1. Test kit E5444449 for Multi-handy 2051 2. Female coupling joint E47894 (1) 3. 600 litre flowmeter, order the following: 4. Set of unions for pressure test and hydraulic flow CAS 30038. 5. Set of high pressure hydraulic hoses CAS xxxxx (including two high pressure hoses). Identification of hydraulic components Pump 330-1-03-00-24a_1 Control valve cs01m603 cs01m602 6 solenoid valve bank cd05L001 Preparation before inspection Releasing pressure in the hydraulic system 1. Position the machine on hard, flat ground. 2. Open the bucket until the cylinder rod is completely retracted. 3. Extend the dipper until the cylinder rod is completely retracted. Lower the boom so that the end of the dipper is resting on the ground. Lower the tool to the ground. 4. Check with the diagnostic display in "S" mode that the following values are shown. 5. Lower the engine speed to idle for 30 seconds, then shut down the engine. 6. Turn the starter key switch to "ON", without starting the engine. 7. Lower the pilot control cancellation lever. 8. Operate each control more than 10 times in both directions to release pressure in the circuits. 9. Press the button located on the hydraulic reservoir breather to release pressure in the reservoir. Installing the pilot pressure test point Installing the flowmeter 1. Disassemble hose (1) from port (A2) of the pump being checked. 2. Install the elbow union (2) (CAS xxxxx) on the hose (1). 3. Connect the elbow union (3) (CAS xxxxx) to port (A2) of the pump. 4. Install the hose (4) (CAS xxxxx) on the elbow union (3). 5. Install the flowmeter (6) on the hoses (4). 6. Install the hose (5) (CAS xxxxx) on the flowmeter (6) and on the elbow union (2). 7. Connect the multi-handy 2051 connecting cable to the plug on the flowmeter (6) detector (7). 8. Proceed in the same manner to check the other stage of the pump (A1). Flow curve CX330 Tier 3, Curve valid for a new pump I: Current valve for electromagnetic proportional pressure reducing valve. Pd: Delivery pressure. Pf: Power shift control pressure (at reference value). Pi: Pilot pressure. Tin: Input torque. Pressure in this curve shows total pressure P1 + P2 or Pf + Pr (Consumption torque for point gear pump is not included in Torque line graph) Display on the "CHK1" monitor display Warming up the engine 1. Start the engine. The engine will have warmed up in 10-15 minutes. 2. Run the engine until the message "AUTO WARM UP" disappears from the display monitor. Warming up the hydraulic fluid 1. Display the "CHK1" monitor display. 2. Actuate the bucket and dipper controls in one direction (against the cylinder stops) for 30 seconds. 3. Actuate the bucket and dipper control in the other direction (against the cylinder stops) for 30 seconds. 4. Repeat Steps 1 and 2 until hydraulic temperature reaches 45-55C on display "CHK1". 5. Actuate the boom, swing and travel controls in both directions to warm up all the circuits to 45- 55C. Checking and setting procedure Location of secondary relief valves Main pilot system relief (H) 1. Connect a 0-100 bar pressure gauge to pressure test point M3. 2. With the engine at full speed, select mode "S". 3. Move the pilot cancellation lever to its low position. 4. With the attachment, swing and travel controls in neutral, read the value on the pressure gauge: The value should be 39�1 bar (3.9�0.1 MPa). 1. Loosen the lock nut and turn the valve adjusting screw (H) until 39�1 bar (3.9�0.1 MPa) is reached. 2. Tighten the lock nut while holding the adjusting screw in position. 3. When the adjusting screw has been tightened, check the pressure again and make sure there are no leaks. Checking the pilot accumulator 1. Raise the boom completely and extend the dipper. 2. Shut down the engine, with the starter key switch on "ON". 3. Operate the boom lowering or dipper retracting control several times consecutively. 4. The pressure in the accumulator should enable the boom lowering or dipper retracting function to be performed about six times. Main relief (A) 1. Display the "CHK1" monitor display. 2. With the engine at full speed, select mode "S". 3. Operate and hold in position the dipper retracting control (against cylinder stops). 4. Read the pressure on the monitor display: 1. Disconnect and plug the power boost pilot hose on the main relief. 2. Using a wrench, hold the adjusting screw (3) in position and loosen the lock nut (4). 3. Tight the adjusting screw (3) up to the stop. 4. Tighten the lock nut (4). 5. Start the engine and run it at maximum speed, select mode "S". 6. Operate and hold in position the dipper retracting control (against cylinder stops). 7. Loosen the lock nut (2) and turn the adjusting screw (1) until the power boost pressure is reached. 8. Using a wrench, hold the adjusting screw (1) and tighten the lock nut (2). 9. Check the pressure again. If the desired value is not obtained, repeat steps 6 to 9. 10. Cary out the standard pressure setting. 1. Disconnect and plug the power boost pilot hose on the main relief. 2. Using a wrench, hold the adjusting screw (3) in position and loosen the lock nut (4). 3. Start the engine and run it at maximum speed, select mode "S". 4. Operate and hold in position the dipper retracting control (against cylinder stops). 5. Turn the adjusting screw (3) until the standard pressure is reached. 6. Using a wrench, hold the adjusting screw (3) in position and tighten the lock nut (4). 7. Check the pressure again. If the desired value is not obtained, repeat steps 2 to 6. 8. Stop the engine. 9. Reconnect the power boost pilot hose to the main relief. Attachment control valve secondary reliefs (B, C, D, E, F and G) 1. Disconnect and plug the power boost pilot hose on the main relief. 2. Using a wrench, hold the adjusting screw (1) in position and loosen the lock nut (2). 3. Tighten the adjusting screw (1) 180. 4. Using a wrench, hold the adjusting screw (1) in position and tighten the lock nut (2). 5. Start the engine and run it at maximum speed, select mode "S". 6. Display the "CHK1" monitor display. 7. Operate and hold in position the corresponding attachment control (against the cylinder stops). 8. Read the pressure on the monitor display, the pressure should be: 9. Carry out Steps 10 to 14 only if one of the attachment secondary reliefs has to have its pressure set. Otherwise go on to step 15. 10. Using a wrench, hold the adjusting screw (4) of the secondary relief concerned in position and loosen the lock nut (3). 11. Operate and hold in position the corresponding attachment control (against the cylinder stops). 12. Turn the adjusting screw (4) of the secondary relief concerned until the correct pressure is obtained. 13. Using a wrench, hold the adjusting screw (4) in position and tighten the lock nut (3). 14. Check the pressure again. If the desired value is not obtained, repeat steps 10 to 14. 15. Using a wrench, hold the adjusting screw (1) of the main relief concerned in position and loosen the lock nut (2). 16. Operate and hold in position the dipper retracting control (against cylinder stops). 17. Turn the adjusting screw (1) until the correct standard pressure of the main relief concerned is obtained. 18. Using a wrench, hold the adjusting screw (1) in position and tighten the lock nut (2). 19. Check that the standard pressure of the main relief is correct, otherwise carry out steps 15 to 19 again. 20. Stop the engine. 21. Reconnect the power boost pilot hose to the main relief. Boom safety valve secondary reliefs (B1 and B2) Dipper safety valve (D1) 1. Disconnect and plug the power boost pilot hose on the main relief. 2. Using a wrench, hold the adjusting screw (1) in position and loosen the lock nut (2). 3. Tighten the adjusting screw (1) 180. 4. Using a wrench, hold the adjusting screw (1) in position and tighten the lock nut (2). 5. Start the engine and run it at maximum speed, select mode "S". 6. Display the "CHK1" monitor display. 7. Operate and hold the dipper extend control. 8. Note the pressure on the check screen. The pressure should be at 392�5 bar (39.2�0.5 MPa). 9. If the value is not correct, loosen the lock nut (1) and turn the pressure setting screw (2) to adjust the pressure. Tighten ... Swing port secondary relief (I, J) 1. Disconnect the connector (green) from the swing cancellation solenoid valve. 2. Display the "CHK1" monitor display. 3. Start the engine and select mode "S". 4. Switch on the swing brake control on the instrument panel (indicator lamp ON). 5. Slowly operate the swing control lever to the right and gradually increase the engine speed to full speed to make sure that the swing is locked. 6. Repeat step 5, for the LH swing, the pressures must be: 1. Carry out steps 1 to 5 in "Checking". 2. Using a wrench, hold the adjusting screw (2) and tighten the lock nut (1). 3. Slowly operate the swing control lever to the right and gradually increase the engine speed to full speed to make sure that the swing is locked. 4. Turn the adjusting screw (2) until the correct pressure is reached. 5. Using a wrench, hold the adjusting screw (2) and tighten the lock nut (1). 6. Check the pressure again. If the desired value is not obtained, repeat steps 2 to 6. Checking the swing brake release pressure 1. Disconnect the swing brake supply hose at the hydraulic motor end and connect a pressure test point 0-100 bar pressure gauge to the hose. 2. With the engine at full speed, select mode "S". 3. With the swing control in the neutral position, switch on the swing brake control on the instrument panel (indicator lamp ON), the pressure should be between 0 and 3 bar. 4. With the swing control in the neutral position, switch off the swing brake control on the instrument panel (indicator lamp OFF), the brake release pressure should be about 39 bar. Travel secondary relief (K, L) 1. Overset the secondary relief. Attachment main relief chapter). 2. Start the engine. 3. Carefully lock the travel on the side to be checked by positioning the locking pin (A) between the sprocket and the undercarriage as shown above. 4. With the engine at full speed, select mode "S". 5. Display the "CHK1" monitor display. 6. Operate and maintain the corresponding travel control (locking the sprocket). 7. Read the pressure on the monitor display, the pressure should be: Pressure setting 380�5 bar (38�0.5 MPa). 8. Go on to step 9 if one of the secondary reliefs has to have its pressure set. Otherwise, reset the pressure on the main relief. 9. Remove the swing motor secondary relief concerned. If the two secondary reliefs have to be removed, mark them to ensure they are replaced in their original position. 10. Tighten the body of the secondary relief (1) in a vice and remove the plug (2), the guide (3), the shims (4), the spring (5) and the check valve (6). 11. Remove (to reduce pressure) or add (to increase pressure) the number of shims (4) needed to obtain the correct pressure. 12. Install parts (1 to 6) in the secondary relief and tighten the plug to 156 Nm. 13. Install the secondary relief on the travel motor and tighten it to 78.5 Nm. 14. Check the pressure again. If the desired value is not obtained, repeat steps 9 to 14. 15. Rest the pressure of the main relief. Checking the pressure delivered by the proportional valve (Y7) 1. Connect a pressure test point and a 0-100 bar pressure gauge to pump port a4. 2. Display the "CHK1" monitor display. 3. With the engine at full speed, select mode "H" and then mode "S". Checking travel drift 1. Check the pilot pressure values on both travel spools (must be higher than 30 bar). 2. Check the hydraulic leak values on the travel motors. Checking for leaks on the travel motor 1. Press the breather to release pressure in the hydraulic reservoir. 2. Remove the travel motor protective shield. 3. Disconnect the hydraulic motor drain hose and plug it. 4. Use a hose to connect the drain port to the receptacle. 5. Lock the travel mechanically on the side to be checked by positioning the locking pin (A) between the sprocket and the undercarriage as shown above. 6. With the engine at full speed, select mode "S". 7. Operate the travel control of the hydraulic motor to be checked and measure the quantity of oil which leaves the drain for 1 min. 8. Repeat steps 1 to 7 to check the other motor. 9. Compare the quantities of oil collected; if the difference between the two motors is greater than 1 l Checking the swing motor for leaks 1. Disconnect the connector (green) from the swing cancellation solenoid valve. 2. Display the "CHK1" monitor display. 3. Start the engine and select mode "S". 4. Switch on the swing brake control on the instrument panel (indicator lamp ON). 5. Slowly operate the swing control lever and gradually increase the engine speed to full speed to ensure that the swing is locked. 6. Shut down the engine. 7. Press the breather to release pressure in the hydraulic reservoir. 8. Disconnect the hydraulic motor drain hose and plug it. 9. Use a hose to connect the drain port to the receptacle. 10. Start the engine and run it at full speed in mode "S". Operate the swing control to the right or the left and measure the quantity of oil which flows out of the drain during 1 min. 11. Since the quantity of oil can vary depending on the test point used, repeat the measurement (Step 10) with the upperstructure at 90, then at 180. Troubleshooting Travel drift Not possible to select 2nd travel speed No swing or slow swing (No problems with other functions) With the excavator on a slope, the swing brake does not hold No movement on any function (Control cancellation lever in the low position) Lack of power or speed on one of the attachment movements (No problems with other movements) Not possible to select cushion control The boom or the dipper does not lower (No problems with other movements) . Notice: This is a preview not fully updated, please download the full version at https://wimanual.com