HYDRAULIC EXCAVATOR SHOP SK200-8 MANUAL model SK210:c-8 INDEX SPECIFICATIONS SECTION MAINTENANCE SECTION SYSTEM SECTION Sac DISASSEMBLY SECTION TROUBLESHOOTING ENGINE SECTION PROCEDURE OF INSTALLING OPTIONS SECTION KOBELCO Book Code No. SSYN0018E01 0-1GENERAL SAFETY INFORMATION [Awarning] Do not operate or perform any maintenance on this machine until all instructions found in the OPERA- ‘TOR’S MANUAL and this MANUAL have been thor- ‘oughly read and understood. Improper operation or maintenance of this machine ‘may cause accidents and could result in serious in- jury or death. Always keep the manual in storage. Ifitis missing or damaged, place an order with an authorized our Distributor for a replacement. Ifyou have any questions, please consult an autho- rized our Distributor. (1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safe- ty rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the man- ual and on the machine should be read and under stood by all personnel before starting any work with or on the machine. (2) Operation, inspection, and maintenance should be ‘carefully carried out, and safety must be given the first priority. Messages of safety are indicated with ‘marks. The safety information contained in the ‘manual is intended only to supplement safety codes, insurance requirements, focal laws, rules and regulations. (3) Messages of safety appear in the manual and on the machine : All messages of safety are identified by either word of "DANGER", WARNING" and “CAUTION’. 1) DANGER: indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows: WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows: [A WARNING] 2) 0-2 3) CAUTION: indicates a potentially hazardous situation which, if not avoided, may result in mi- nor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as fol- lows: [Acaution) (4) Itis very difficult to forecast every danger that may ‘occur during operation. However, safety can be en- sured by fully understanding proper operating pro- Cedures for this machine according to methods recommended by Manufacturer. (5) While operating the machine, be sure to perform work with great care, so as not to damage the ma- chine, of allow accidents to occur. (6) Continue studying the manual until all Safety, Oper- ation and Maintenance procedures are completely understood by all persons working with the ma- chine.SAFETY PRECAUTIONS ‘The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR'S MANUAL for the machine. Improper performance of lubrication or mainte~ nance procedures are dangerous and could result in injury or death, Read and understand the MAN- UAL before performing any lubrication or mainte- nance. ‘The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important o use caution when performing service work. A knowledge of the system and or components is im- portant bofore the removal or disassembly of any com- ponent. Because of the size of some of the machine compo- rents, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting proce- dures when removing any components. Weight of com- ponents table is shown in the section ; ‘SPECIFICATIONS. ‘The following is a list of basic precautions that must al- ways be observed. (1) Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine (2) Always wear protective glasses and protective shoes when working around machines. In particu- lar, wear protective glasses when using hammers, punches or drifts on any part of the machine or at- tachments. Use welders gloves, hoodigoggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fit- ting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery, (8) Disconnect the battery and hang a "Do Not Oper- ate" tag in the Operators Compartment. Remove ig- nition keys, (4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine 50 itdoes not roll while working on of under the ma- chine, Hang a *Do Not Operate" tag in the Opera- tors Compartment. (8) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack 0-3 stands, capable of supporting the machine, before performing any disassembly, [AWARNING| Do not operate this machine unless you have read and understand the instructions in the OP- ERATOR’S MANUAL. Improper machine opera- tion is dangerous and could result in injury or death. (6) Relieve all pressure in air, oll or water systems be- fore any lines, fitings or related items are nected or removed. Always make sure all raised ‘components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. (7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the ma- chine. f this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correct- ly to prevent it from dropping unexpectedly, (8) Use steps and grab handles when mounting or dis- ‘mounting @ machine. Clean any mud or debris from steps, walkways or work platforms before using. ‘Always face to the machine when using steps, lad- ders and walkways. When it is not possible to use the designed access system, provide ladders, scaf- folds, or work platforms to perform safe repair oper- ations. To avoid back injury, use a hoist when lifting com- ponents which weigh 20kg (45ibs) or more. Make sure all chains, hooks, slings, etc., are in good con- dition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. (10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in fines, tubes and compartments. (11)Be careful when removing cover plates. Gradually back off the last two capsorews or nuts located at opposite ends of the cover or device and carefully ry cover loose to relieve any spring or other pres- sure, before removing the last two capscrews or nuts completely, (12)Be careful when removing filer caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liq- uuids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot, ie @)(13)Always use the proper tools that are in good condi-_(21)Do not operate a machine if any rotaling part is tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera~ you understand how to use them before performing tion. Any high speed rotating component that has any service work. been damaged or altered should be checked for (14)Reinsiall all fasteners with the same part number. balance before reusing. Donot use a lesser quality fastenerifreplacements _(22)Be careful when servicing or separating the tracks are necessary. (crawiers). Chips can fly when removing or install (18)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and formed only with the benefit of the appropriate ref- Jong sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away ‘from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged frorn the sprockets. Block the ma- erence information and by personne! adequately ‘rained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and eleotrodes, rods or wire to provide @ weld metal strength equivalent at chine to prevent it from moving. least to that of the parent metal. Make sure to dis- connect batlery before any welding procedures are attempted. (16)Do not damage wiring during removal operations. Reinstall the wiring so its not damaged nor will be ‘damaged In operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring toa line contain- ing fluid. (17)Be sure all protective devices including guards and shields are properly installed and functioning cor- rectly before starting a repair. if guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed. (18)The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a faling attachment. Don't fell to lower the attach ment and place the bucket to the ground before starting the work (19)Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Donot bend ‘strike high pressure tines or install ones which have been bent or damaged. Inspect lines, tubes ‘and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in ‘@ high velocity oll stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. (20)Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are stalled correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oll spray onto hot ex- haust components in event of a line, tube or seal failure must be installed correctly. 0-4‘Book Code No. INDEX $k200-8 SK2101C-8 Title Distribution Year-Month ‘SSYNO118E01 20068 OUTLINE ‘S5YNO218E01 NEE SPECIFICATIONS ‘SSYNO318E01 30068 /ATTACHMENT DIMENSIONS ‘SSYN1118E01 0088 TOOLS S5YN1218E01 STANDARD MAINTENANCE] 2006-8 TIME SCHEDULE ‘SSYN1318E01 MAINTENANCE STANDARD 2006-8 AND TEST PROCEDURE ‘S5YN2118E01 MECHATRO CONTROL 2006-08 SYSTEM ‘SSYN2218E01 cnees HYDRAULIC SYSTEM ‘SSYN2318E01 a tes Fag ELECTRIC SYSTEM SSYN2418E01 a fies Fag COMPONENTS SYSTEM ‘S5YN2518E01 |AIR-CONDITIONER SYSTEM ag ‘S5YN3118E01 ry DISASSEMBLING om 2006-8 Fe & ASSEMBLING [i ba SBvN219E01 Fy ‘ATTACHMENT a ‘S5YN3318E01 g UPPER STRUCTURE 2006-8 4 oe rat TRAVEL SYSTEM Ko soynastaeot BY ERROR CODES Seer: BY TROUBLE cd sevnasiaen4 Sm TROUBLE DIAGNOSIS MODE i sovnerigrnt ENGINE ca YN41-45001~ Yoroe00: a APPLICABLE MACHINES 0-5NOTE: This Manual is prepared as a technical material in which the information necessary for the maintenance and repairing services of our hydraulic excavators are collected, and is categorized into 7 Chapters, Specitica- tion, Maintenance, System, Disassembly, Trouble- shooting, Engine, and Installation Procedures for Optional Attachment. ‘The Chapter “Specification” describes the specifi- cations for entire machine and material, which are instructive for replacement and repairing of attach- ments. ‘The Chapter "Maintenance" describes the material, which is helpful for maintenange service and adjust- ments for entire machine. ‘The Chapter "System" describes the operating sys- tem like hydraulic system, electric system, compo- nents, and so on. ‘The Chapter "Disassembly" describes the removal and installing of assembly mounted on the upper structure and undercarriage, and the assembling and disassembling of the associated hydraulic equipment. ‘The Chapter “Troubleshooting” describes how to find the fault equipment. ‘The Chapter "Engine" describes the engines mak- ing use of the "Maintenance Manual” provided by the suppliers. ‘The Chapter “Installation Procedures for Optional Allachment” describes the supplements added on request as required 0-6 This Manual may be properly revised due to the im- provement of products, modification of specifications, elc, And there are cases where the system on actual machine and a part of the contents of this manual may differ due to the variations of specification by countries. For the section in which the description is hardly under- stood, contact our distributor. ‘The number is assigned to every part handled in this Manual on account of the description, but the parts, which cannot be supplied as service parts are con- tained. Therefore, the order must be placed with re- ‘spective formal number with due confirmation on the Parts Manual for applicable machine.1. OUTLINE ‘TABLE OF CONTENTS 1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS w..rnnsesennssennet 13 1.1.4 PREPARATION BEFORE DISASSEMBLING... Satta 4.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING. nnn AQ 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ...ccscsesuen 4.1.4 ELECTRICAL EQUIPMENT td 1.1.5 HYDRAULIC PARTS 7 7 7 7 wot 5 1.1.6 WELD REPAIR... soon . 15 1.1.7 ENVIRONMENTAL ISSUES aa 15 1.2 INTERNATIONAL UNIT SYSTEM 16 Book Code No. S5YN0118E01 144. OUTLINE [ Issue Date of issue Applicable Machines Remarks | | 'SK330~-8 : LC10-07001~ S8YNO118E01 | i K | ies eee stu 2006 | sxas0L¢-8 : Y010-03601~ (ASIA, OCE) ‘ ‘August 2008 8200-8: YNtT-46001~ + Kl [SK210LC-8 : YQ11-06001~4. OUTLINE 4.1. GENERAL PRECAUTIONS FOR 2) Attach "Don't operate" tag to control lever, and MAKING REPAIRS begin a meeting before starting the work 3) Before starting inspection and maintenance 1.1.1 PREPARATION BEFORE stop the engine. DISASSEMBLING 4) Confirm the position of first-aid kit and fire i extinguisher, and also where to make contact for emergency measure and ambulance to prepere for accidents and fire 5) Choose a hard, lever and safe place, and put attachment on the ground without fail 6) Use hoist, ets, to remove parts of heavy weight (23kg [50 lb] or more) 7) Use proper tools, and change or repair defective tools. (1) Knowledge of operating procedure Read Operator's Manual carefully to understand the operating procedure. (2) Cleaning machines Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled machine into the service shop, causes making less efficient work and damage of 8) Machine and attachment required to workin the parts lifting condition should be supported with (2) Inspecting machines supports or blocks securely. Confirm the disassembling section before starting 4.4.3. DISASSEMBLING AND ASSEMBLING work, determine the disassembly procedure taking HYDRAULIC EQUIPMENT the conditions in work shop into account, and request to procure necessary parts in advance, (4) Recording Record the following items to keep contact and (1) Removing hydraulic equipment assy Prevent malfunction from recurring, 1) Before removing pipes, release the pressure of 41) Inspecting date, place hydraulic oil tank, or open the cover on the 2) Model name, Serial number and Record on Tetum side to tank, and take out the filter. hour mater 2). Drain the oil in the removed pipes into pan to prevent the ol! rom spilling on the ground 3) Pipes with plugs or caps to prevent ail leaking, entry of dust, ete 4) Clean the outside surface of equipment, otc before disassembling, and drain hydraulic ot and gear oil before putting them on working bench, 3} Trouble condition, place, cause 4) Visible oil leak, water leak and damage 5) Clogging of filters, oil level, oi quality, oil contamination and looseness. 6) Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour meter. (8) Arrangement and cleaning in service shop 1) Tools required for repair work, (2) Disassembling hydraulic equipment 41). Since performance and function of hydraulic equipment after disassembly and assembly 2 peer the places to put the disassembled results in immunity from responsibility on the La manufacture’s side, disassembly, assembly 3) Prepare oil pans for leaking oil, ete. and modification without permission are strictly prohibited, 4.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING 2) IFitis unavoidably necessary to disassemble and modify, it should be carried out by experts oF personnel qualified through service training, (1) Sefety 4) Before disassembling, read Disassembling 1) Wear appropriate clothing, safety shoes, safety Instruction in advance, and determine if the helmet, goggles, and clothes with long sleeves. disassembly and assembly are permitted or not 1-31 OUTLINE @ 4) 15) 5) For parts which are required to use jig and tools, don't fal to use the specified jig and tools. For parts which can not be removed in the specified procedure, never force removal. First check for the cause. The removed patts should be pul in order and tagged so as to install on proper places without confusion, 8) a) 8) For common parts, pay attention to the quantity and places Inspecting parts 1) Check that the disassembled paris are free from adherence, interference and uneven working face. 2) Measure the wear of parts and clearance, and record the measured values. 3), If an abnormality is detected, repair or replace the parts. Reassembling hydraulic equipment 41) During the parts cleaning, ventilate the room. 2) Before assembly, clean parts roughly first, and then completely. 3) Remove adhering oll by compressed air, and apply hydraulic oll or gear oil, and then assemble them, 4), Replace the removed O-ring, back-uprings and oll seal with new ones, and apply grease oil on them before assembling 5) Removes dirt and water on the surtace on which liquid sealant ere applied, decrease them, and apply liquid sealant on them, 6) Before assembling, remove rust preventives on new parts 7). Use special tools to fit bearings, bushing and oi seal 8) Assemble parts matching to the marks. 9) After completion, check that there is no omission of parts. Installing hydraulic equipment 1) Confirm hydraulic oil and lubrication oi 2) Air release is required in the following cases ; 4. Change of hydraulic oi Replacement of parts on suction pipe side Removing and attaching hydraulic pump Removing and attaching swing motor Removing and attaching travel motor Removing and attaching hydraulic cyl 1-4 114 (AWARNING| If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. 3) For air bleed of hydraulic pump and swing ‘motor, loosen drain plug on the upper part, start engine, and run in fow idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely. For air bleed of travel motor and hydraulic, cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed. 4) [WARNING] For cylinder, don’t move it to the stroke end at beginning. 5) Air in pilot circuit can be bleed out by only operating digging, swing and travating motions thoroughly Check hydraulic oil level Move attachments to hydraulic oil cheok position, and check hydraulic oil level of tank. Refill oii the oil level is lower than the specified level How to check oil level of hydraulic ail tank 8) [eee eet ed Or et ora of tank {ie indiestore oe macs, the any 'Sacceptabie ELECTRICAL EQUIPMENT (1) The disassembly of electrical equipment is not allowed. (2) Handle equipment with care s0 as not to drop itor bump it. (8) Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire (4) Check that connector is connected and locked completely. (8) Engine key off before removing and connecting connector,4, OUTLINE (6) Engine key off before touching terminals of starter, and alternator. (7) Remove battery grounding terminal before beginning work close to battery and battery relay with fools. (8) Wash machine with care so as not to splash water ‘on electrical equipment and connector. (9) When water has entered in the waterproofed connector, the removing of water is not easy. So. check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting, [AS WARNING] Battery fluid is dangerous. The battery fluid is dilute sulfuric acid, and causes ‘scald and loss of eyesight by adhering on eyes, skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical advice. + When it has adhered on skin ; Wash with soap and water. + When it has got in eyes ; Wash in water for 10 minutes or moro immediately. + When it has spilled out in large quantity ; Use sodium bicarbonate to neutralize, or wash away with water. + When it was swallowed ; Drink milk or water. + When it has adhered on cloth Wash it immediately. 4.4.5 HYDRAULIC PARTS: (1) O-ring + Check that O-ring is free from flaw and has elasticity before fitting. + Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections, the rubber hardness also differs according to the pressure force, and also the quality differs depending on the materials to be seated. So, choose proper O-ring. + Fit O-ring so as to be free from distortion and bend. + Floating seal should be put in pairs. (2} Flexible hose (F hose) + Evenifthe connector and length of hose are the same, the parts difer according to the withstanding pressure. Use proper parts. + Tighten ttotne spectig torque, and check that I its free from twist, over tension, interference and cil leak 1.1.6 WELD REPAIR (1) The weld repair should be carried out by qualified personnel in the specified procedure after disconnecting the grounding cable of battery. Ifthe grounding cable is not disconnected, the electrical equipment may be damaged. (2) Remove parts which may cause fire due to the entry of spark beforehand. Repair attachments which are damaged, giving particular attention to the plated section of piston rod to protect it from sparks, and don't fail to cover the section with flame-proof clothes. @ 4.1.7 ENVIRONMENTAL ISSUES (1) Engine should be started and operated in the place where air can be sufficiently ventilated. (2) Waste disposal The foliowing parts follows the regulation. Waste oil, waste container and battery (8) Precautions for handling hydraulic oi! Hydraulic oil may cause inflammation of eyes. Wear goggles to protect eyes on handling it + When it has got in eyes Wash eyes with water until the stimulusis gone. + When itwas swallowed : Don't force him to vorit it, but immediately receive medical treatment. + When it has adhered on skin ; Wash with soap end water. (4) Others For spare parts, grease and oil, use KOBELCO genuine ones4. OUTLINE 1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations Introduction Tablet-4 Atthough this manual uses the SI units system. Outline QUANTITY [UNIT SYMBOL | FORMULA of SI units system is described here. Frequency hertz He tHe=tis Given hereinunder are an excerpt of the units that are Force Inewton N ig: mis? related to this manual Proscure and 1. Etymology of SI Units stress [Pesce i Ar English : International System of units Energy, Work 2. Construction of SI Unit System and Quantity of joule J Nem heat Base units Power __|watt Wi, ws Tabet | ___ Fea) _[ Brive units Quantity of | ouiomb c ee ‘Supplemen | r-|of base unts electricity ro [Stunts Lt taryunte Table 1-3 y [ st unit 1 | Table 1-2 a Electrie isystem|f =" Peers. potential | caring peculiar one sesignatons afore, | it v WIA jh [ebe'm4 | Voltage, and a El iv Prefixes of SI pone {n-th power of 10, where n is an integer force a Quantity of slaticelectricty (1) Basic Units and Electric |'*"° 7 Ae Tablet-1 capacitance (QUANTITIES DESIGNATION | SIGN Electric on 9 VIA Length Meter ™ resistence a Mass Kilogram kg Celcius [Peleus Tins Second > temperature [229728 & co | 27a.15)« Current lAmpere. degree. Thermodynamic Kelvin K Muminance Jur. us Simin temperature Gram molecule Mol mol ree oe Luminous intensity Candela cd Tablet-5 PREFIX POWER eee aya DESIGNATION SIGN Tablet-2 Giga 6 10" QUANTITIES DESIGNATION | SIGN Mega M ‘108 Piain angle Radian rad Kilo k 10° Solid angle [Steradian st Hesto h 10° Deca da 10 (3) Derived Units of Basie Units Seal 5 08 Tablet-3 Conti c 10° QUANTITIES DESIGNATION SIGN Mi m 108 ‘Area [Square meter mm Micro a 10 Volume Cubic meter me Nano n 102 Velocity [Meter per second ms Pico B 10 Acceleration [Meter per second / second | mis? Density Kilogram per cubic meter_|_kglm* 1-6(6) Unit Conversion Table ‘QuanTimes [vis | S1_[ REMARKS Mass kg | kg Force kgf | ON ‘Akgf=9.807N 807Nem Torque kgfm | Nem | kat Pressure | kgtfom? | MPa__ tkgfom'=0.098MPa Motive power| PS | kW | 1PS=0.7355kW Revolution | rp.m_| minx | trp.m=tmin- 1-7 4, OUTLINE4, OUTLINE [MEMO]2. SPECIFICATIONS TABLE OF CONTENTS 2.4. NAME OF COMPONENTS 23 2.2 GENERAL DIMENSIONS. : 24 2.24 $K200-8/SK210LC-8 [5.65m (18f-in) Boom +2. 94m (9-8) Standard Arm+0.80m?(1.05curyd) Bucket Shoe}...2-4 22.2 SK200-8/SK210LC-8 [5.65m (18f-6in}+2.4m (7ft-10in) Short Arm+0.93me (1.22curyd) Bucket Shoe].....24 2.2.3 SK200-B/SK210LC-8 [5.65m (18f1-6in) Boom+3.5m (148-Gin) Long Arm+0.70m (0.92curyd) Bucket SHOE)... 25: 2.3 WEIGHT OF COMPONENTS 26 24 TRANSPOTATION sn DB 241 OVERALL DIMENSIONS OF MACHINE ON A TRAILER, 28 24.2 DIMENSIONS OF ATTACHMENT 7 7 oo 2-8 2.5 SPECIFICATIONS AND PERFORMANCE ... . 7 244 25.1 SPEED AND CLIMBING CAPABILITY. 244 25.2 ENGINE... 7 seit 244 2.8.3 HYDRAULIC COMPONENTS 24 254 WEIGHT eal lt 214 2.6 TYPE OF CRAWLER. sos Seeeseeeeeaeee 242 27 TYPE OF BUCKET. se os F en BAZ, 2.8 COMBINATIONS OF ATTACHMENT. oo 7 a 243 2.9. ENGINE SPECIFICATIONS .escscunns 244 2.9.1 SPECIFICATIONS sons : ror 244 2.9.2 ENGINE CHARACTERISTIC CURVE (HINO JOSE-TA) 215 Book Code No. S5YN0218E01 2-12. SPECIFICATIONS issue Date of Issue ‘Applicable Machines Remarks SK200-8 : YN11-45001~ ISsyNO218E01 First edit 1, 2006 eee SK210LC-8 : Y11-06001~ (ASIA, OCE)2. SPECIFICATIONS 2.41 NAME OF COMPONENTS ARM CYLINDER ARM BUCKET, CYLINDER SLEWING BEARING IDLER LINK: SLEWING MOTOR FUEL TANK FUEL TANK | wyomauuc tan CONTROL VALVE BUCKET, SHOE AND TRACK LINK. FRONT IDLER IDLER ADJUST _-—~ UPPER ROLLER, ROTALY MULTI CONTROL VALVE (OPTION) LOWER ROLLER BATTERY 232. SPECIFICATIONS 2.2 GENERAL DIMENSIONS 2.24 $K200-8/SK210LC-8 [5.65m (18f-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m (1.05cusyd) Bucket Shoe] i lil Unit : mm(ft-in) iil 8 t a | ealhnrents b | _arrasi989 see 2200 (92°) ——— 2 pe99) (IF Note Dimensions marked * do not include the height of the shoe lug, [ Jinclude LC specifications, 2.2.2 $K200-B/SK210LC-8 [5.65m (18ft-6in)+2.4m (7ft-10in) Short Arm+0.93m' (1.22curyd) Bucket Shoe] Unit : mmift-in) 242. SPECIFICATIONS 2.2.3 SK200-8'SK210LC-8 [5.65m (18ft-Gin) Boom+3.5m (11ft-6in) Long Arm+0.70m: (0.82euryd) Bucket Shoe] ss0¢ary _Unit: mm(fe-in) Dimensions marked * do not include the height of the shoe lug, [ Jinolude LC specifications. 2-52. SPECIFICATIONS 2.3 WEIGHT OF COMPONENTS Unit; kg (Ib) Model $K200-8 SK210L0-8 item Machine complete 20,200 (44,500) | 20,600 (45,400), 1. Upper frame assy (Assembly of following :) 9,500 (27.000) = 1.4 Upper frame 41,770 (3,900) . 4.2 Counter weight (Semi-weighted) 4,840 (10,280) + 4.3Cab 260 (570) + 1.4 Engine *840 (1,190) « 1.8 Hydraulic oll tank 7150 (330) . 1.6 Fuel tank "110 (240) - 1.7 Slewing motor (including reduction unit) 210 (460) | « 1.8 Control valve *230(510) | « 1.9 Boom oylinder “170 (875) x2 < 4.10 Pin (for mounting boom) 70 (180) « 4.41 Pump "130 (290) © 4.42 Radiator (including intercooler) 790 (200) « 2. Lower frame assy (Assembly of following :) 2.4 Lower frame 2.2 Slewing bearing 2.3 Travel motor (Including reduction unit) 2.4 Upper roller 2.5 Lower roller 2.6 Front idler 2.7 Idler adjuster 2.8 Sprocket 2.9 Swivel joint 2.40 Track link with 600mm (23.6in) shoes assy Track link with 700mm (27.6in) shoes assy Track link with 800mm (31.Sin) shoes assy 6730 (74,840) 2,260 (4,980) 250 (550) 280 (670) x2 | 20 (44) x 2 30 (66) x14 | 110(240)x2 | 100 (220) x 2 50 (110) x2 *30 (66) 4,260 (2,780) x 2 1,470 (3,240) x 2 1,600 (3,530) x 2 7,430 (18,720) 2,420 (5,340) 30 (66) x 16 4,350 (2,980) x 2 1,560 (3,840) x 2 4.700 (3,750) x 2 2.10.4 Track link assy 540 (1.120) x2_| 540 (1,190) x2 3, Attachment (Assembly of following / STD -) 3.420 (7,540) = {5.65m (18ft-6in) Boom + 2.94m (9ft-Bin) Arm + 0.80m° (1curyd) Bucket} 3.1 Bucket assy (STD) 640 (1,410) ‘ 3.2 STD Arm assy (Assembly of following :) 1,050 (2,318) . 3.2.1 STD Am 1660 (1,455) . 3.2.2 Bucket cylinder "140 (310) - 3.2.3 Idler link 20 (Ad) x2 . 3.2.4 Bucket link 90 (198) « 3.2.5 Pin (2pes. for mounting bucket cylinder / 2pcs. for mounting bucket)| 100 (220) + 3.3 Boom assy (Assembly of following :) 1,730 (3.818) = 3.3.4 Boom 1,310 (2,890) = 3.3.2 Arm cylinder "255 (580) « 3.3.3 Pin (Mounting arm + Mounting arm cylinder) 80 (180) e 262. SPECIFICATIONS, Unit; kg (Ib) : Model 7 aa 8K200- 8 SK210LC-8 Item 4. Lubricant and water (Assembly of following |) 550 (1.270) < 441 Hydraulic oll 200 (440) « 4.2 Engine oil 20 (48) « 4.3 Fuel 310 (680) © 4.4 Water 20 (44) < (Chote) Marks * show dry weight. 272. SPECIFICATIONS 24 TRANSPOTATION 2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER (1) 5.65m (18f-6in) Boom+2.94m (9ft-Bin) Arm+0.80r» (1,05curyd) Bucket Mode] SK200-8 SK200LC-8 item ‘Width 600mm (23.6in) shoes 2,800 (Sf-2in) 2,990 (9it-40in) Weight 20,200kg (44,500 Ibs} 20,6009 (48,400 tbs) Unit : mm (ftein) 2280 (759) s7s0(i2s) mean woe cater), ese aey SECTION AA * marks indicate LC specifications, 282. SPECIFICATIONS 2.4.2 DIMENSIONS OF ATTACHMENT (1) Boom Type| item LengthxHeighbawiath eer m (fein) Weight kg (Ibs) 5.85m (18f1-6in) Boom 5:2" 22 1,670 (3,680) 1.87 x 0.67 (2) ARM AND BUCKET 2.4m (7ie10in) Arm + 0.93m »(1.22cusyd) Bucket 2.94m (9feBin) Arm + 0.80m >(1,05euryd) Bucket 3.5m (T1f-6in) Arm + 0.70m2 (0.82curyd) Bucket 475 x 0.9% 1.33 (157211) 5.29 0.9 x1.16 (aT ar2"11"%4') 5.88 x 0.9 1.08 (1935211"937") 1,740 (3.840) 1,680 (3,700) 1,880 (4,150) 2.4 m (T-10in) Arm 2.94 m (9ft-in) Arm 3.5 m (1Mft-6in) Arm 3.40 x 0.86 x 0.56 (CN232"10°% 110") 3.94 x 0.86 x 0.56 (1241x2401 10") 4.53 x 0.87 x 0.56 (14'10"%2'10°%1'10") Type Item LengthxHeighbWith LxHxW m (in} Weight kg (68) (3) Arm Type| Item: LengitntHeighbavviath LxHxW m (fein) Weight kg (Ibs) 41,020 (2,250) 4,044 (2.300) 4,260 (2,780) 292. SPECIFICATIONS (4) Bucket Type Hoe bucket LongthoeHeighbWidth Tg] 197 x 4.26 0.87 [1.87 x 120x107 | 1.37 x 1.26% 1.16 [1.97 x 1.26 4.33 Lew aexa2%2t07) | (eraser) | 4era'25a'10") | (4'et4'2sa'4") Weight ig (Ibs)]__ 520 (1,150) 630 (1,390) (640 (1,410) 740 (7,560) Bucket capacity mcuvd| 0.51 (0.67) 0.70 (0.92) | STD0.80(1.05) | _0.93(1.22) Type Hoe bucket [Slope finishing bucket LengthaHeighixWiath ig g| 137%1.26%1.16 | 1.26%0.90%2.20 LHW (aorxa'2'x3t0) | (artxatt'x7'3") Weight kg (Ibs)|__750 (1,650) 890 (7.960) Buoket capacity inv curyd| 0.80 (1.05) HD 0.82 (1.07) © Slope finishing bucket 2-102. SPECIFICATIONS 25 SPECIFICATIONS AND PERFORMANCE 2.5.1 SPEED AND CLIMBING CAPABILITY ee Meee $k200- 8 sK210Lc-8 ttem Swing speed imin= ep) 72.5 (12.5) Travel -speedi2- Favel speed (t-speed/2- a (miei) 3616.0 (2.2/8.7) speed) : a 7 Gradeabiity ‘% (degree) 70 (35) oe 252 ENGINE Eaghe meae EGRET Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-cherger ‘4-112 mmx 130 mm | (4.41 in 5.12 in) Type Number of cylinders—BorexStroke Total displacement I 5.123 L (312.61 ourin) Rated oulput/ Engine speed 144 KW (155 PS)/ 2,000 min* Maximum torque / Engine speed | 572 Nem (422 Ibfefty 1,600 mint Starter i T Hf 24. V7 5.0KW Alternator 7 2A VI12KW. ina 2.5.3 HYDRAULIC COMPONENTS. Hydraulic pump iz Variable displacement axial piston pump x 2 + gear pump x 1 Hydraulic motor (swing) ‘Axial piston motor x 1 BH Variable displacement axial piston motor x2 (with counterbalance valve) Control valve B-spool control valve x1 Cylinder (Boom, Arm, Bucket) Oil cooler Air-cooled type Hydraulic motor (travel) Double action cylinder 2.5.4 WEIGHT Unit: kg (Ibs) Fully equipped weight 20,200 (44,500), 20,600 (45,400) Upper structure 9,500 (21,000) < Lower machinery 7 (600mm grouser shoe) 6,730 (14,840) 7,130 (18,720) ‘Attachment 7 §.65m (18 ft-6in) Boom+2.94m (Stt-Bin) Arm 3,420 (7,540) | « +0.80m (1,05euryd) Bucket 2412. SPECIFICATIONS 26 TYPE OF CRAWLER Shape Shoe width mm (in) Sere eee Ground realy kPa Grouser shoe Socam |STD 2,800 (9'2") 45 (6.53) Lc 2,990 (9'10") 43 (6.24) ISTO 2,900 (9'6") 40 (5.80) le uc | 3,090(102") 38 (6.51) STD | _3,000(910") 35 (6.08) 46 LINKS| 800 (31.5) Lc. 3,190 (108") 33 (4.79) Note) Use 600mm (23.6") grouser shoes on rough ground (areas covered with racks and gravel). If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, ete.) 27 TYPE OF BUCKET ee stuck ge weer | TERI | Number] W or wio | “=#25UY| woignt ith side] Without side | oftace teu tooth | side cut mycurya) [P| cutter | cutter | “| SIE CUBE | ghover_| Ko (bs) Hoe bucket 0.39 520 | 70 (210" (26") | yes }9.51(067)) iggy) | 870210") | 77028 3 w (1150) 0.62 tl a 630 0.70 (0.82)} (5,99) | 1080 ('7)) 980(9") | 5 w YES | 360) {Covania Sty) 0.59 oe er) | w Yt 640 Meas) | (ory | P1608 10] 1.080 6) 5 eS | 410) {SE Asia STO} 1 | 0.80 (1.05)| 0.59 ane er w bo Side pin. | (077) | 2780 (910%) 1,080 (96) | 4 YES | 460) type 0.67 . : 710 | 990429] song) | 1990449] 122004 | 5 w YES | c's) 2-122. SPECIFICATIONS. 2.8 COMBINATIONS OF ATTACHMENT A oe Bucket ‘Available Arm Type [NeaPes capacity) — Struck | 2.84m (a-Si) Arm | 8.5m (THf-Gin) | 2.4m (7R-10in) Arm li im (curya) me (curya) _ (STD) |__+arm (Sh 0.51 (0.67) 0,39 (0.51) oO Oo O° 9.70 (0.92) 0.52 (0.68) ° 9° Oo [Oceania STD} 0.89 (0.7) ® A ° Hoe bucket 0.80 (1.05) (SE.Asia STO] 0.80 (1.08) 0.59 (0.77) ° A ° Side pin type 0.93 (1.2) 0.67 (0.88) A x Breaker - — oO ° Nibbler = = O° ° Note © Standard combination O General operation : Excavation or loading of sand, gravel, and clay A Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel) Prohibited combination : There are problems from the view points of strength and stability. + Use the attachments recommended by KOBELCO. The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibilty ARCAUTION Hf any other bucket, except for the backhoe bucket, is tuned over and used for excavation, damage to the arm and bucket may occur, 2-4132. SPECIFICATIONS 29 ENGINE SPECIFICATIONS 2.9.1 SPECIFICATIONS Applicable machine Engine model Type, ‘SK200- 8, SK210LC -8 HINO JOSE-TA Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger Number of cylindersBoraxStroke om (in) 4x 112 x 190 (4.41 x 5.12) Total displacement ce (cusin) 5,123 (313) Compression ratio 18.0 Rated output Maximum torque kW (PS) at min’) Nem (ibeft) at 194 (155) at 2,000 572 (422) at 1,600 mins High iting min 2,000 #30 Low idling rain 1.000 +30 Injection starting pressure MPa (psi) 50 (7.250) ‘Thermostat action erica 380 (170) 1963 (194) Firing order 7-3-4-2 MPa (ps) ‘Compression pressure 3.4-3.7 (499-537) at 280 at mins Fuel injection timing o Valve clearance Open Chose iébefore top | d0°after bottom Valve clearance Intoke valve | 0:8 mmatoosl | Ges oint | dead point Cxnaust vane | 048 mnatcoe |store bolton | 1Sraer top dead dead point point Starter capacity Vk 245.0 Generator capacity (Alternator) VxA 24x60 Cooling fan drive method 650 (25.6") x suction type 7 fans, V-belt drive, pulley ratio Crank / Fan= 0.89 Full evel 18.0 (4.76) Engine oi! quantity L (gal) Low level 18.0 (3.96) Total 21.5 (6.68) Dry weight kg (ibs) 580 (7,260) Fuel consumption ratio GikWen (Gipsy) 217 (160) Allowable inclination (Limited by E/G lubrication) Dimension (LxWxH) Rotating direction mm {in) Front / Rear and Right / Left: 35° 1,063 x 725 x 895 (@i-5.86in x 26 bin x 89.2in) Counterclockwise seeing from fiywheel side 2442.9.2 ENGINE CHARACTERISTIC CURVE (HINO JO5E-TA) Condition to be measured: The net value is indicated, measuring without cooling fan. ‘© marks show the rated point 2. SPECIFICATIONS, (N +m) 600 (kw) i rm 8 — 500 @ | e 120) 400 & T y i — 7 300 100) | 5 807 7 5 3 E | % 60}— llg/kW-h) 40 260 & é | Zz + aI 240 2 g 3 20 — 220 8 [| | | 4 — + 200 4 | | g | : O00 1000 400 1800-2200 2600 3000 ENGINE SPEED (min-1) Fuel consumption volume Fuel consumption rate X kW X Load factor (@) 0.835 X 1000 = PATON x tak x 0.835 X 1000 a: Standard load factor (0.70~0.80) w 29.6 a. Lh Fuel consumption in regular operation (load factor 0.70-0. 20.7 Linm23.7 Lih 2415 80)2. SPECIFICATIONS [MEMO] 2-16TABLE OF CONTENTS 3.4 BOOM eae a 3.1.1 BOOM DIMENSIONAL DRAWING... 3.1.2 BOOM MAINTENANCE STANDARD. 3.2 ARM. 3.2.1 ARM DIMENSIONAL DRAWING. 3.22 ARM MAINTENANCE STANDARD 3.3 BUCKET . Set 3.3.1 BUCKET DIMENSIONAL DRAWING 9.3.2 BUCKET DIMENSIONAL TABLE 3.3.3. LUG SECTION DIMENSIONAL DRAWING 3.3.4 BOSS SECTION DIMENSIONAL DRAWING. 34 3. ATTACHMENT DIMENSIONS 312 312 312 343 344 Book Code No. S5YN0318E013. ATTACHMENT DIMENSIONS issue Date of Issue “Applicable Machines Remarks jSK200-8 : YNT1-45001~ IS8YNO318E01 First ect A [erect wgust, 2008 | e<940LC-8 : YQ11-06001~ (ASIA, OCE}3. ATTACHMENT DIMENSIONS 3.41 344 BOOM BOOM DIMENSIONAL DRAWING SECTION X-X ig. 3-1 Boom dimensional drawing Unit: mm (fein) STD = 5.65M (181t-6in) BOOM ee 7 No NAME DIMENSION. ‘A Boomlength 5,650 (186") = B [Boom foot wiath 670 (26.4") ~ [Boom end inner with 347 (13.7") - D —_|Boom end outer width 482 (19°) - E__ [Height of boom cylinder rod pin 4,008.5 (3: - F Height of arm oylinder (head side) pin 1,203.5 (311 i G _|pistance between pins of boss R2,589 (8'6") - H [Distance between pins of bracket 2,829.5 (9'3") - | |Arm cylinder (head side) inner width 126 (4.96") = J Outer wicth of bracket on the arm cylinder (rod side) 468 (18.4") - mounting 1 [Boom foot pin dia 6 90 (354°) = 2 [Boom cylinder (rod side) pin dia 0 85 (3.35") - 63 Pin dia. of boom end. 0 90 (3.54") - d4__|Arm cylinder (head side) pin dia. 9 85 (3.35") = 3-33. ATTACHMENT DIMENSIONS 34.2 BOOM MAINTENANCE STANDARD (1) Clearance of pin and bushing on boom section ASIA eee Unit : mm (in) ‘Sandard value Clearance 1 sym} in | Repai tal Item Pin partNo. | a. aig | Pin aia ate S| Standard oe Service | Remedy tolerance| value | lit tolerance| level | +0020) +0217 | +0287 @ 90. |(+0,0008)| +0.0088)| (+0,0003) A | Boomtoot | YNO2B01719P4 eee (3.5433)} -0.020 | +0.071 | +0054 (-0.0008) | (+0.0028)| (+0.0020) 9 | 70243 | = 0.288 Boom cylinder 085 | 0.010)| (0.011) 8 ‘YNo2B01720: acao | (Head side) | YN0?°P1720P1 Jos a4gsy), OR, | +0.085 | +0.085 | More ou HH ( ) |¢+0.0083)] (+0.0033)| than | 25 teeing +o.020 | +0247 | +0267 | 20 | (on) [Nn Boom cylinder | | (+0.0008) (+0.0097)} (+0.0105) | (0.08) i © | (Rod sidey | YN°B01721P4 =0.020 | +0.093 | +0.073 685 | (0.0008) | (#0.0037)| (+0.0097) | (3.3465) + 0.030 | +0.252 | +0.282 ‘Acm oylinder (+0,0012)] ¢+0.0098)| (40.0111) © | Head side) | YN0E01889P1 -0.030 | -0.099 | +0.069 I (-0.0042} | (-0.0039) | (+0.0027) 3-43. ATTACHMENT DIMENSIONS OCEANIA Unit: mm {in) 1 Standard valve Clearance sym. i ue tem Pin part No. india. | PY" | standard | PP" | service | Remedy bol Pin dia id bie tolerance | value limit tolerance level +0020 | +0217 | +0297 A | Boom foot | ywoaBor7iget | 290, |(+0.0008) (+0.0085)) (0.0008) (3:5433)} -0.020 | +0071 | +0051 (-0.0008) | (+0.0028)] (+0.0020) i + 0.283 | +0289 ° Boom cylinder 088 (+0.010)} (0.011) -0.010 © | ead side) | YN02801720°1 | 2465) doote | *2085 | +0.085 | More Be {-0-00%6) | 40.0033) (+0.0033)} than | 25 ines soar | +0267 | 20 | (a) |Ponne Boom cylinder i (+0.0097)} (+0.0105) | (0.08) © | Rod sidey | YNO#BOI72IPT +0.020 | +0.093 | +0.073 9.85 |(+0.0008) (+0.0037)| (+0.0097) |(3.3465)| -0.020 | +0.230 | +0.250 ‘Arm cylinder (-0.0008)] (+0.009) | {+0.010) | D | load side) | YN02BO1722°4 | ogee -rboie I (+0.003) | (+0,002) 3-53, ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the boom eylinder installation section [La PL4 ea | xa] 2) SECTION B-B SECTION AA Fig, 3-3 Clearance in thrust direction on the boom cylinder installation section Unit ; mm (in) ‘Clearance X adjusted with shim Basic size fislori Eas) Pin length Sec item Remedy Siandard |Reparabie| Service No.| Size No.} Length vatue | ievel_|_ timit Boom oo AA [Boom foot tr LE84L| 05 (0.02) pur] 23! cee 676 | orless (327) i (26.6) 20 | 258 Bot ellen 105 (0.08) | (0.10) ep [Boom cylinder vt tp L419} 06-10 pil 241 (Head side) 411 | (0.02~0.04) (9.49) Upper trame aan Shim a adjust i t cc [Boom oxtiner POMevInEeT | 4) 443) | 6-20 | 30 | 40 pus) 738 | (Rod side) “) 468 | (0.02~0.08)} (0.12) | (0.18) (28.0) Boom Ls (18.4) [Arm oylinder ies pup [Armeylinder 7 ig L472) | 06-10 | 2.0 28 [ay 4) 260 (Head side) 726 | (0.02-0.04)] (0.08) | (0.10) (10.2) fee (4.38) 3-63.2 324 ARM ARM DIMENSIONAL DRAWING 3, ATTACHMENT DIMENSIONS SECTION Y-Y SECTION 2-2 Fig. 3-4 ARM DIMENSIONAL DRAWING YN12500904F1 (ASIA) Unit : men (fein) 2.94m (9f-8i S4m (91-8in) ARM) 3800802F1 (CE) Code] NAME DIMENSION |Code] NAME DIMENSION C_|Arm iength 2,940 (98")_| _N_|Bracket inner with 126 4.96") Distance between pins of boss : iia aepuaneelt R874 (84.4") | [Bracket inner width 111 (437°) Dit [LD of boss, 2110 (433°) | P [idler ink dimension 530 (248°) D2 |1.D of boss: 085 (3.35")_|_Q_|Bucket link dimension 610 24") BE loeb ease: 2105 (4.13%) | R [Relontbeween pins ofboss andl 3 7, 55 loenter Distance between pins of boss ae 7 Fs loa ereelat R2,169 (7'1") | dt [Pin dia 280 (3.15") Distance between pins of boss F in 5 epee R420 16.5") | 42 |Pin dia. 270 (2.76") Height between pins of boss and 7 7 & racket 665.5 (26.2") | 03 [Pin dia 085 (2.35") Height between pins of boss and : 7 Hl precket 3212.3") | d4 |Pindia 290 (3.54") K_[Arm top end boss width 325 (12.8") | a5 |Pindia 280 (3.159) [Arm link section boss width 323 (127°) M_[Boss width 342 (13.5°) 3-73. ATTACHMENT DIMENSIONS 3.2.2 ARM MAINTENANCE STANDARD (4) Clearance of pin and bushing Fig, 3-5 Clearance of pin and bushing on arm section ASIA Unit: men Gin) ‘Standard dimensions ‘Glearance No. ltom FinpatNo, | gig | Pindia. | Bushingid.| Standard | Repairatie| Senice | Remody tolerance | tolerance | value | _level_| _ limit 70.253 | +0333 Seeere (70,0100) | (0.0131) A. |Anm point 0.020 | +0.080 | +0.100 280 | (0.0008) | (+0.0031) | (+0.0039) 'y12802407P4 ae (3.1496)| -0.080 [+0284 | 70.204 [Bucket ink 0.0031) | (+0.0172) | (0.0143) (Bucket sida) 40.158 | 40.178 (10.0081) | (+0.0069) 0.253 | 0.313 ter tok on o70 0.0100) | (0.0123) © Connectespan}ywraR024061 E20) a osretiooa os of arm) (40.0076) | (+0.0078) o +0232 | 0.292 1p [Bucket ink ©) | (40.003) | (20.0715) (Idler link side) 0.060 | 40.161 | 40.161 Ha z (+0.0063) | (+0.0063)| 2.0 25 an eiieenaa (0.0024) | _¢ 2B02412P1 s0.338 | oe) | oon | sho py [Bucket oyinger 080 (40.0133) orpin (Rod side) (9.1498) 0.278 | 40.141 (+0,0109) | (0.0086) +0.141 | 40.308 ‘Bucket cylinder (10.0056) | (40.0121) © loca ane) |YN1280241304 paren Sta (0.0012) (90.0044) 0.030 [+0252 | 40.282 JArm cylinder 685 | (0.0012) | (+0,0089) | (40.0111) F Jerod side) |YNO2BOTEIOPT | 3 3455) 40.079 | +0.049 (0.0031) | (+0.0019) +0.020 | 40.202 | 10.312 ‘Arm foot nfo 090 | (40.0008) | (0.0118) | (+0.0123) i coon Pan |YNIZBO2415P1 | 13 5433)| 0.020 | 20.195 | 40.175 0.0008) | (40.0077) | (+0.0089) 3-83. ATTACHMENT DIMENSIONS OCEANIA Unit: mm fin} ‘Standard dimensions Clearance No. Item PinpartNo. [oo iq | Pindia. |Bushingid.| Standard [Repairable] Service | Remedy tolerance | tolerance | value | level | limit +0283 | +0313 Saas (40.0100) | (+0.0123) Ast ene -0.020 | +0080 | +9.100 80 | (0.0008) | (+0.0031) | (10.0039) peeeoeeioet (3.1496) | -0.060 40.220 +0.280 [Bucket ink 0.0024) | (0.009) | (40.0110) (Bucket side) 40.076 | +0.006 (+0.0030) | (0.0038) 0.285 | 40.325 ater ink fi 070 (0.011%) | 0.0120) © feomerosnennszeczwer |, “0.0112) | (40.0128 {+0,0050) | (+0.0050) © [+0205 | 0.285 [cet ine (©) | 0.008) | ¢eo.ot00) ter tink side) ~o01 | 19.083 | 0.043 Replace (-0.0016) {+0.002)_| (+0.0020) 20 25 YN12B02217P1 ¢ 40.285 | (0.08) | (0.01) | Pests o Bucket cylinder 080 (+0.0110) e (os side) (0.1496) so2a5 | 40.089 {0.010} | (0.0040) 10.089 [40.265 Bucket oyinder (+0.008) | (0.0700) & [Pym | yropozzters 0.088 (+0.0030) et +0.020 [so250 | 0.250 cylinder 285 | (0.0008) | (0.009) | (+0.0100) [Rod side) [*N07B04722P1 | ig 34555] 0.020 | 0.065 | +0.088 (6.0008) |_@0.003) | (0.0020) 0218 | 40.234 ‘Arr foot 990 (40.008) | (+0.0090) 6 omectes pad|ucrasozos¢r1 | |, 24, aera evanar (46.003) | (+0.0020)3. ATTACHMENT DIMENSIONS (2) Clearance of arm and cylinder installing sections in thrust direction SECTION C-0. SECTION E-€ SECTION F-F PL? LPs SECTION B-B SECTION D-D SECTION GG Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction 3-103. ATTACHMENT DIMENSIONS Unit : mm (in) Clearance X adjusted with shim Pin en feed (total of both sides) ee Sec. item Smee Remedy No.| Size | Sandard |Repaitablel vice imi] No,| Length value_| level 326 acm (1279)|1.0(0.04)| 2.0 A |Acm poi Pl eee puke || 228 | orless | (0.08) st : (12.83) 481 18.9) Link side ; Pen ee 2-8 |Buoket link wpe _ 7 PL Bucket ea 323 25 ater ink cc jae am | is | c27 Ave on | 8 |Pvs (eam connection eas - ) Bucket lnk Rod side 7 D-D | (ler tink Lincaise | Lt] 32 aor connection) eta (12.72) (16.8) os-1.0] 20 Shim Rod side 108 | 024-002} (0.08) ne adjust [Bucket link (4.13) bo uw -ment (Rod side) eae 11 (437) 105 exe [Pucketoyincer TPES || v4.13) pis) 28 (Head sice) reat 111 (0.25) «sr | 0620] 30 40 720 | o.oe-a08)) (0.12) | (0.18) R ecg [Armoylinder ease | 1272) pie] 260 |(Rod side) ty 126 (10.2) (4.98) cm ae (1346)| 05 | 1.0 25 505 6.6 Jarmt oe boom | | 8a | 002) | oa | 10) |) e199) (13.66) 3-113. ATTACHMENT DIMENSIONS 3.3 BUCKET 3.3.1. BUCKET DIMENSIONAL DRAWING (1) Hoe bucket Fig. 3-7 Bucket dimensional drawing No. NAME: No. NAME: ‘A [Distance between pin and bracket G [inner width of bucket bottom B [Distance between bucket pin and tooth end H [Bucket outer width of front side C Inner width of bucket top end 1 |Pitch between teeth D [inner width of tug fo |Pitch between teeth E__[lnner width of bracket dt_[Outer dia. of bushing F _ [Outer width of side cutter 02 [Pin dia, 3.3.2 BUCKET DIMENSIONAL TABLE Unit: mm (fin) Tye Hoe bucket (SE. Asia S10) opis) 0.80 m* ee 0.54 me 0.70 m* 0.93 1.08 ewe) | oper) | (OST euya)) | (OS2euyd) | (1.24 cua) Side pin type PartNo | YN61B00272F1 | YN61B0025eF1 | YNeiB002e7F1 | YNOiBOOZSGR1 | YNeTBOOZEErI A Ra30 16.9") © © € © 8 Ri,440 (49°) © = e © ¢ 1,008 (33") © Tie (28°) 925 (364°) 1176 (407) D 399 (15.7") © © © e E 327 12.9") © a © © F 1.187 (8) © 868 (34.2") 7,073 66) 1330 (44°) G 863 (34") < 572 (22.5°) 765 (30.9") 7,036 (95) x 7.087 (36°) < 76 (30.2") 979 (38.5") 7.230 (4) 1 224 (6.82") © 300,(11.8") 203 (7.99") 266 (10.5") 0 224 (6.82") = 300 (17.8°) 203-(7.98") 286 (10.5) at 095 (3.74) © e © © 2 280 (3.15") = © © & 3-123. ATTACHMENT DIMENSIONS 3.3.3 LUG SECTION DIMENSIONAL DRAWING y 8 | Ba i q | | ‘i oo x an a Boss a 1 vyastB01002°1 139) Apply ust prevention o : » / oF} ON go | i a | ; cL \ Boss SEM lveinstateg MSeVtthis pin tush with surface ye61801002P1 ‘at shipping) SECTION X-X DETAIL B Fig. 3-8 Dimension of lug section Unit : mm (ft-in) g 2° g | als gs 2 Cepacty of BES aE ede e/ele/$ ‘Type of —_ PatNoot js }/2]/s | 8/3 )/S] 8/3) 38) 2 puceet | BERL | ket ge ;e;e/e/e]elel sigs ‘cuye) fre;e)2le)s)eie)a)é eis i|2l|Flé isle slai 8 aAlepi[olelri[eo[Hiuluin [SE. Asia STD] bat (nas) | uesa00arar | [Oceania ST] | | Hoe 0,80 (1.05) YN61B00258F1 | ps0 | 25 | 995 | 13 | e180 25 16170 | 36 | 140, bucket | PT LB | oben] Fy SE] FOR) | 1016 | 0 B8ey BE [coy els }o.s1(0.67) — | YNetBooze7F4 | 0.70 (0.92) YN61B00280F1 | o.93(1.21) — |YNetBo0288F1 | | | | L 3-43,3. ATTACHMENT DIMENSIONS 3.3.4 BOSS SECTION DIMENSIONAL DRAWING A go seer) Fig, 3-9 Dimension of boss section Unit : mm (ft-in) Wwe] Comes | oma | pes orf mae | PenMeet | re | on | yp Foc | oof e | F | oo | a T | 1 bucket] m’ (cue) ISE. Asia STO) 25 0.80(1.08) | YNe1B00272F1 [Oceania TD] 0.20 (1.05) | YN61800258F') YestBor602°1 0510.67) | ynexeco287F1 0.70(0.92) | vnereocze6r1 0.93(1.21) _[yne1B00288"+ Hoe bucket a fuss} ss] a | oe | ow | os 319} 4157 | 4399 | sry | (150 | (oes | 5124] (nosey 3-1411. TOOLS TABLE OF CONTENTS 11.1, TIGHTENING TORQUES FOR CAPSCREWS AND NUTS 143 11.2, SCREW SIZE. ange 145 41.2.1 CAPSCREW (BOLT) 115 11.22 CAPSCREW (SOCKET BOLT) ...... att 115 41.23 SOCKET SET SCREW..... enn eB 11.3 TIGHTENING TORQUE FOR HOSE AND FITTING 116 11.3.4 JOINT (O-RING TYPE} oo ene 116 14.32 HYDRAULIC HOSE (30° FLARE TYPE) 116 11.3.3 JOINT (ORS TYPE). edt . 116 11.34 SPLIT FLANGE fae seninnne 1B 11.4 TIGHTENING TORQUES FOR NUTS ANDO SLEEVES. 7 445 PLUG felt 118 11.5.1 PLUG FOR HYDRAULIC PIPE JOINT. 7 118 11.5.2 PLUG FOR HYDRAULIC EQUIPMENT 119 11.6 SPECIAL SPANNER FOR TUBE vn 7 1444 417 SPECIAL TOOLS.....cn ms nme ese AZ 14.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......14-14 11.9 SUCTION STOPPER. a . 5 11-15 14.8.4 COMPONENTS. . sees AB: 119.2 DIMENSION oo 11.8.3 APPLICABLE MODEL 11-15 14.10 COUNTER WEIGHT LIFTING JIG laa aoc 11-16 11.11 UPPER FRAME LIFTING JIG... ent 1-17 11.12 ENGINE MOUNTING PEDESTAL... . 14-18 14.13 TRACK SPRING SET JIG ... #7 7 fs 14-19 Book Code No, S5YN1118E01 14-411. TOOLS Issue “Date of Issue Applicable Machines “Remarks _ First edition August, 2006 SK200-8 : YN17-45001~ ISK210LC-8 : YQ11-06001~ SSYN1118E01 (ASIA, OCE} 11-241.4 11. TOOLS TIGHTENING TORQUES FOR CAPSCREWS AND NUTS Tables Tablet1-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given. Overtightening cf bolts may result in a twist-off and a fracture under load. Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques. Tabie11-1 Tightening torque for metric coarse threads (not plated) Unit : Nem (lbfeft) classification 487 7 10.97 Nominal size |No lubrication| Oil lubrication] No lubrication] Oil lubrication] No lubrication] Oil lubrication ie 7 44x05 | 37404 | gext0 | g1soe | 174s18 | 14.7418 204) | (27403) | (7140.7) | 6.0206) | (12.813) | (10.8#1.1) Me paizg | to7et1 | 9.0209 | 235820 | 19.6120 | 422839 | 25.9239 (7.9208) | (6620.7) | (17.381.5) | (14.681.5) | (31.1229) | (26.082.9) Mio Pets 21.642.0 | 17.9818 | 46.1249 | 39.283.9 | 83.438.8 | 70.626.9 (15.981.4) | (13.2813) | (34.0836) |_(28.942.9) |_61.5%65) | (62.185.1) wiz pays | 96939 | stasze [ 7oae7e [osreb | tasers | 12iei2 (26.822.9) | (23.242.4) |_(68.685.8) | (49.2851) |_(10511) | _(69.288.9) an 87.9259 | 49.0949 | 126818 106210 | 226820 | 191319 __| 42.7244) | (36.1836) | (92.980.6) | (78.227.4) | (167218) | (141814) Naaeeeet 86.386 | 74.5469 | 191820 veisté | 343eg9 | 284820 | (05.146.5) | (55.086.1) |_(1ate15)_|_(119#42) | (253429) | (209821) Mis 122412 103210 285429 226420 461448 402239 (90.038.9) | (75.887.2) | (195321) | (167215) | (955296) | (297429) ieneeeetpeae test? | tadeta [373239 | 314229 | 667469 | 559559 (ia7s13)_| (voss10) | (275829) | (232421) | (ao2e5t) | (412%44) 22 226220 192420 00849 | 422839 902488 755878 (167215) | (142415) | (@eges6) | (attez) | (esses) | (557258) Meee 204229 | 235129 | 637209 | 620249 | tie0st18 | 941z98 "| rz) | (73s24) | a7oss1y | (a8aes6) | (856887) | (694272) iat agia39 | 363x990 | oats98 | 7e5e78 | 17003167 | 13702137 (318#29) | (260s29) | (eoae72) | (S84#58) | (12508123) (10104101) aot 586259 | 490249 | 12852127 | 107es108 | 23008235 | 19402196 (434244) | (961236) | (948294) | (796280) | (17002173) | (14902145) ron 794s78 | 667869 | ‘17262177 | 14512147 | 31108314 | 26102265 a _ (686258) | (492851) _| (12702131) | (1070#108) | (22908232) | (19302195) seed 7030208 | 863388 | ve6ss186 | a010e402 | 33602333 (7e0e72) | (637465) _| (16408167) | (13708137) | (29604297) | (24808246) 11-311, TOOLS Table11-2 Tightening torques for metric fine threads (not plated) Torque value Unit : Nem (Ib) Classification 487 TT 409 Nominal size _ [No lubrication] Oil ubrication|No lubrication] Oil lubrication| No lubrication] Oil lubrication Me pao | Msett | Obe10 [245220 [ 206120 | 441239 | 97.983.9 (9.3408) | (7.00.7) | (18.121.6) | (15.281.5) | (2522.9) | (27.5#2.9) Mio peta5 | 226820 | 187218 | 4atsa9 | 412439 | a7ce8e | 73.569 (16.7218) | (13.881.4) | (95.543.6) |_(90.942.9) | (64.4265) | (54.225.1) Miz Pei2g | 392839 | 22229 [ e62s88 | 71.0260 | 154216 129813 (28.9429) | (24.6821) | (62.9465) | (52.885.1) | (114812) | (95.280.6) wie parg | 922288 | 775278 | 196820 169817 363239 304829 (68.046.5) | (67.2258) | (145215) | (126813) | (268820) | (224221) hoes 186219 155216 | 402430 333229 | 726269 |” 608269 (i37et4y | (is4et2y | (297820) | (24x21) | (635851) | (448244) toateeeepue 314228 265229 | 686269 s60n59 | 12402118 | 1030298 (22421) | (1gss21) | (606851) | (a20eaay | (e15387) | (760872) heats 627359 saot49 | 13002137 | i167e118 | 25008255 | 20808206 (470244) | (991296) | (10302101) |_ (#53287) | (1840%188) | (15901152) Hegemon 859288 706270 | 1e60st@6 | 18508155 | 3360x934 | 27908275 (ezge65) | (62te52y | (93708137) | (11408114) | (2470#248) | (20608203) Waeeeeipes yo7os108 | 8eze8e | 23308226 | 19402196 | 42002422 | 35008363 (7eoxe0) | (esese5) | (17202167) | (14302145) | (3100#811) | (25804260) 11-441. TOOLS 11.2 SCREW SIZE 41.24 CAPSCREW (BOLT) Nominal [8mm | Nominal [8mm screw size sorew size | 7 Tool size 7 Too! size “Me | 10 "M36 55 MB 13 a2 cy M0 7 Mas 70 Miz 18 Mae 75 (4) 22. MSE 85 M16 27, (M60) 90) (Mia) a7 Med 95 M20 30. (M68) 100) (422) 32 M72 105) M24 36 M76 110 (M27) at M80 115 M30 46 ath 11.2.2 CAPSCREW (SOCKET BOLT) Nominal Simm] Norinal [Bm er 820 en | OS ra ia) 28 | Wao | a (M4) 3 (M22) 7 d {MS) 5 M24 19 M6 5 (M27) 419 MB é M30. 22 Mio | 8 __ M36 27 wiz [40 | wae a2] wig [easy | MiG | 14 M48 36 (wt6) 14 MSZ 36 Sunes 11.2.3 SOCKET SET SCREW Nominal [Bini] Nomnal [Bam seen 6 ogi sae [SCM S2®| ool aze é w25 [127 | wea we [ 48 | Mio 18 we 2 [wig] ws | 28 | te “| 6 5 M6 3 M20 70 | ise Peay 11-511. TOOLS 11.3. TIGHTENING TORQUE FOR HOSE AND FITTING 44.3.1 JOINT (O-RING TYPE) Size Wrench Tightening toraue PA ia Neale o-niNe opine 178 4 4722 (1321.5) / 7 14 19 3642 (2787.5) LL: 2, 7 3/8 22 7a (5524) ae " 5 1g —_| 3/4 36 16220.8 (11927) _ 1 41 25529.8 (18847) HYDRAULIC HOSE (30° FLARE TYPE) Size Tightening torque (PF) Wrench(mm) site A 178 id 7512.0 (1181.5) 14 79 2084.9 (2120.8) 3/8 22 4924.9 (9613.6) 1/2 27 TeE4.9 (5843.6) 3/4 36 11620.8 (6727.2) ace 41 137215 (101211) #4 7 11.3.3 JOINT (ORS TYPE) Tightening Torque Unified screw size | Opposing flats ightening Torqu: CONNECTOR O-RING FITTING Unified screw size | Nem (loft) i y) 6 177216 (131813) 41 206226 (162216) 47116612 UN 46 206: east) NUT i 11.3.4 SPLIT FLANGE ___ Tightening torque Nem (Ibi) FUNGEHEAD | CLAMP HALE size | Standard pressure | 534,| Hipressure | ao ta / series eg series cae f 20.6 MPa 41.2MPa 37a | 35.8856 (2544) [WHO | 90.5256 esa) | wi ny j 7_| 42.4256 (3124) [M10] 62.2856 (4624) | M12 1 « |ASS \ “Viral “55.147.1 (4185) | wo |__93.528.4 (6926) | Mid || ce 11/2] 70684 (6286) | mi2 | 169811 (12528) | M16 I 2 81.948.4 (6086) | M12 | 22411 (20838) | M20 So 1-611. TOOLS 11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES ‘Table11-3 indicates standard tightening torques applicable to cases where no particutar note is given. Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe connections, Always lighten nuts and sleeves to proper torques. Tablet1-3 Working Tube size | Opposing] Tightening torque Manufacturer's name| Pressure OD xthickness | flats Nem (Ibft) i MPa (psi) mm (in) (HEX) mm 10x15 | 9.8 (3627.2) (osesvoose) | 1 49:020.8 (9647-2) 2152.0 | 3212 (8728.7) (0.591x0.079) a ited teed 21825 : ie Nippon A.M.C. 29.4270) | io-r0970.098) 32 1a7e15 (190811) 2223.0 16422 (16081 (0.866%0.118) = beeen ett 226x4.0 275827 (2008: coon at 5427 (200820) 285%5.0 #44 (3308: Ihara Koatu 29.4 (4270) (1.3600.197) 55 saveae (930839) 7 SLEEVE san NUT as| So | WAL. 4 Tube size Paris No. Tube size | Opposing Paris No. ed Thara Koatu | Nippon AMG ed flats thara Koatu_ | Nippon AMC. a (HEX) mm é 293806000 = 8 14 2F93N06000 = a 293808000 = 7 Zr93noeo00 [ 40 ZFS3S10000 | ZA93S10000 19 ZF93N10000 | ZAG3N10000 42 ZF93S12000 = 22 2F93N12000 = 18 2F23815000 | ZAe3S15000 | 27 ZFO3N15000 | ZA93N15000 18 2F93818000 | ZA93S18000 ae ZF9anie000 | ZA9SN18000 22 2F93S22000 | 2A93822000 [ 36 2F93N22000 | _ZA93N22000 28 ZF93S28000 | ZA93S28000 a ZF9aNza000 | ZA93N26000 32__ | zFe3s32000 = 50 2F93N32000 = 38 2F93835000 | ZA93S35000 55 ZF93N95000 | ZAS3N35000 38 7793838 = 60 ZF93N38000 i 1-711. TOOLS 11.5 PLUG 11.5.1 PLUG FOR HYDRAULIC PIPE JOINT (1) Cap nut (Joint plug) (2) Plug (Tube plug) Sleeve Nut Type joint body (3) Nut dscrew i Applicable tube Cap nut parts T sorew lOpposing flats No. BLA ZFe3HO6000 | Mi2x15 14 | 14 ZF83H10000_| M16.x 1.5 3HoBoo0 _| Mt 2F83H12000_| M18 x15 ZF@3H15000_| M22 x 1.5 ZF83H18000_| M26 x 1.5 ZF83H22000_| M30x 1.5 ZF63H28000_| 36x 1.5 ‘Applicable tube | Plug parts No. O.D'A 6 2F63P06000 8 ZF83P08000 40. ZF&3P 10000 2 ZF83P 12000 15__ | _2F83P 15000 18 ‘ZF83P 18000 22 | _ZF83P22000 28 ZF83P28000 ‘Applicable tube | Nutparts No. | d screw |Opposing flats O.D:A | 6 __| 2FOsNO000 | MI2x45] 14 | ZF93Nosooo | Maxis] 17 jo | zFeani0000 [wiex ts] 19 12__| 2F9ani2000 | Mi8x 15] 22 78 | 2Fosnis000 | Me2xis| 27 78__| Zroaniao00 | M26xi5| 32 22 ZF93N22000 | M30 x 1.5 6 26__| 2F93N26000 | waex15| 41 32 __| 2FOsNS2000 [WAZ x15] 50 35__| ZF93N35000 | masx15| 55 ~~36__ | 2F93n36000 [M48 x15] 60 11-811. TOOLS 11.5.2. PLUG FOR HYDRAULIC EQUIPMENT (1) PF screw Plug paris No. |2 mm] O-ring paris No. | Nominal O-ring E72x04000 | 19 | Z012P07100 | 18 Pit E72x06000 | 22 | Z2D12P01400 18 Pia ‘2E72x08000 | 27 | ZD12P01800 4B P18 2E72x12000 | 36 | Z2D12P02400 1B P24 PF screw Ze72x16000 |_41 | 2D12P02900 18 P29 (2) PT screw B PT screw PT screw| Plug parts No. Bmm rie | Zee2To2000 | _5 pri | Ze82T04000 | 6 PT3/8. 2E82T06000 8 pri | zee2toso00 | 10 praia_| Ze82T12000 | 14 pti | ze62T16000_|_17 PT114 | ZE82T20000 22 prise | zee2t24000 | 22 (3) Plug for (F) flare hose PF screw PF screw] Plug parts No. [8mm pra | 2442272001 | 24442272602 PR _| 24047272603, . Praia _| 2444z272004 Opposing flats B PFt 24442272805 PF screw) Plug parts No. | E mm | F mm. PFi4 | 244az2720D1 | 14 | 19 praie_| 24a4z272002 | 17 | 22 pet2 | 2aaaza72903 | 23 | 27 pra4 | 2aaqz2720D4 [27 | 36 “Opposing pe1_| 2asazzr2005 | 36_| 41 fats E Prt ia | 2agaz272006_| 40 | 50 11-914. TOOLS {4) Plug for ORS joints Male ‘Sorew size | Applicable ‘Opposing | O-ring [Nominal A hose 0.0 | PUG ParSNO. pus iex| parts No._| O-ring 114UNS | 021.7 |YNOTHO1001P1, 27 _|ZD12A01600| 1BAt6 13/16-12UN| 927.2 |YNO1HO1002P1) 36 |ZD12A01800| 1B A18 17/16-12UN| 634.0 |YNO1HO1003P1) 41 | ZD12A02100) 1B A21 Female Screw size | Applicable’ Opposing A | tube 0.0 | Plug parts No. inate (HEX) st A 1-14UNS 921.7 |YNO1HO1004P1} 32 13/16-12UN| 027.2 [YNO1HO1005P1) 36 1 7/6-12UN| 934.0 [YNO1HO1006P1} 41 (6) Pig for hal clamp 40H For standard pressure : 20.6 MPa (2990 psi) Plug O-ring Size} parte, [CMM] D mm mm |Hmm part No. sre |zer2008000| 38.10 | 1748 S59 | aszoi02 314 |Z£12012000| 47.63 | 22.23 | 188°} 11 jzD12P02600 + |ze12@18000| 52.37 | 26.19 |88:75°| 11 212P03400 4114 2€12020000] 58.72 | 30.18 |“.58") 11 'z012P03800 For high pressure : 41.2 MPa (5970 psi) Plug T ‘O-ring Size | partno, [ORm|Dmm| Emm Hmm) anno 112 |ze13008000] 4.49 | 10.24 |*857"| 9 [2aaszeato1 314 |2€13012000| 50.80 | 23.80 |S.) 11 |z12P0z600 1 |2E13Q16000] 57.15 | 27.76 | Se/e> | 13. [zD12P02400 1114 2613020000) 66.68 | 31.75 |“4,5&| 15 |zp12Pcse00 14-1011. TOOLS 11.6 SPECIAL SPANNER FOR TUBE Applicable tube diameter Part No HEX (mm) Drawing of a special spanner mm (in) mm (in) 182781, 2 16 (0.881) | 24217160 ar oe0) anit sr) 127 (0800332) 701210 gt 18 (0.709) | 2421T138 32 Pane, woe Boo) ee = ox OE ago) 2F SO 800335) 702.76) 420.9) TA ges oH 22 (0.866) 24217130 36 (0.908), eran NEEL [Bessy ne 12740500332) 7091429) Seopa 28 (1.10) 2421715 at dl ne ae Ne. HEX 2043.15), 10014.29) gest] 28 (4.10) 24217234 46 ok Or} parteno. FAH sa) a 19.08% (07603) 80(3.18) , 1004.20) Fe5(0 045) | 32 (1.26) 24217232 50 od [Poe nee" 119.087 (0.76038) 816,19), 9003.58 35 (1.38) 24217314 55 ad exes 11-1111. TOOLS 11.7. SPECIAL TOOLS Tablot1-4 No.| Tools name [Tools No ‘Shape Applicable % [E Allen wrench | zrooq10000 | 5 x Pump 1 Nominal oe eee B:10,C:11.3 vas. L Commercial oo angth (Lt) - ut ength = Requied length 40 (1.87°) - 10 (0.98") = 30 (1.18°) ‘Spanner or 2 socket |General toots Heh Nominal 8 : 17 3 | Spanner | 2712A36000 Swing motor Nominal $ : 36 AB port 81 (3.19°) - 16 (0.63") = 65 (2.56") ‘Addiional M10 X22 forti0 Bye bot 7 Plug 2€72X12000 Jor M10 eye bol For slinging the PRS/4 swing motor Pron ‘O-ring 410 Eve bot Eye bot | 2891C01000 : For slinging the One. or swing motor commercial & equivatent : Flare hose ¢ t Fm T ! iB Eye bolt Pl i 2F83P22000 (Nominal wed 22 aeinrant | Fare tose Eye tor | 2897000800 ve 2F93N22000 ¢ iasie: Nut ' CAdationas i treading for Me Eye bot 11-12Tablet1-4 11. TOOLS Me Eye bolt 8X 18 Plug YNOTHO10011 Esko + reading Norninal \ 7 | 4414UNs | Flare nose Eye bot | 2891C00800 | _AAAUNS a MB Eye bolt | | MB x18 ‘Aadtiona Plug | YNotHot002e1 threding NX Nominal 8 | taner2un | y Flare hose Eye bot | 2S91C00800 ee Piug 2E25F 08000 i‘ PrI2 For slinging the Coupling swivel joint halt TORX driver seems For instrument 10 proof) — | Point shape renal eevee 730 | \ (For M6) 11-1311. TOOLS 11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND (1) For general use ue Manufacturer ae Loctite | Three-Bona | Fou tow #242 1 300K | strongth Screw locki crew locking aa ia Middle compound strength High ial 1908 | strength Sealing commons | #585 te15 | Sealing (2) For specific location No. |__Use | Manufacturer] Name Equivalent Aoplicable (Manufacturer; Loctite) #1904 |Anti-seizure loyiinder Three-Bond |#1218 gray #8609 Swing motor #1211 white #52011 | wing motor fe r3038 leon [Main pump (Manufacturer; Theee- Bond) Beate #222 # 134an Main purnp 1 & #277 [#1907 Pilot valve adhesive (Manufacturer; Three- Bond) Loctite Parmatexosd |v 1121 Hydraulic ol tank Sumitomo Chemical Co., {cyano Bond PO-t Hose Ls Shel Shell Alvenia EP2 |New Molyknock Grease 2 |Swing bearing grease bath petroleum 11-1411. TOOLS 11.9 SUCTION STOPPER 41.9.4 COMPONENTS No. | NAME PARTS No. [QTY — SUCTION STOPPER ASSY [24100P076F2| 4 [ROD 24207486001] 1 Sines 2_[NUT zn16co8007 | 1 — 3 [COVER lataTat2302| 1 It 4 [O-RING |4579106 1 | 2Nut 7 3 cover 4 O-1ing Fig. 11-1 Components of suction stopper 11.9.2 DIMENSION 20 cal eet T *e 113 (4.45") M8 NUT 7 _Iil os 0.3155 dl ; g a Ty & fags e og s| ge, es e & 3 @ Bel Sl 8) | Grsacn et “| RRO. Sorry | “ie (4.25") COVER Fig. 11-2 Dimension of suction stopper 4193 APPLICABLE MODEL NN Applicable xclale wl model slzlele/S)S\/8le/#l Ble ~ S18) S/S /S/8/2/28/8/ 818/818) [roto 9-1 515 | 5151515151551 81515 | 8 | | 2a100Po7er2 e[olofofofofolofolofofolo] 11-15,11. TOOLS 11.10 COUNTER WEIGHT LIFTING JIG (1). Standard eye boit Fig. 11-3 Eye bolt 11-16 Size] Vera MB [mao (ate 18 18 PartNo. | atin | j ant | Meta | Z5eiG00800| 80(176) | 2891001000] 150 (331) | M12 22. 2891001200 220 (486) Mi6 27 2891001600| 450 (982) [zo 30 2391602000 | 630 (1390), 24 38 891602400 950 (2080) [so 45 2891603000 | 1500 (3310) use| 55. 2391603600 |2300 (5070) aa] [maa 2400 (7480) [4500 (9820)|41. TOOLS 11.11 UPPER FRAME LIFTING JIG aa ra 7) | | 130(8.12°) 65 (0.748")19 80 B15) Qty :2 sets Material : Mild steel Fig. 11-4 Uppor frame lifting jig 1-1711. TOOLS 11.12 ENGINE MOUNTING PEDESTAL 245 (2.65) Material : Wood Unit ; mm (inch) 6 4 ar Als =H g TT] alts z z é ® 744 (29.3) 409 taf 945 (97.2) 5 °. 1 6 215 500 toa Tay 2X 1 piece 4X1 piece 1X tpiece 400 (157) 570 26.4) EE 430 (185) +s dig ayer a | boca a a tT a Es ras q ‘150 \) 3 @ als 2 leo 3 124(0.95) a" | 2 124,098) 5X1 piece 3X1 plece “670 (26.8). foo e572) 2 | 6X8 ples Sl ect fe 4049.93) Ee Tao OY 0.30, Fig, 11-5 Engine stand 11-1811. TOOLS 11.13 TRACK SPRING SET JIG M30 _ Retainer nut S~ Retainer plate 700 380 Base Fig, 14-6 Track spring set jig 11-1911. TOOLS [MEMO] 11-2012. STANDARD MAINTENANCE TIME TABLE q ‘TABLE OF CONTENTS 12.1. STANDARO WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4 12.2. ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) cnn . vanes AB: 12.2.4 MEASURING METHOD 7 ne 1246 12.2.2 WORKING CONDITION... ene 2A 42.2.3 STANDARD TIME CONSTITUENT. Fl 12-48 12.24 MEANING OF WORDS IN USE 1247 Book Code No, SSYN1218E01 12412, STANDARD MAINTENANCE TIME TABLE Issue “Date of Issue Applicable Machines [_____ Remarks [SK200-8 YN11-45001~ SBYN1218E01 First edit ju eee August, 2006 SK210LC—8 : YQ11-06001~ (ASIA, OCE) 12-212, STANDARD MAINTENANCE TIME TABLE PREFACE, (1) Working Conditions 1) Workers More than one worker shall be ‘st class service technician (having five years or more of field experience and having received training in the operation). 2) Equipment Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The ‘maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for specific self inspection activities. 3) Place ‘Aflat land where work may be performed and to which a service car or a truck crane is accessible. (2) Range of standard maintenance time i 1) Standard maintenance time=Direct maintenance timexPreparation time 2) Direct maintenance time : Net time actually spent for maintenance 3). Spare time ‘Time needed to move machines for service, prepare safety operations, discuss work, and process the needs of the body. (8) Extra time (not included in the standard service time) 1). Repair time Machining, sheet metal, welding, melt cutting, folding and extracting tolls, servicing parts, and painting. 2) Items excluded from service time because of uncertainty in time Receiving 2 vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults, diagnosis, and inspection. 3) Indirect time Time for; field work, preparation of necessary paris before leaving for work, return for field work, waiting time because of user's convenience in the field, paper work after returning to shop, and preparation of bills. 4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately. 5), Separate calculation : The operating time for service cars, trucks with a crane and erane trucks. (4) Applicable machine for estimation of standard maintenance time 1) Standard machine 2) A.well maintained and controlled machine with a standard combination of attachments which is used in a general environment. 12-312, STANDARD MAINTENANCE TIME TABLE 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR (1) Standard maintenance time table 1) 2) 4) 5) Units of working time : 6 minutes = 0.1 hour Calculating method of standard maintenance time Maintenance time=Working timexNumber of workers (Working time=Maintenance time+Number of workers) When more than one operation is going on ‘Add each standard service time. A pure time (readily started) is given exceptcovers easily removed by hand. Assy works include the following works marked with black dot « OIH : The removing and attaching time is not included ‘Abbreviations in the table. AIC Air conditioner cv Control valve on Over haul ASSY — : Assembly cyl Cylinder SOL: Solenoid ATT —: Attachment BIG Engine sw Switch BRG Bearing Fhose : Flexible hose v Valve (2) Classification of working code No. Group Remarks Ee 01 [Attachment Indicates installing, removing, replacement anc overhaul 7 02 |cab & Guard 03 [Swing frame 04 [Travel system 95 [Etestie Indicaies the instaling, removing and replacer ent of single items lequipments i 09 (|E/Grelation Indicates overhaul of the single engine. ot |(Materiais prepared by manufacturer ) (8) Conditions for standard service time of the engine 1) 2) 3) Tools designated by B/G maker are used Genuine parts are changed Correct working procedures are observed. + The time required for works specified in this Chapter shows the total time for maintenance. 12-412. STANDARD MAINTENANCE TIME TABLE croup Location MORO yi Remarks is (00 [Bucket relation ‘See 3212 PEE IEEE 01 [Bucket ASSY Deizenvatacn| 1 pe. [Include adjustment. 06 02 |+ Bucket ataching and detaching postion | Preparation} 1 pc. on 03 |+ Bucket attaching pin Betachiatacn| 1 Include stopper pin. on 04 |+ Bucket drive pin Detachiatach| 1 on 05 |+ Bucket sling and movement Preparation] 1 pe. 02 06 | Bucket (single) OI | 4 pc. | Notinclude attaching and detaching | 2.4 07 |+ Tooth Replace | 1pc. | 06 08 |+ Side cutter Replace | 1 pe. 12 09 |+ Bushing Replace | 1 po. 06 10 [Arm relation [See 92.1.3 11 [arm ASSY SESE Detachiatech| 1 po. 5 12 12 |+ Bucket cylinder attaching and | Preparation} 1 po. | 04 detaching position and piping 13. |+ Bucket cylinder rod pin Detachattach | 1 pc. {Include stopper pin on 14 |+ Bucket cylinder head pin Detachiatch | 1 pc. |include stopper pin on 18 |+ Bucket cylinder assy Detactiatach | 1 pe. on 46 |+ Arm cylinder rod pin etaeriatacn] 1 pe. |Include stopper pin ot 47 |+ Boom top pin Detzchiatiacn| 1 po. [Include wire stop pin. o4 i 48 |+ Arm sting and movement etacniatach) 1 pe. 02 2 [30 [Boom relation [Seoda.1.4 5 [31 [Boom ASSY T Betcnatacn| 1 pe 14a 32 |+ Boom attaching and detaching posiion| Preparation] 1 pe. on 33 |+ Boom cylinder temporary slinging Preparation} 2 pes 02 34 [+ Boom cylinder rad pin Detachiatiach | 2 Include two stopper pins. | 02 35 |+ Boom cylinder piping Detactvaticn| 2 pc. 02 26 |+ Arm & bucket piping Detachiatacn| 1 pe. 02 37 |+ Boom assy temporary slinging | Betachvatacn | 4 po. | o1 38 |+ Boom foot pin Betachitiacn| 1 [Include stopper pin. 02 39 |+ Boom assy slinging Detachiatacn| 1 po oz 40 |/Arm cylinder attaching and detaching | Detacnatach | 1 pc. 04 41. |+ Arm cylinder piping Detechisticn| 4 pe. 02 42 |» Arm cylinder head pin Detactvatach | 1 pc. |Include stopper pin on 43 |+ Arm cylinder slinging Cetachatacn | 1 pe. on 50 |Boom oyinder attaching and detaching | Detactattach| 2 pes. 07 51 |+ Boom cylinder piping Detachatach | 2 03 52 |+ Boom cylinder head pin Detachiatisch | 2 pes 02 53 |+ Boom cylinder slinging Detechiattacn| 2 02 60 |Bucket cylinder oir 1 36 61 |+ Pin bushing Replace | 1 _ | include seal. 12 70_|arm cyindar om 1 36 12-512, STANDARD MAINTENANCE TIME TABLE Group Location Moree) Unit Remarks a 71 |» Pin bushing Replace | 1 set include seal 12 ~ | 80 (Boom cylinder ort 2 70 © | a1 |+ Pin bushing Replace | + set include seal 42 10. |Cab relation See 38.12 11 [ca assy Datechetacn| 7 po. 14 12 |+ Front lower glass, floor mat Detzcnetact| 4 po, each oa 18 |+ Seat rear cover top, bottom Detacniatac | 4 places| 02 14 |+ seat rear cover top, bottom Detachiataeh 4 pe. each 02 46 |+ Right side panel (include NC duct) | Oetechatach| 3 03 16 |+ Cable and hamess (electric) | ewenattach) 6 02 17 |+ Cab mounting bott Detacattaeh | 8 pes. 02 18 |+ Cab slinging Detaciattach |3 places! 02 20 [Guard relation See 33.14 21 [Bonnet assy (11) Deiachitacn| 1 pe. 02 22 [Guard (5) Dstachiatacn| 1 pe 02 23. |Guard (6) Detachatacn| 4 pe 02 24 |Guard assy (3) Detaciatacs] 4 pe. 02 25 |Stay (7) etaratacn| 4 pe. 02 B] 25 [ouars2) outaowatach | 1 po 02 G | 27 |Panel assy (21) Dotachvattach | 1 pe. 0.2 |) 26 [Panel assy (23) Detecnatach) 1 pe 02 8 | 29 |Panet assy (22) Detachiatacn] 4 pe 02 | 30 [Guard assy (18) etacwataen] 1 pe. 02 31 [Guard (14) Detachatacn| 1 po 02 92. |Guard (15) etaevatacn| + po 02 38. [Guard (17) Detacatacn| 1 pe 02 34 |Pllir (14) etacvatacn| 1 po. 02 35 [Beam (4) etachitaen] 1 pe 02 36 [Pillar (10) Detachatacn| 1 pe 02 37 [Pillar (12) Detactvateen| 1 pe. 02 38. |Guard assy (18) Detacvatisen} 1 po 02 39 [Guard assy (13) Detaciataen | 1 pe 02 40 | Guard (19) Detachiatacn| 1 pe 02 41. Cover (2) Detach} 4 pe. 02 42 |Guard assy (1) etachatacn| 1 pe 02 43 |cuard assy (3) atachsttacn| 4 pe 02 44 {Plate (20) Detachatiacn | pe 02 45 | Cover assy (1) etacnanacn| 1 po 02 Note: The numbers the peronthesis ike guard (14) match the guard numbers on the upper structure, 12-612, STANDARD MAINTENANCE TIME TABLE Group Location busibadead fet Remarks ee done Hour 80 [Under cover relation See 33.1.8 61 [Cover (1) Deieenatacn | 4 po. oA 52 |Cover (2) ataciatach | 1 po o4 53 [cover (3) Detechlatach| 1 po oa 84 [cover (4) Detachiatach| 1 po oA 85 [Cover (5) Detaciatacn| 1 po. on Z| 56 |cover (6) Delacistach | 4 po ot | 87 (Cover (7) Detactten | 4 po o4 | 58 |cover (8) Datacivataen| 4 pe ot é 3 [[o0" [counterweight retafion e035 1 |Counterweight ASSY Deachiatech| 1 po 06 62 |+ Counterweight iting eye bot | Detaavarach| 1 get oA 63 |+ Counterweight temporary singing |Preperation| 1 pe. 02 84 |+ Counterweight mounting bolt | oetentataen} 1 pe. 02 65 |+ Counterweight slinging Detnetattien| 1 pe ot 70 [intake relation See 33.1.9 11 |Aircleaner ASSY Derschiataen| 7 pe. 04 12 |+ Hose (3) Detachotecn| 4 of 48 [+ Air cleaner mounting bolt Detacvntach| 1 sat 02 14 |» Element Replace | 1 01 20 [Exhaust relation fs0033.1.10 24 [Muifier ASSY Deacniatacn| 1 pe 04 22 |+ Ubolt otachianaen| 1 pe. 02 9 | 23 | Clamp ASSY etaevataen| 1 pe 02 a ‘© |_30 [Radiator relation S00 33.1.12 3 | 31 [Radiator ASSY Deaciatech| 1 pe. 40 & | 32 [+ Cootant (Luc) Replace | 1 pe 03 33 |++ Concentration of coolant Measuring | 1 pe 02 aa |+ arc condenser betactiatach| 1 pe. 03 a8 |+ Stay Delachatach] 1 po. 01 38 |+ Bracket ewctatacn | 4 63 37 |+ Sub tank hose Detachatacn] 4 po. oa 38 |+ Fan guard Detaciataen| 1 pe. 03 39 |+ Water hose (radiator~£/G) | oetecvatacn) 2 08 40 |+ Radiator mounting bolts removing | Detachatiacn| 1 set 02 41 |+ Under cover etacnaieen| 1 pe. oa 42 |+ Hydraulic oi tank suction stopper | Detacivatacn| 1 pe 02 43. |+ Hydraulic oll piping Detachietacn| 1 pe os. "Note: The aumnbers in he parenthesis ike cover (2) maich the guard numbers on the upper stuciure 12-712. STANDARD MAINTENANCE TIME TABLE croup Location WIRE ya romans el 44 |* Inter cooler hose & tube Detachiatiach | 2 pos. 05 {EIG to inter cooler) 45 | Radiator titing or hoisting Detacrvatacn| 1 pe. 02 46 |- Radiator inter cooler core & oil cooler | Cleaning | 1 pe. 4.0 50_[Fuel relation See 33.16 51 [Fuel tank ASSY Detachiatiacn| 1 po. 18 52 |+ Fuel Replace | 1 pc. 03 53 |+ Hose (water separator side) Detechitiach) 2 on 84 |+ Water separator Detechiatach | + po. O41 85 |+ Tube (tank side) Detachiattach| 1 o4 57 [+ Fuel tank installing bolts Detzchiattach| 1 pe. 03 68 |+ Tank slinging Detachiatiach| 1 pe. oa [Other necessary works Betechiatich} 1 po. [Removing and installing guard | 0.4 60_|Hydrauic oil tank relation [See 33.17 61 [Hydraulic oil tank ASSY Detacnvatach | 1 po. 30 © | 85 f+ Cover Detechiatach | 4 po. 02 5 + Hydraulic oil Replace | 1 pc. 05 a | 68 |+ Pilot drain hose Detechiatach | 1p. 02 3 + Pump suction hose Detachattach | 1 po. 08 © | 70 [+ Mounting dott Dotaciatach | 1 pe. 02 © | 71 |+ Hydraulic oil tank slinging Delaoniattach | 1 po. 03 72 |e Return fiter Replace | 1 02 73 |+ Suction fter Cleaning | 1 02 80_|Pump relation See 33.18 @1 [Pump ASSY Detachvatach | 4 pec 32 82 |+ Hydraulic oll tank cover Detachiattach | 1 pe. 02 83 |+ Strainer & stopper Dotachattach| 1 po. 03 84 |+ Piping Detzchiatach| 1 set 1.0 85 |+ Guard Detachlatach| 5 pcs. 10 86 [+ Pump slinging Detachiatach | 1 pe. 05 87 |+ Cleaning Cleaning | 1 pe ot 88 |+ Vent air Adjust. | 1 po ot 89. |Pump ASSY on | 1 pe 40 90_| Swing motor unit relation [See 33.14.19 91 | Swing motor ASSY Detachiatach| 1 pe. 24 92 |+ Piping Detachatach| 1 set 10 93 |+ Mounting bot Detachattach | 1 pe. 07 94 |+ Unit singing Detechvatach | 1p. 05 95_|+ Cleaning and sealant Cleaning |_1 set 02 12-842, STANDARD MAINTENANCE TIME TABLE Group Location Merete Pe Unit Remarks oe 96 [Swing motor om | te. 36 97 | Swing reduction gear om | 4 pe. 42 700 [Swivel oint relation See $3.1.20 701 [Swivel joint ASSY Detachiatacn | 1 26 102 |+ Piping (Top part only) Detachiaiacn| 1 set os 103 |+ Whirl stop bolt Detachiatacn | 4 02 104 |+ Cover Dotachiatiacn| 1 04 405 |+ Joint & elbow Detacriatach| 1 set 04 406 |+ Mounting bott Detachiatach| 1 sot 04 107 |+ Swivel joint slinging Detachiatach| 4 04 108 |+ Cleaning Cleaning | 1 set 03 109 | Swivel joint OM | set |Removing and installing guard] 3.6 other necessary works Cetachiatach| 1 set |Lower piping 06 10 | Mull control valve (For Oceania) See 33.115 1H [+ Mull CIV ASSY Detachiatach| 1 (Alter removing guard 17 g | 112 Joie hose name on muni Cv comecting nose] Oetaciatach] 1 set 03 | 113 |+ Piping Detachiatach| 1 set 0s | 114 [+ Mounting bott Detachiatach| 1 set 03 Z| 215 |+ cleaning Cleaning | 4 set 02 8 JOther necessary works Detechiatiach| 1 set |Guerd 04 1120 [Main control valve See 35.116 121 [Main control valve ASSY Detactiattach| 1 pc 26 122 |+ Attach tag to port name of pipe | Preparation! 1 pe. 06 123 |+ Piping Detachiatach| 1 set 17 12d |+ Bracket mounting bolt Detacniatach| 1 pe. on 425 |+ Valve slinging Detachiatach| 1 pe oa 4126 |Main control valve ASSY Detachiatach| 1 set 60 Jother necessary works Detacvatach| 1 set [Guard 04 190 [Valve relation OPT 131 [Solenoid valve ASSY Detacwatach| 1 10 192 |+ Attach tag to port name of pipe [Preperation] 1 02 133 |+ Piping Detachiatach| 1 sot 08 14 |+ Mounting bolt Detactvatacn| 4 03 140 [Engine (ES) mounting relation see 33.113 141 [Engine ASSY Detacwatacn| 1 pe. [Alte removing pump & radiator | 1.8 142 |+ Hames connector & grounding & | Detastvatech| 1 po. 03 cable connection 143 |+ Fuel hose Detachiatech| 1 pe oA 12-912. STANDARD MAINTENANCE TIME TABLE Group Location Peat Unit Remarks fae 144 [+ Others Detaewatacn| 1 set 05 145 |+ Mounting bott Detachiatach| 4 pe. 08 146 |+ Engine stinging Cetgcrianach| 1 set 02 147 |+ Cleaning Cleaning | 1 pe. 03 148 | Engine OH | set Reference for engine (Chapter 51) Other necessary works Detachlotsch| 1 set |Removing and instaling guard | 0.6 Cetacratech| 1 set {Removing an stating Counterweignt | 0.6 Detacratach| 1 set |Removing and installing pump | 3.2 Detachiatach) 1 set_ [Removing and installing aircleaner| 0.4 2 DetacWatach| 1 set [Removing and installing muffler | 0.4 = Detachiatiacn| 1 set |Removing and installing radiator | 4.0 5 ® 1780 [upper trame [See 8.1.21 8 1751 lUpper frame ASSY Deiechatach| 1 pe. [After removing swivel joint 13 182 |+ Mounting bolt Detachiataen| 1 set 04 188 |+ Upper frame slinging Detacwatiacn| 1 pec 04 184+ Cleaning Cleaning | 4 pe. 03 185 |+ Sealant Apply | 1 pe. 02 Other necessary works Detachiatach| 1 set [Cab 14 Deizevatacn| 1 set [Guard oa Cotechatacn| 4 aet_|Counterweight 00 Detachiatiach| 1 set [Boom 14 00 [Travel relation See 34.12 01 [Track link ASSY Detachatiach |One sidelinclude adjustment of tension | 4.5 02 |+ Track ink staching end detaching ostion | Preparation One side| of 03 |+ Master pin Detachattacn [One side| 0s 04 |+ Track link extending and winding | detachiataen One side! 0s 05 Shoe plate Replace | 1 pc o4 g & [10 [Upper rotter relation See 34.13 3 A [Upper rotor ASSY Oeiachiatach| 1 [After removing track link 02 3 | 12 |Upperrotter on 1 10 © [20 [Lower roller relation [See 34.14 21 [Lower roller ASSY Detachiatach| 1 02 22 |Lower roller on 1 15 30. [Front idler relation See 34.1.5 31 [Front idler ASSY Detactvatach [One side|Atter removing track tink 06 32 |Front idler ASSY stinging Detachatach |One side| 02 33 | Front idler ASSY Detaching |One side 03 34 [idler ASSY of _ [one sice| 10 12-10412. STANDARD MAINTENANCE TIME TABLE Group Location wort Pe nit Remarks ae 36 [idler adjuster ASSY OI One side| Replace spring 24 36 |+ Grease cylinder OI One side| 08 40 [Sprocket see 34.1.6 41 [Sprocket Replace [One sidel After removing track link 06 50_ [Travel motor relation See 34.1.7 51 [Travel motor ASSY Detachiatiach [One side Afier removing track link 17 52 |+ Motor cover Detachiatach |One side| ot 53 |+ Hydraulic piping Detachiatiach |One side| 0.9 ¢ | 54 [+ Motor mounting bok Detachiatach |One side! 08 5 | 55 |+ Motor stinging Detachiatiach |One side} ot 2 | 56 [Motor cleaning Cleaning |One side| O41 & | 57 [Travel motor OHH |One side| 36 5 58. | Travel reduction gear Ol [One side! 36 {80_[Swivel joint relation 81 [Pipe on ewival joint travel side Deiachianach| 1 pe. [nce tomar aay ova evden | 08 62 | Swivel joint OH} 1pc. |See33.2.6 36 70 [Swing bearing jsee04.1.0 71 [Swing bearing ASSY Detachvatacn| 1 pe. After removing upper frame 07 72. | Swing bearing mounting bolt Detachatiacn | 1 po. 0s 73. |Swing bearing slinging etacratiacn| 1 pe. 03 [Controller 6-1 |Conirolier (KPSS) Replace | 1 08 6-2 |Gauge cluster Replace | 1 10 -4 |Air conditioner Amplifier Replace | 1 20 Diode 2 | 0-4 [Diode Replace | 1 08 & | 0-5 |Diode Replace. 1 03 3 | 06 [Diode Replace | 1 03 2 | 0-9 [Diode Replace 1 03 Bono cece asa ap i 8 |D-12|Diode Replace | 4 03 D-13|Diode Replace | 1 03 D-14|Diode Replace | 1 03 0-15 | Diode Replace | 1 03 0-16 | Diode Replace | 1 03 0-17 |Diode Replace | 1 03 12-1112. STANDARD MAINTENANCE TIME TABLE Group Location ote T unit Remarks oe D-16 [Diode Replace | 1 03 D-19 Diode Replace | 4 03 0-20 [Diode Replace | 4 03 Electric equipments Ext [Fuse & relay box Replace | 1 08 &-2 |Alternator Replace | 4 10 €-3 |Hour meter Replace | 1 03 E-5 |Hoxn (High) Replace | 4 03 £-6 [Hom (Low) Replace | 1 03 £-7 [Tuner AM & FM (OPT) Replace | 1 08 E-6 |speaker lett Replace | 1 03 E-9 |Speaker right Replace | 1 03 E-10| Receiver dryer Replece | 1 _|Include gas sealing 40 -11 |air compressor Replace | 1 |eeriecoutereohirrornganciessing. | 1.0, E-12| Battery Replace | 2 04 e | E13 Travel alarm (OPT) Replace | 1 os 5 | E-14| cigarette ignter Replace | 1 03 S | £215 [Fusible tink Replace | 1 02 8 | g-24JoPs antenna Replace | 1 05 % | -25|PDC antenna (IT controller) Replace 1 or 1 |e20z7|Acoo!amergency mode resistance 12 | Replace | ‘pair 08 Light T-1 [Boom work ight iat Replace | 1 [Bub 02 L-2 |Work tight right Replace | 1 02 8 [Swing fusher & work light (lft) Replace | 4 02 L4 [Swing fusher & work light (ight) | Replace | 1 02 LS |Room light Replace | 1 02 L-6 [Boom cylinder work light (right) Replace | 1 02 ‘Motor 1M [Starter motor Replace | 1 [incite Comwatntronovnganéwatairg | 1.0 M3 | Winer motor Replace | 4 08 Mt [Washer motor Replace | 4 08 M8 [Grease motor (OPT) Replace | 4 08 M9 | Skylight wiper motor (OPT) Replace | 4 08 Propotional vaive PSvAlAim variable recreuation propotonalveive | Replace | 4 08 psv.s/P2 bypass cut proportional valve | Replace | 1 rowcenorenouredecrrenanyosesuing | 0.8 Psv-c|Travel straight proportional valve | Replace | 1 08 12-1212, STANDARD MAINTENANCE TIME TABLE Group Location [Work 0 66) ni Remarks ae Psv.0|P1 bypass cut proportional valve | Replace | 1 0s psves]P1 pump proportional valve Replace | 1 0s sve2|P2 pump proportional valve Replace | 1 os Relay Ht Re [Battery relay Replace | 1 03 R-2 [Starter rotay Replace | 1 03 R-3 [Glow relay Replace | 1 03 R-4 [Safety relay Replace | 1 ot R65 |Hom relay Replace | 1 ot R6 [Work light retay Replace | 1 ot R.23| Auto idle stop relay 4 Replace | 1 ot R-24 | Auto idle stop relay 2 Replace | 1 4 | R-25|£/G emergency stop relay Replace | 1 ot | R-26 | Safety lock lever relay Replace | 4 on R-28| Alternator relay Replace | 1 | a4 R-29| Wiper motor relay (Normal rotation) | Replace | 1 o4 |R-30|Wiper motor relay (Reverse rotation) | Replace | 1 of § | R-31|Wiper motor relay arc prevention relay! Replace 1 04 = | R-82|Washer motor relay Replace | 1 on 3 |__|Sensor sania S| | 8 Pressure sensor : Bucket digging | Replace | 1 03 Pressure sensor : Bucket dump Replace | 1 | 03 Pressure sensor : Boom up Replace | 1 03 SE-4) Pressure sensor : Boom down Replace | 4 os SE-5|Pressure sensor : Swing Replac 1 03 ‘SE-7|Pressure sensor : Arm in Replace | 1 03 ‘SE-8 Pressure sensor : Arm out Replace | 1 03 SE-9/Pressure sensor : Travel right Replace | 1 |inclute uncer coverremeving andintating) 0.5 /SE-10) Pressure sensor : Travel left Replace | 1 jinclate undercover removing andinstating! 0.5 SE-11| Pressure sensor : P2 side OPT. Replace | 1 |inclie undercover removing andinstating) 0.5 [se-13] Engine speed sensor Replace | 1 |Inctuse undercover removing ancintating| 0.5 ISE-15)Engine water temperature sensor | Replace | 1 —_|incuse guard emoving nd instating | 0.5 ISE-16| Accel potentio Replace | 1 05 SE.20|Prossure sensor: Pt side :P1 side (OPT}] Replace | 1 |incudeundercover removing andinstling| 0.5 SE-22)Pressure sensor : P1 pump Replace | 1 0s 'SE-23| Pressure sensor : P2 pump Replace | 1 0s Solenoicl | SV-1 | Swing parking SOL T Replace | 1 [imusscronen vive necro aonasing | 0.5 SV-2| Attachment boost pressure SOL Replace | 1 |racovoporiaraitasrencigandnsaing | 0.5 12-13,12. STANDARD MAINTENANCE TIME TABLE Group Local ote Unit Remarks [ents ‘SV-3|2-speed travel SOL "| Replace | 1 (navapemnavanncrnon onic | 0.5 8V-4| Safety lever lock SOL Replace | 1 |rewencroroutvsvenscrreningwaieaivn, | 0.6 a ‘Switch 7 B /swalkey owitch Replace | 1 03 § |Sw-4|Swing parking release switch Replace 1 03 E |we7fenain of pressure teh repace | 41 03 5 |SW-8|Clogged air filter switch Replace 1 03 i | sw-t0 Horn switch (left) Replace 1 03 © | sw-ti|Safety lever lock switch Replace | 1 03 ‘sW-19] Wiper interlock switch Replace | 1 03 sw-20]Attachment power boost switch (right)| Replace | 4 03 sw-27]Engine cooting coolant level switch | Replace | 1 03 eee EEE eee 12-1412, STANDARD MAINTENANCE TIME TABLE, 12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) Preface This standard working time is based on the work time required for service of engine like disassembly, check, adjustment and assembly and so on under a following condition This standard working time is provided under the following conditions. 12.24 MEASURING METHOD (1) The time from the worker beginning working at the regular position of machine to the returning to the reguler position after completion of the work is counted as working time. (2) The measuring unit is in 0.1 minute, and then round up the fractions. (3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two workers is counted 2s the working time. But light work which can be carried out easily by a person and the efficient is higher is counted as a workman 12.2.2. WORKING CONDITION 42.224 TOOLS, INSTRUMENT (1) Hand tool: ‘Tools which are commercially available and each workman usually carries (2) Common tool Tools which are commercially available and each workman do not usually carry but the storing place is specitied (3) Special tool; Tools especially prepared by HINO Motors Lid. and the storing place is specified (4) Machine tool ; ‘When measuring equipment and instrument are used, the time required to move parts lo the specified place is included but the time waiting for tool is not included as a general rule 12.22.2 WORKING PROCEDURE The disassembly and assembly should be carried out according to working procedure prepared by HINO Motor's Ltd. Service Technical Dept. Training Group. 12.2.2.3 STANDARD WORKMAN QUALIFICATION, Workmen shall basically acquire 2~3 years of maintenance experience of HINO 122.3 STANDARD TIME CONSTITUENT 1223.1 STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD ALLOWANCE TIME (1) Net working time The time workman works actually and the time required for measurement, cleaning, and so on is included, but the time required for troubleshooting is not included Standard time Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts and s0 on, and for the work site clean- Standard allowance time Calculate the allowance time directly required for workmen from the following equation 2 2 Net standard time x HINO allowance rate Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position and so on. 12-1512. STANDARD MAINTENANCE TIME TABLE 12.232 ALLOWANCE RATE, STANDARD PREPARATION TIME 12.2.3.2.4 HINO allowance rate (0.15~0.75) (1) Basic rate : 0.10 (2) Working posture allowance (Fatigue coefficient): Take any one of the followings according to the work contents. Standing work : 0.05 Work in bent posture : 0.19 Work while lying : 0.15 (3) Difficult work allowance : 0.30 (4) Seized rusted section (For new vehicle) : 0.50 Take any one of above (3) and (4). Min. allowance rate = Basic allowance + standing work allowance = 0.1+ 0.08 = 0.15 Max, allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 + 0.5=0.75 12.2.3.2.2 STANDARD WORKING TIME (1) Working standard time : 3 minutes {One time for a set of works) (2) Special toot standard time : 3 minutes (One time for @ set of works) (3) Standard time of non-portable machine : 3 minutes (For single work) (4) Part standard time : 6 minutes (up to 10 items), 10 minutes (10 items or more) (One time for a set of works) (5) Test : 15 minutes (One time for a set of works) (6) Preparation time for chain block, measuring instrument, piston, heater and so on : 3 minutes (One time for a set of works) (7) General cleaning : 2 minutes (One time for a set of works) (8) Safety treatment like wheel stopper, and so on : 3 minutes (9) Visual checks : 2 minutes The preparation time is classified into as described above, and only items required for the every work are selected, calculated and counted as preparation time of the work. 12-1642. STANDARD MAINTENANCE TIME TABLE 12.2.4 MEANING OF WORDS IN USE + Completed machine : When detaching, replacing and adjusting the specified parts, it means the time which is determined by addition of the preparation time, net working time and standard allowance time of the work. + Single unit When detaching, replacing and adjusting the specified parts, it means the time in which the preparation time of the work is omitted and which is determined by addition and subtraction to/from the work for "Completed machine’. + Removal and installation The work to remove specified parts from machine and to attach the parts, and then to perform necessary adjustment + Simultaneous replacement to perform necessary adjustment + Adjustment The work to carry out necessary adjustment with the specified parts removed or attached + Overhaul ‘The work to remove specified assembled parts from machine, disassemble and check them, and then to attach the spare parts to machine and to perform necessary adjust mert + Include Explains the contents of work to make the specified work range clear + Exclude ‘Shows the wark which is not included in the specified primary work + Unit Time is shown by hour. 424742. STANDARD MAINTENANCE TIME TABLE seam [_ see Work No. Work ‘Work unit Works a 7 Poser] aro = = Sonaa| rg anon : eer eee eaustnent eet machine _|Valve clearance adjustment es a 2 | 00109 [enone aausimen 8 set Comotdl a setandronae advent | — = sal Ea wai oe a | otis |eompression messing Cont enna or oa “8 a Jand battery specific gravity measurement 6 asarz {Replacing oytinder, block, piston, ing ‘Single unit |From engine is removed condition | 27.4 316 tnd ne smuteneouty Reolcng cork sat nap «| er sna From engines erove conatin | 20.8 a8 90013 and liner simultaneously. 7 epee eee nang ener son oe ve Sec thon Replacing cylinder block ‘Seto uni clade: Instaling expansion plug kneck | 24 isa bn | ors” Reinang cance Signi Prom anghe wvoved onlin | wa 12 | oorar_[Repacg wank shat taa boarg [slew Pom enghe serove anaton [134 wa enor aon fructose po poe uc. vabe appre 15 | 00181 |Ensine ova st st ranting 0s as Crete Reo tein pa, one sate, wr meee ot Sac outa una ge Fe Taso a a | Fow sone creecrg oa 17 | e018 [renueno aston ser | NB os] os fos] os rom io & cmneaig SO 12 | cor fresacna stn ane ht EN o2 [oz] 02 19 | 00185 | Replacing cylinder aner ‘Single unit Free nian Eanes elt o4 a4 [os oa enovedcandtons From pion &comoaing wae 20 | 00157 Replacing connecting rod ‘Single unit. ei oa ree 03 03 | 03] 03 removed condone ern comeing ol wa orga a | ootse sige vt earn ca] ot | oe] ox ns; Resning | aoe [Repsdng pamson og cage alae fea | aa 41 | 00202 [vane ceaance achstnent —_|oTHRS! 1" 20 wr] came Reoicigwckoranborcoa? 15 = i per 15 | name [Posen re Cnwset [rca Renova and ita wpe] — 48 44 | o0a04 [Replacing recker chamber cr ‘One set 13 14 sos Removalandinsatng cera [Conon 4s | ooava [Perey cian 26 a 46 | 00018 [Resa ck em cee 26 aa «7 | onare |restcng ckeram aureon [monte 28 us 46 | 0018 [Renting oteram san (COR 28 ea 20 | 0322 |pemottans isting osnae eas | ome! Sone Renoaesinetio) 108 Gamo ie, Ve eg ore Placing oy i mactine | Exclude; Replacing of valve guide i te 12-1812, STANDARD MAINTENANCE TIME TABLE TET ‘Work No. Work Work unit Works oy > ae Te rican | * [ria nt: va ang cence: Roping of ave gi * etal tyne asd tsa 1 esas =| Oretheallot oa machine |water pressure test and replacing Pee te ea se | 1225 [Renting oer nead gasket | O=BCE a2 14 s+ | axe |renacna ve Comat ava 96 132 156 arid] coe; Reva ana aig of enag vate ai 4 35 | ooser relae ve sing ee ° ee een] Eco: Renal ad ang olcng ae em a sr | exe [roping peo narnia 3 oa Reval ad ang ow 61 | 00376 ot el ‘One set 12] 02 | 16] 02 rain og Removal ans isling cash wit Sonia Pee [epee [camshaft gear) machine ad a ‘ih ano ard nea Nir Indie; png Retains cinder ead lt; Reoval a sting of 63 | 00352 | (one piece end one set require same Single unt erat ce Co 65 lovinder nead,replecing valve guide, eee |water pressure test and replacing rave sea Uno 0 | 0285 Jeeps eve out vaiott wo| 08 | 20] 0 | o86i Raped son a See oa [aa Poe [2 Repicig eter ar va | worr Fron cone eeqae san] UES os on rau Fensargrosaram suse | yaa, 74 | oosre Jtoneneransone serene same on on ounce Inoue), tana 7 | 00072 lpepesnoroserambusnne | Uae’ oa] os [al os Gtr ORO ToT ane 76 | 00374 |Ropiecing valve ying yeoron os} os | os] os Include; Valve tapping Unit oFT [From cyinder head is removed finder |condition Unit oF [From cylinder head le removed cofinaer lconsivon 77 | 00375. |Repiacing vaive soring o2z| o2 | o2] o2 78 | 00300 |reptacing valve stem seal os] 03 | os] os ‘81 | 00406 Removal and instaling supply pump | One set include: Function check 23 23 4 _| 00411 _|Tigtuening of! pan ‘Shale unt [From engine s removed condition | 05 05 ‘85 00412 [Removal and instaling oll pan ‘Single unt [From engina ie romoved condition | 05 os 26 | 00413 _|Repisong oll pan ‘Shaie unt [From engine Is emmoved canaition | 0.7 07, 87_| 00414 |Repiacing ol pan gasket ‘Sogie unt From engine is emoved cendition | 07. oF '28_| 00421 [Replacing oi pan rain cock ‘Sagte unt [From engine is removed cendiion [05 05 '80_| 00422, Replacing i pan drain cack gasket_| Single wit From engine is removed cendiion [05 05 ‘22 | 00843 [Replacing breatner hose ‘Shale una [From angina is emaved cendtion | v2 | 02 [03 | 02 ‘93 | 0084 [Replacing of level gauge Shale unit [From engine is removed cendiion | 0.4 ot 34 | "00645 [Repiacin oi level gauge guide| Single wit From enginais removed cendtion | 02 02 85 | 00446 [Replacing cilievel gauge bracket | Sioge wnt From engine is removed cendtion | 0.2 02 402 | 00512 [Replacing ty wheat housing ‘Sngle unit [From engine s removed cenation | 2a 3a 103 | 00541 [Replacing fy wheot housing gasket _| Single unt [Fram engine s removed condition | Sa 5a 104 | 00542 [Replacing rear end plate ‘Singin unt [From engine le removed candlion | 5.4 54 105 | "06649 _[Reolacing rear end plate gasket | Single uni | From enine is eemoved condition | 5.8 5a 106 | 00515 [Replacing crank shaft rear oilseal__| Single vot| From engine is removed condition | 5.4 5a 12-1942. STANDARD MAINTENANCE TIME TABLE: ‘sama _[_ saws ‘Work No. Work ‘Work unit Works ea 7 ed wren * lore Tia_| ode [ Raping cocoa on acon | sage wl cm ty wherivomoved con | 92 2 121 [co [Reisng ile meted Cnet [no Poplin tgugankot_—_| 20 23 122 | oste_[Repaong ie nado gsi | One et [neue Aspling tad geet | 20 2a Femoral and nt eke ae 88 One et 1 1 Sore {manifols side) a iu 7B eae |Rencns io be (nated 3s] Ones a m 125-| coat” [Reiang arate hse ‘ne set os | aS fo | oa 72e-[ coset [Repacng ania oe nest oa o2 | 04] oa 157_| ones [raniang ara oe One at [Fut carperronmeressar | oa oa 728 | ona [Rang rhe ps Qooset [Ar cumnor iota charger | 04 [03 0a | 02 120 | coors [renin tence voay Sonoma os| ez [os] 02 vez | cones [rahonngeiuctmenicis [ove 00 3 14a | copes. [Removal and instoing exhaust COPEIEES pp insulator and stud bolt 28 32 mane rae ont nae: Rpincng Hud Ba vow Pe ete ear nee ‘vachine_Jone and insulator (Tl system) bas ae c 14s | e054 [Renan ena mant goer | STE! 2s a 146 | 00546 | Replacing exhaust heat insulator Compe | rarger a ft 24 28 1a | toast Rernng tune Onesat we we 1ao-[_opes3_[Reiaing exnast pip gaaker_—[ Ones mH 8 12-[_opes [Reval adnetng to carer | One cl 29 zs 185. [_o00a7_[Reiacng to carer ness ccna Repaeng aa 2 ver | onus elaig isto hrgeraiaare [9 ., |ne:Ronevlondinisog | = ie oe oe ec ye | oman [Renodng arin irowirerToneg a i coveromani) emorl and ring erg ard vege wvoroved naan 122 | oor fing oar cover roount|nsud;Renovalandrstatingst | 54 ss whens) yin end ape cree creer om gn aroved sonar s20 | oor [Reentrina e agent ne Removal andsiaingat | 64 sa epee cylinder head cng ting or co oa Froming gor cove Woman 1 eget 7 190 | oorte (ly wheel housing) re jcondition fi ti alc ning gence ie Framing parca broad : beats ear end plate} A leondition as head atc ng um cove a Placing timing ge 7 From timing gear cover is removed s20 | oorte [poet ent | 10 10 fem en tonsa) sg gor re romorel 199 | 00725 [reporter warinany [Sogou i 02 0 om in pear coer ev 14 | onrae frees tr gor (ut gen ON OW 1 To4 os 125 | oorae | repan tergar anata) | Spm ENGGEATCOvarG removes [9 oa 198 | ox7a7 [resacng ier gearanan ut) | sapeum[m iia ope coverBremores Tg on Tar wares [Reagan tage a oa 201 | 00738 [Replacing cam ice gear Siglo we [HOM ena OFF covers removed | gg o4 12-2012, STANDARD MAINTENANCE TIME TABLE, Saas ‘Work No. Work Work unit ‘Works cu ae] 7 aa mos] ' [ore Fra ing aero od soning comidgew sat |S wl 2ez | corer [Reining comidger srt | se wu oa 0 zea | corer [rep coneat Sige on emt Tea 28 201 | corse [esaong canst gar cageua|Fom rg eeremerirenees | ay 08 zai | ora [Resa spy oa wa i 2a [ent [ralng cans moe ores 2 Fn 257 | onse_jrelcig ck sta onto” [ eset a2 22 epg ant sao of zea | ors [Pei = 28 esac a Sa on aos ee Lear [retainer gasket rere f i ait | 92m [oncnineton ig eae 08 28 za | Ga” [Rese pma new Gorse ‘a 3a 227 | oni [onmr tl ng Hor —[ Ow a 08 0 225 st Peng tough ee vave [Oe ne 08 a0-[enk_Recg hl iycion pos] onset ae [er [ae [oe 258 | coast [recrg titer asentiy | onset 8 os 21 | toast [Ropacrg il tacaticgn ——[ Oreo 38 23 262 [ene [Rainy thse rt 8 08 2st | tare [reacrg tlatoponn [eet 98 8 27a_| oor [Ralerg ate cage [Onset rm 28 fesnor tan Rar a7 | cova nese on 0s 0907 |reguiator valve) Fao a arate wre ae eee (il fiter regulator valve) One set a fa i ain [reacrg ete ensy abo [ Ones a ra 200 vt [eseng i erst va ig Oe 28 3 Beet lovee reg we 201 ng ge ing sage ii tom engrelermoredcenatin | 6 a cin) nog ger coe 2a tor [reaiig opamp Sageua [fmm ogra waatcnaon | FB a 220 | onet[Reacra ssw ga Sage [ru one omovies ts 257 [tort [ovr f ain Seo Fam ese emoredenion [ES 3s zan_[ ond _[Reinng sun stoma | ows a 1 Zar ut? [esny ssn stanor Og —[ nese 1 3 aut | oss Resin ot ge nese oa) oa [oa] 8 az | ast [Reinga fee Ones da [oa [oa [88 203 [16 [Ree oot : ov 92 [ez [82 227 [eae [Revove nding wap | Oot [adda Fig sade eats —[ 40 2 22e [010 [Resi wae pp reset [nce Fling erg cintie [40 2 san | eto [ovied swamp Sia 38 oa gat [oer [Rena wae nao ily [seo 8 0 234-[ ron [Rencng wae pm asin gal | One set [Ud gi 2 ‘a sez [rise _[Roaang csi fn crest a8 a 2a [rie [Repeang hd ncouing [esa 08 fo 2at [tue [Resiasy erro arg Ove et ni Fg ogra cain [3 i 225 | 01 [Rosary mest snp Ger Ono te: Finger secitun [1 i oer | oa [Pena memonit ina 6 | orcs le ng ene ceciin | 10 1 230 | ore feng most neat [PS Ses ere a te 12-2142. STANDARD MAINTENANCE TIME TABLE, Samoa [aia ‘Work No. Work Work unit Works oy 7 aaa 7 P| crimn| * [ores ics Cracing romper 939 | 01049 | Checking thermostat Cone set |/AOUsei Checking eee bi 10 rave wt opening 2ai_| 08% [Repnchgcatrowe Saat ae [ aa [aa | ea 222 | 054 [pepiacng dno hose Onwsel os} a2 [oa | a2 2aa-[_01071 [Reig fd an ceung i 03 03 oae [01072 [Rela cooing tn i 03 03 2a [0107p water puro 1 Fem cng on onovodcnston! 17 7 | 010% Owe noes ; 0 oa 22 | 01401 |Renovlandinsaingalsnaer —| Svea oa 8 102 | 010 [Reino teat nwa 08 03 104 [01406 TRepacig aura supp att | On at 1 ‘a 05 [1408 |Reoteng Vat oneal 3 as 222" | e100 [Rome and ig pay | One et [ia Funclan ek 20 20 729 | oven [Resaca say ouno nese ne: Faton one 20 20 Rerovel ond iting coninon a aan | otaao |288enby ‘One set |Include; Function check 38 38 et resets res into Resadng cannon esoney 41 | oveos [tres sng possi | One st [nce Funton check as a8 nie) «a2 | ors [Femeatendisisinginsor cont uncon chuck 28 a ent ns Fanon check an «a2 | orto [researc steno “4 40 eee = machine _|reprogramming «x4 | oraor [femora anaisiaing necro. a [incie;Funaon check rs] oz | re] 02 sendy nda; Fan eck end 145 | 01000 |resocns eject: esemby one et 2a| 02 [24] 02 ea [ [reprogramming Renova and rang pcr ob wae | ova neat fae; Funaton ch 8 18 ue [names assembly i cer | ere [Peres meer hese] on tina Raton heck 18 ‘8 ‘| ene a nani ow dango | One wt [nde; Funton ck iz[ oa [7a] 0a | 01812 IRepocr to dumper One st nde; Fnaion check i2[ 23] te] 08 450 | one [Remevlancnnatino resize | on ae: Funcon heck 12 12 ai] oie [reece rena ute Set nce; Fondion cs 2 z 452 | orere [Femesracommenateretsue | oe nce: Funston check 12 2 GEE | are ecg mn ang speed esr] On et nde: Funan crak 2 @ 1454 | 01617 [Resacng ab erie speed enor | One at [nde Func check 12 2 tong cook epee 455 | overs [Reena suis ‘one set linclude: Function check 12 12 56 | 18d esac il peratr ansr | One at [nc: Fneion cack 2 7 257 [01820 |fesoeng ec srsr ne et ne, Funcion deck 5 is 40 | o1eza [Faveetereimatinaesie | Tia; uncon hack 03 03 461 | 01824 feet meet 4 include; Function check 03 03 165 | raze |Renucrg pc Seat fae Frain ae ia[ a faa oa ec 464 | 01827 Placing fuel ps ‘One set |inclide; Function check 12 on 42 On [conn ts sup um) | TBH |Rensorg tt estope poe) Gre se rae Fnson ches 7 a 169"| e160 [hwhing atae ofprensozed ad One st nau, Funcion deck a rH 12-2212, STANDARD MAINTENANCE TIME TABLE Sao Werk Ho Wor Work unt Works [Ar o1901_ [Replacing main engine speed sensor] One sel |inolude: Function check - i | [Tare_[ 1902 |Repiacing sub engine speed sensor | One set [inde Function 12 epiacng coolant lempersture ] ans ete Pe One set inclue; Function check hie 12 (aa Reniacing secl sensor Gre wet linha; Funcion check | A a5 Removal and insating EGR waive | One st [ncude: Function creck [aa 476 [Replacing EGR vaWve | nw eat [indo; Function chack zi | 479 Removal and instating EGR cooler | One set 1 480 | O17 [Replacng EGR cooler | One sat a Tas Removal and insaling dos 4e1 | ore dediaietuichietel ‘one set os entiator Gee | 1570 Replacing dosed ventiator Ones os 12-2342. STANDARD MAINTENANCE TIME TABLE [MEMO] 12-2413. MAINTENANCE STANDARD AND TEST PROCEDURE TABLE OF CONTENTS 13.1, HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED...13-3 13.2 PERFORMANCE INSPECTION STANDARD TABLE... aie 13-4 19.3. MEASUREMENT OF ENGINE SPEED.......... ect 13-6 43.3.1 MEASUREMENT OF ENGINE SPEED....... : re AE 18.4 MEASUREMENT OF HYDRAULIC PRESSURE ee wo AT 18.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE........ see ABT 13.4.2 PLACE TO INSTALL PRESSURE GAUGE..... : 13-7 43.4.3 PRESSURE ADJUSTMENT POSITION 138 4844 PROCEDURE FOR ADJUSTING RELIEF VALVE. i ntsc 410 18.5 MEASURING TRAVEL PERFORMANCES... serene BND 13.5.1 TRAVEL SPEED cnn ieee elated ssn AZ 19.5.2 DEVIATION OF TRAVEL..... oo a 13-12 19.53 PERFORMANCES OF PARKING BRAKE 13-13 13.54 DRAIN RATE OF TRAVEL MOTOR. : seer AAG 13.6 MEASURING SWING PERFORMANCES. Belt 43-45, 13.6.1 SWING SPEED........ ne aa soe AB 13.6.2 PERFORMANCE OF SWING BRAKE ws... oo ABB 13.6.3 PERFORMANCE OF SWING PARKING BRAK: 13:46 13.64 DRAIN RATE OF SWING MOTOR 1847 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES. : 13-48 13.7.1 OPERATING TIME OF CYLINDERS tet i oe AB 13.7.2 OIL TIGHTNESS OF CYLINDERS Sai i 13-19 13.8 MEASURING PERFORMANCES OF SWING BEARING 13-20 13.9 MECHATRO CONTROLLER 13.21 13.9.1 ENGINE CONTROL INPUT / OUTPUT. 13-21 1292 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A:B-C ADJUSTMENT) ..13-24 42.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPVENT OF MECHATRO. CONTROLLER 13-27 Book Code No. S5YN1318E01 13-113. MAINTENANCE STANDARD AND TEST PROCEDURE Issue Date of Issue ‘Applicable Machines Remarks {SK200-8 : YN11-45001~ SSYN1318E04 Frstediion | August, 2008 |xosquc-8. Yar1-06001~ (ASIA, OCE) 13-213. MAINTENANCE STANDARD AND TEST PROCEDURE 13.1. HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED (1) Application @ @ 4) When the machine is new ; Confirm that the performances are in accordance with standard specifications as compared to the performance standards, 2) At specific self inspection ; (Rule by country) Use the data for the criterion, for the purpose of correction, adjustment and replacement. 3) When performances are deteriorated Determine whether itis caused by 2 fault or end of service life after long hours of operation, to be used for safety and economical considerations. 4) When main components are replaced ; For example, use data to restore performances of pumps and others. Terminology 4) Standard values ; Values to be used to condition or assemble a new machine. Where special notes are not given, these values represent standard specifications (machine with standard attachments and standaré shoes). 2) Reference values for remedy Values at which readjustment is required, In order to ensure performance and safety its strictly prohibited touse the machine over the specified values. 3). Service limit ; This is the limit value at which reconditioning is impossible without replacement of paris. If the value is expected fo exceed the service limit before next inspection and correction are performed, replace the parts immediately. The operation over the specified values causes increase of damage and requires the down time of machine, and also causes satety problems. Cautions to be Exercised at Judgment 1) Evaluation of measured data ; Disagreement of measuring conditions, variations of data peculiar to é new machine, and measuring errors are tobe evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values. 2). Determining correction, adjustment or replacement ; Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels, Therefore, determine correction, adjustment ot replacement, depending upon the operating hours, kind of work and circumstances in which the machines placed, and concition the machine performances to its most desirable levels. ‘Other Cautions to be Exercised 4) Parts liable to degrade Rubber products, such as, hydraulic hoses. O rings, and oil seals deteriorate with ime ; replace them at regular intervals or at overhauls 2), Parts requiring regular replacement ; Out of critical hoses that are necessary to secure safety, we designate Very Important Paris (V.1.P) and recommend tht they should be replaced regulariy. 3). Inspection and replacement of oils and greases ; In performing maintenance, itis necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication oracedures. Refer to the operators manuals as well 13-313, MAINTENANCE STANDARD AND TEST PROCEDURE 13.2 PERFORMANCE INSPECTION STANDARD TABLE Note The mode is already "S" mode when power is thrown. Unless otherwise specified, measure it on "H" mode. Tabiet3-1 7 ‘Measuring Postion | Standard Tolerance wa |i] Measuring eee Position | Size | Port value Hi bo nk | Pont condition g [Cleaves orate oiftyaunconintank | MSY — PP ET leanntre *2 [Hydraulic oll temperature | Tank surtace socizal +5 can] _-5(@3) -¢ |_—_|Amearhercteme 8 ae fre~s0re [Water temperature Radiator surface racer] + 15659) 180) CF] [raoreotasey 5 Hi mode Le ilo 1000) “a0 LOW throtie 3 } H mode Hi idle beaeerid — 2000] + 30) EB [Futtthrottio (1 ite) 5 B mode Hiidie_|ePredstmelieisplay on] zooo] +3, || BS |Performall Be erence tte gauge ctuster, or Sod Fini] BB =| 5 Lam measure with diesel - eee §| 2 Doce! | oroed moter 050+ 30) Ey) E |i ai-condtioner S mode Hi idle 1800) + 30} - 30 OFF", Pitt primary pressure circuit | pump ‘a | 5017265) +05 073) of [Prt [arias a 3 ATT Et at 94.3 (4970) + 0.7 (+100), - 0.5(-73) MR1 Boom: 3 Pe a2 ¢ C73) Up £2] toon S| spatsano] voce) -osero] | wet 3 ost [re a AEE ee wom LE ay | S78 80] 9) -40¢se0] | ORS [Boom down Ble H 92.7 5760) ol-socecq] — [ORS [Boom up 5 R| 2 30,7 6760] of 5.0 (858) [ORS [Armout 8) 2 | am & 22 gg wa] § [Pru 31.6 (5400 o| 4.0 (580) yee ORT [Armin g| 2 rR} § 37.8 (5480) | -4.0(-566)) (8 | ORZ [Bucket dump 5) 3 ral at ez} = ee A = 39.7 (5760)] 9] - 5.9 -868)) OR1 |Bucket digging EL Boag LRH ao | Bioaaasl| = 60 6870] >| ‘ORE [Swing RH E 9 (aH 22.0 14208) + 6.0 (+870) a} [Tors [Swing LH FW = eis] te at | 343.4970) +07 (+100) -05¢72) —|simuttaneous ois EW operation of travet a LH rv a2 | 34.3 (4970) +0.7 (+100) - 0.5 (-73)] IRH and LH 13-413, MAINTENANCE STANDARD AND TEST PROCEDURE Inspection iter Standard | Unit zs - value [Sprocket revolution tstspesd [805-275] (RH.LH) 2nd speed —_| 50.4 ~ 45.6 Up__| 25-34 Boom 2 Down | 22~28 8 [Operating time of ae In 3.0~36 | . 2 cylinder Out 23-29] %° [Atnoload) & Diggit ~ | s Bucket |Diasing | 22-26 | g Dumping | 4.7~23 | i RH | ‘Swing speed jj 42~54 | secs trev LH ‘stspeed | ron shoe | 19.5 ~ 21.5 Travel speed | sec / 20 m 2na speea| Iron shoe | 11.9 ~ 13.1 ‘Amount of travel 2nd speed 0~240 | mms20m deviation ut Parking brake dritt | 15 degree gradient| 0 | mm/Smin g |Performance of Swing [Neutral postion after a & [brake 120" ful speea swing | 887 | degree E |Pertormance of Swing aaa Tre 5 i 8 [parking brake 15 degree gradient | 0 mm ® Tip ofthe bucket tooth] 160 ATT amount of arift Boom cylinder 414 |mm/10min|(At no load) __[ arm eviinder " [Amount of horizontal play at the bucket tooth] 30-50 | mm (Crete) ‘The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in advance, (1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down (5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out @) (a) ofew a feo (7) @B) LH RH CONTROL LEVER 13-513, MAINTENANCE STANDARD AND TEST PROCEDURE 13.3 MEASUREMENT OF ENGINE SPEED 13.3.4 MEASUREMENT OF ENGINE SPEED (1) Warming up of engine Start engine to raise the coolant temperature of engine to 60 to 90°C (140 to 194°F) at surface of radiator upper tank. The E/G coolant ter-perature gauge is used to measure. The range in white color shows the temperature of approx. 65 to 105°C (149 to 221°F), 0 confirm that the pointer indicates the temperature within the white range. Engine speed measured value through service diagnosis (See Fig. 13-2) 1) Turn "ON" the starter switch with the buzzer stop ‘switch pressed, 2) A program No. and an actual engine revolution are displayed as the No.2 Item. 3) The screen advances like No.2, No.2....each time the “Wiper switch” on the gauge cluster is, pushed, 4) The soreen returns like No.45, No.44....each time the "Washer switch" is pushed. 5) The display does not disappear unless the starter switch is turned to"OFF” GAUGE CLUSTER, LAWASHER ‘SWITCH fey 7 WIPER SWITCH SCREEN CHANGE SWITCH Fig. 13-1 Switch for E/G speed indication Fig. 19-2 Service diagnosis for E/G speed measuring (Example) 13-643. MAINTENANCE STANDARD AND TEST PROCEDURE 13.4 13.44 (1) Hydrautic equipment 6.9 MPa (1000psi) pressure gauge : {unit 49 MPa (7100psi) pressure gauge : 2 units Pressure measuring equipment and instrument for analysis : 1 set (2) Measuring cleanliness of hydraulic oil (A\WARNING| After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value is higher than the standard value, replace the return filter or change the hydraulic oil. 13.42 PLACE TO INSTALL PRESSURE GAUGE (1) Main circuit After releasing the pressure in hydraulic oil tank. and system, replace plugs PF 1/4 of main pump gauge ports (a1) (a2) with plugs for pressure measurement, and attach pressure gauge 49 MPa (7100 psi Pilot circuit Replace pilot gauge plug (a8) with plug PF 1/4 for pressure measurement, and attach pressure gauge 6.9 MPa (1000 psi) 2 13-7 MEASUREMENT OF HYDRAULIC PRESSURE PREPARING TO MEASURE HYDRAULIC PRESSURE, Povo Fest eave) Fig. 13-3 Gauge port on main pump13, MAINTENANCE STANDARD AND TEST PROCEDURE 13.4.3 PRESSURE ADJUSTMENT POSITION (1) Main control valve (sods PLUG FOR OR8:ARM(R) OPTIONAL RELIEF MACHINE FRONT 7 \ MRI (MAIN RELIEF ORS-BOOM(H)_ OR2: BUCKET (R) (ATT & TRAVEL) \VIEW FROM THE TOP OF THE MACHINE OR4:BOOM(R) ORI: BUCKET (H) ORT :ARM(H) PLUG FOR OPTIONAL RELIEF VIEW FROM THE BOTTOM OF THE MACHINE Fig, 13-4 Relief valve position on main control valve 13-843, MAINTENANCE STANDARD AND TEST PROCEDURE (2) Pilot relief valve ‘The pilot relief valve PR1 is focated on the gear pump that is attaches to the main pump. PRI ADJUST SCREW FOR PILOT RELIEF i Fig. 13-5 Pilot relief vaive position (3) Swing over load relief The swing motor is equipped with plugs PA,PB for pressure measuremert, but the measurement is carried out using gauge ports (a1) and (a2). (See Fig. 13-3) SWINGLEFT SWING RIGHT OVERLOAD RELIEF OVERLOAD RELIEF ‘ORS ORS Fig, 13-6 Swing over load relief position 13-943, MAINTENANCE STANDARD AND TEST PROCEDURE. 13.44 PROCEDURE FOR ADJUSTING RELIEF VALVE (1) Pilot relief valve Adjust it with adjust screw (311) ae 24 mm, Tightening torque : 29.4 Nem (22 tbfft) = emm No. of turns of adjust screw |Pressure change MPe (psi) tun ‘Approx. 2.1 (305) (2) 2-stage main relief valve (Commom for travel and ATT sections) Start from the boosting side, first, Loosen nut (1), adjust the pressure with adjusting screw (2) and tighten nut (1) after completion of the adjustmenton the boosting side. Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten nut (3) after completion of the adjustment a 32mm Tightening torque : 27.4~31.4 Nem (20~23 Ibfeft) 22 mm, Tightening torque : 27.4~34.4 Nem (20-23 Ibfft) A 19mm, Adjust screw 6mm No. of turns of adjust screw |Pressure change MPa (osi) Boosting side f tum | Approx. 17.6 (2560) _ STD side t tum ‘Approx. 17.6 (2560) (3) Over load relist vaive (Boom, bucket, arm sections) Loosen lock nut (1) and adjust it with adjust screw 2) a 22mm, Tightening torque : 27.4~34.4 Nem (20-23 Ib © -emm No. of turns of adjust screw | Pressure change MPa (psi) turn Approx. 17.7 (2560) 13-10 = LOCK NUT HEX24 Sst Fig. 13-1 Pilot relief vaive HEXG2 HEX19 1 2 Fig. 13-8 Main relief vaive (Travel section, ATT common section) Fig. 13-9 Over load relief valve (Boom, busket, arm sections)13, MAINTENANCE STANDARD AND TEST PROCEDURE (4) Over load relief valve (Swing) When the adjustment of pressure is required, loosen lock nut (1) and adjust the pressure with cap @). a® -50, 38 mm, Tightening torque : 118 Nem (87 lot) © s 12mm Fig, 13-10 Swing over load relief valve No.of turns of adjust screw [Pressure change MPa os) rn | Approx 10 (1450) (5) Travel over load relief vaive ‘This valve was adjusted by valve maker. Do not replace any inner parts except for O-ring. Fig. 13-11 Travel over load relief valve 13-1143. MAINTENANCE STANDARD AND TEST PROCEDURE 13.5 MEASURING TRAVEL PERFORMANCES 13.5.4 TRAVEL SPEED (1) Purposes Measure the travel sprocket revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system, (2) Conditions Hydraulic oil temperature ; 45~55°C (113-131°F) Crawler on the right and left sides are tensioned evenly. Preparation Attach the reflection panel with a magnet to the travel motor cover. ‘Swing the swing frame through 90°as shown in Fig, 13-12 and make the crawler on one side take off the ground, using the attachment. Measurement Engine revolution; Hi idle 2-speed travel switch; 1st speed and 2nd speed Measuring points ; Right and left Method, example 1 ; ‘Measure revolution with a stroboscope Method, example 2 ; Measure the revolutions per minute visually @ 13.5.2 DEVIATION OF TRAVEL 1) Purpose Measure the amount of deviation at 20m (66ft) travel and confirm the horizontal balance between the hydraulic pump and the travel motor of the travel drive system Condition Hydraulic oil temperature ; 45~65°C (113~131°F) RH and LH crawler are tensioned evenly. Firm, level ground Engine revolution; Hi idle @ 13-12 PANEL Fig. 13-13 Adhering position of reflection panel Sprocket revolution Unit = mine vessveneni ten] SS? S| Seale R[H mode tstspeed| 30.5~27.6 | 23.8-21.5 | 19.4 or ess LH] Himode 2nd speed] 60,4-45.6 | 90.3~35.6 | 32.2 ortess Fig. 13-14 Travel position13, MAINTENANCE STANDARD AND TEST PROCEDURE (3) Preparation 41) Straight course more than 30m (108A) 2) Travel posttion in which the bottom of the bucket is lifted by about 30cm (if), (4) Measurement 1) Measure the max. deviation distance of the circuler arc in the 20m (86ft) length, excluding the preliminary run of 35m (10~16it). 2) Operate the travel lever at the same time 13.5.3. PERFORMANCES OF PARKING BRAKE (1) Purpose Confirm that the parking brake holds @ stopped Condition ofthe machine in 2 no-load travel position and ona 18 degree slope. (2) Condition A slope with (Approx. 15 deg) gradient and a stopped condition in a no-load travel position (3) Preperation Place an angle meter on the shoe plate and confirm that it makes an angle more than 15 degree. Hang 2 perpendicular in parallel with the guide frame rib on the track frame and puit a mark (matching mark) on the shoe plate. Measurement Five minutes after the engine stops, measure the movement distance of the matching mark. 4 13-13 Travel deviation Fig, 13-15 Measuring method Unit: mm (in) / 20m (884) Teasuring ‘A__ [240 (9.88) ortess| [Peerence val) ‘orretnedy (480 (18.9) | 720284)” Standard value Service BOOM FOOT PIN AL = ee Fig. 13-16 Parking brake operating position GUIDE FRAME Fig, 13-17 Method of measurement Parting ake Unt: maya ee a c 0 10.04) | _2(0.08)13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.5.4 DRAIN RATE OF TRAVEL MOTOR (1) Purpose To measure the drain rate ofthe travel motor and to confirm the performances of the travel motor. (2) Conditions Hydraulic cil temperature ; 45~55°C (113-131°F) Engine revolution; Hi idle (3) Preparation 41) Place a stopper under the RH and LH travel sprockets. 2) Stop the engine and release pressure from the hydraulic circuit 8) Connect a hose with the drain port of the travel motor and take drain in a container. (4) Measurement ; at Travel Lock (A. WARNING| Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper “B" in some cases. (See Fig. 13-18) 4) Start the engine and relieve pressure at the full stroke of the travel lever. 2) Measure the drain rate for 30 seconds of relieving 13-14 FORWARD <— : 210 (954 (0.3947) + i é. ROTARY DIRECTION Fig. 13-18 Location of stopper applied to travel sprocket Fig, 13-19 Method of measuring the drain rate of travel motor ‘Travel deviation Unit : Liga30sec MSaEPO | eancard vue Perera | Service mit Drain rate | 9124) | 16(42) | 23164)13, MAINTENANCE STANDARD AND TEST PROCEDURE 13.6 13.6.1 SWING SPEED (1) Purpose Measure the swing time and confirm the performances between the hydraulic pump end the swing motor of the swing drive system (2) Conditions Hydraulic oll temperature ; 45~55°C (113-131°F) Firm, level ground Engine revolution; Hi idle (3) Preparation Put the bucket empty and extend the boom, arm and bucket cylinder fully ‘And the machine becomes a position of minimum reach, (4) Measurement ‘Swing the machine by bringing the swing lever tots full stroke, Measure the time required to make two turns after one tum of preliminary run and calcutate the time required for one turn MEASURING SWING PERFORMANCES. Fig. 13-20 Swing speed measuring position (at the 13.6.2 PERFORMANCE OF SWING BRAKE (1) Purpose paeenpeaeey Confirm the braking torque performances by the Masaueg ‘positon. swing reliaf valve, wipers (2) Conditions mea Hydraulic oil temperature ; 45-55°C (113-131°F) eee Firm, level ground Engine revolution; Hi idle (3) Preparation 1) Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinders fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. 2) Puta matching mark on the outer circumference of the swing bearing of the upper frame side and of the track frame side, Place two poles (flags) on the front and back of the extended fine of the matching mark, 13-15, min. reach) Unit: secrev sanard vas ESS] Service nt ase | seo | 7. BOOM FOOT PIN Fig. 13-21 Swing brake performance measuring position13, MAINTENANCE STANDARD AND TEST PROCEDURE (4) Measurement 4) When operating in regular swing speed, by shiffing lever to neutral position at pole position the swing operation stops. 2) Calculate the swing drift angle by the following equation, after the upper swing body stops, using the amount of deflection (m) of the matching marks on the swing race and the length {m) of the circumference of the swing race ‘Amount of deflection of ‘Swing drift matching marks [m (ft-in)) MEASURING THE LENGTH OF THE ARC OVER ‘THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON == OUTER RACE NATCHING MARKS ONINNER RACE Fig. 13-22 Measuring position of swing brake : : erformances angle (") = “Circumferential length of _* 360 it swing race [m ("in}] Swing brake performance Unit: degree MeeSHE | tandara cua] eee] Service limit Swing 100°] 75° as" ° 13.6.3 PERFORMANCE OF SWING PARKING BRAKE (1) Purpose To confirm the mechanical performances of the swing parking brake thatis fitted to the inside of the swing motor, (2) Conditions Ona slope of 1 degree incline. Stop the machine at right angles with the slope. Put the bucket empty, retract the arm cylinder fully ang extend the buokat oylinder fully. And move the boom so that the arm top pin is positioned at same. height with boorn foot pin. (3) Preparation Put the angle meter on the shoe plate and make sure that the angle is more than 15 degree. Puta maiching mark on the outer race side and on the inner race side. Measurement When five minutes has passed afler the engine stops, measure the length of the movement of the matching marks, ‘4 Fig. 13-23 Swing parking brake performance measuring position MEASUREING THE LENGTH OF THE ARC OVER: ‘THE QUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE MATCHING MARKS. CON INNER RAC Fig. 13-24 Measuring position of swing parking brake performances ~ieasuring | postion. c 1 (0.04) | 2 (0.08) 13-1613, MAINTENANCE STANDARD AND TEST PROCEDURE: 13.6.4 DRAIN RATE OF SWING MOTOR (1) Purpose Measure the drain rate of the swing motor and confirm the performances of the swing motor. Conditions Hydraulic oil temperature : 45~55°C (113~131°F) Firm, level ground Engine revolution: Hi idle Preparation 4) Slop the engine. 2) Release pressure from inside the hydraulic circuit 3) Disconnect the swing motor drain hose from Its end returning to the hydraulic oil tank and take olin a container. 4) Put @ plug to the tank side. Measurement ; at Swing Lock 1) Start the engine and put the side faces of bucket 2 @ Travel devia unit ys08e0 against the inside of the right or left shoe plates. tae ee on ara een oantaowe 2) Relieve the swing motor at full stroke of the ce Standard value" “er vemedy swing motion. Drain rate | 2.40.55) | 52(7.4) 3) Collect the amount of drained oil in a container for 20 seconds. 13-1719, MAINTENANCE STANDARD AND TEST PROCEDURE 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES 13.7.1. OPERATING TIME OF CYLINDERS. (1) Purpose Measure the operating time of the boom, arm and bucket and confirm the performances between the hydraulic pump and the cylinder of the attachment drive system. (2) Condition Hydraulic oll temperature : 45~55°C (113-131°F) Engine revolution; Hi idle ‘Operating time excluding the cushion stroke (3) Preparation Firm level ground with the bucket empty (4) Measurement 1 : Boom up and down With the boom operating lever at full stroke, measure the required operating time of the bucket between the ground surface and its highest postion. (AWARNING) When lowering the boom, allow the bucket onto a soft ground or cushioning such as rubber tires ; never put the bucket against concrete or other solid material. Measurement 2 ; Arm in and out, bucket digging and dump In position in which the tooth of the bucket rises to a level of about 30cm (ft) above ground, measure the full stroke operating time required with the arm and bucket operating levers at full stroke. 13-18 30m (1) Fig. 13-26 Measuring position for bucket digging and dump anton ry Cj most react sap. Bucs eps mes extended — =) Fig. 13-27 Measuring position for boom up and down motions, Ores Fig, 13-28 Measuring position for arm in and out motions Cylinder Operating time Unit: sec Nsaston® _|Standar vave|“rvoneay "| Service lit o 22-28 | 26-36 38 ® 17-23 | 22-28 30 @ 25-31 | 3240 | 4 @ 2228 | 28-36 Se @ 30-36 | 3846 50- © 23-29 | 20-37 313, MAINTENANCE STANDARD AND TEST PROCEDURE 13.7.2 OIL TIGHTNESS OF CYLINDERS (1) Purpose Confirm that the cylinder oil tight by checking the moving length of the cylinder rods. (2) Condition Hydraulic oll temperature ; 45~55°C (113-131°F) Firm, level ground After cylinders are replaced, bleed off alr from the oylinders, before checking for oil tightness. Retract the arm cylinder rod 50mm (2in) from stroke ‘end so that the piston does not match 2 same range of the cushioning mechanism (3) Preparation Put the bucket empty. Extend the arm cylinder rod 50mm (2in) from the most retracted position. And ‘extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at same height with boom foot pin (4) Measurement Measure the items five minutes after the engine is, turned off. BOON FOOT PIN AS ARM TO? Pin Fig. 13-29 Ol tightness of elinder Unit: mmvinsmin Measee [cuncae vatue S| Service tt A | 71026) | 110043) | 1400.55) B 6 (0.24) 9 (0.35) 14 (0.43) c = = D 120 (47) | 160163) 13-1913, MAINTENANCE STANDARD AND TEST PROCEDURE 13.8 MEASURING PERFORMANCES OF SWING BEARING (1) Purpose Measure the gap between the lower frame and the bottom face of the swing bearing and estimate the degree of wear of the swing bearing, (2) Condition Firm, level ground ‘The swing bearing mounting bolts are not loosened, ‘The swing bearing is lubricated well, not making ‘abnormal sound during turning, (3) Preparation 4) Install a dial indicator to the magnetic base and fix it (0 the lower frame, 2) Direct the upper swing body and the lower frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the swing body side and set the reading at zero. (4) Measurement 1 (Measuring position 1 and 2) 1) Measure the displacement of the outer race in the axial direction in position 1 {The arm at 90°~110" and the crawler front is lifted by attachment about 30cm (1it)] and in position 2, using a dial indicator. (5) Measurement 2 (Measuring position 3) 1) Retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that, the arm top pin is positioned at same height with, boom foot pin. Then swing the bucket right and left by man power. But in this case, the gap of the attachment is included, 13-20 Location oF MOUNTING BOLTS TH! ee BEARING DIAL INDICATOR RING LOWER FLAME Fig. 13-30 How fo measure the axial play of swing bearing ¥ “en in| GEESE) Fig. 13-31 Measuring position 1 BOOM FOOT ARM TOP ES Fig, 13-32 Measuring position 2 ‘Axa play of swing bear ng MERE Standard vue] Eres] Serica Fmt rn O18 | 25-33] 36: {0.03~0.07) | (0.09~0.13) (0.14) Unit: mm (in) ARM TOP, Pin ra Fig, 13-33 Measuring position 3 Fhhanlotmowmestoetpofbusel__ Unt nm (ey WERE? | stniac he [Ean | Sova lnt uot Seaneranl aoe [aT13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9 MECHATRO CONTROLLER 13.9.4 ENGINE CONTROL INPUT / OUTPUT er: ce: EVERGENC’ ENGINE CONTROLLER ACCEL \ \ \ Et 2 FUSEARELAY BOX GAUGE CLUSTER | PuMe PROPORTIONAL cH VALVE MECHSTRO CONTROLLER Fig, 19-34 INPUT / OUTPUT 13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) 13.9.21 PURPOSE OF THE ADJUSTMENT, There are 3 kinds of adjustment of mechatro controller as shown below, every adjustment is an essential function to ensure performance of machine. (1) Adjustment of engine ("A" adjustment) This adjustment is performed to set the relation between the acceleration command veltage output from mechatro controller to engine controller and the engine speed. (2) Adjustment of pump (°8" adjustment) This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with engine rated output. (3) Adjustment of unloading valve (*C* adjustment) This adjustment is performed fo correct the open variation of unloading valve to improve the operability further. 139.22 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED; When the following parts are replaced or repaired, carry out the adjustment without fal (1) Mechatro controler (2) Engine or engine controller (3) Hydraulic pump or hydraulic pump proportional valve (4) Unloading proportional valve, spool of unloading valve 13-2113, MAINTENANCE STANDARD AND TEST PROCEDURE 139.23 PREPARATION (1) Raise the oil temperature to about 50°C (122°F) to warm up the engine. (2) Tuen the air-con OFF, (3) Turn the starter key switch OFF to stop the engine. When the mechatto controler was replaced, the following error code is displayed because the adjustment data is not entered. A215, A225, A015, A025, AUS As the error codes other than those shown above may suggest failures of machine, repair the machine into the ordinary operating condition according to Error Code List jote For machines equipped with lifing magnet, tum the generator OFF. 13-2213. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.4 ADJUSTING PROCEDURE (=a) = MUTT IseLAr BUZZER STOP SWITCH —_ _- WORK MODE SELECT SWITCH ca _- WASHER SWITCH \ bes ob cs Bee | | ey a setecr siren A rR SCH Fig, 13-35 Gauge cluster (1) Adjustment of engine ("A" adjustment) Procedure 1) Turn starter key switch ON keeping the work mode selector switch on the MULTI DISPLAY gauge cluster pressed, and hold it for 5~10 seconds, and then release it. If (EXAMPLE) the engine is started, the following indication is not displayed. Therefore do not . cote rane) 10:25 [Him 2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release KOTUST it and the screen for selecting adjustment is displayed. When adjustment data READY is not entered in mechatro controller, "READY" is inicated. If the adjustment ees ‘operation is once performed, "FIN" is indicated. ova ‘And the lever lock solenoid is automatically released, disabling all operations. 2) Press selector switch on gauge cluster to display “START ENG". STS ngine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration crema command voltage) are indicated ke Fass 4) After starting engine, press selector switch on gauge cluster, and "MEMORY ENG" is displayed, the engine speed is automatically increased, and the adjustment of engine is performed. (When trying to limit engine speed, press selector switch on gauge cluster at the speed as itis, and the adjustment of engine is terminated. The torque adjustment and unloading adjustment required later are not performed, and default value is written.) 5} When normal HIGH idling speed is detected, the adjustment is completed. And “FINISH ENG is displayed. aid (Press the buzzer stop switch on gauge cluster while this dispiay is appeared, — [xaos and the adjustment of engine is completed, The torquo adjustment ang ig uinigading adjustment requied later are not performed, and defauit value is written) 13-23413. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Adjustment of pump ("B" adjustment) Procedure 1) The adjustment automatically shifts from engine to pump, the speed shifts from LOW idling to HIGH idling, And "MEMORY PUMP" is displayed. And the unloading proportional valve and pump proportional valve actuate, accordingly the loading of pump is increased. ‘The "ENGINE SPEED", P1, P2 "PUMP PRESSURE® and P1, P2 pump "PROPO-VALVE" current (command value) are indicated. 2) After detection of the engine rated speed, the adjustment of pump is automatically completed. And “FINISH PUMP" is displayed (Press the buzzer stop switch on gauge cluster while this display is appeared and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.) (3) Adjustment of unioading valve ("C* adjustment) Procedure 4) The adjustment shifts from pump to unloading, and the unloading valve actuates, accordingly the pump pressure is detected. And ‘MEMORY UNLOAD" is displayed. The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P41, P2 "PROPO. VALVE" voltage (command value) are indicated 2) When the unloading valve operates to the specified value, the adjustment of Unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed. The speed is shifted to the speed corresponding to acceleration potentiomete: The adjusting currant value is indicated on the display of current of P41, P2 unloading proportional valves. The adjusting range is usually 520~635mA. Stop the engine. (The adjusted data is automatically stored.) (4) Corrective actions taken when the adjustment can not be performed; 1) In cases where the adjustment of engine can not be performed; And ERROR ENG" is displayed Judging condition: The read engine speed is SOrpm lower than the last value. It is conceived that the error is caused by the speed read error, pump load applied to the engine and unusual acceleration command voltage applied to the engine controller in the course of adjustment ‘a. Checking speed sensor: Check that itis free fromwrong reading of speed due fo engine vibration b. Checking load applied to pump: Check that itis free from abnormal ease of pump pressure during adjustment of engine through adjustment screen. c. Checking acceleration command voliage: Measure the acceleration ‘command voltage output from mechatro controller to engine controller. Check that signal is regularly input to the engine controller by actual measurement of voltage or with failure diagnosis tool of engine controller. 13-24 MEMORY PUMP FINISH PUMP TWEMORY UNLOAD] FINISH UNLOAD ERROR ENG13. MAINTENANCE STANDARD AND TEST PROCEDURE 2) In cases where the adjustment of pump can not be performed: And "ERROR PUMP" is displayed. Lecce Judging concition 1 see, P1 and P2 average pump pressure at the time when the adjustment is Pee ce aan completed is 25MPa or less. Judging condition 2: The adjustment does not complete although the pump proportional valve current reaches to the specified value. ‘The P1 and P2 pump pressures usually increase to 33~38MPa, When the pressure does not increase; 2. Identify the reason why the pressure does not increase, + Check that the relief vaive operates normally. + Check that the hydraulic circuit is free from leak of pressure, + Check that the pressure sensor functions normally. And s0 on. b. Identity the reason why the actual flow rate does not increase, + Check that the pump proportional valve operates normally + Check that the pump regulator operates normally. And 80 on, 3) In cases where unloading valve can not be performed; And "ERROR UNLOAD" is displayed. Cees Judging condition anne ‘The pump pressure does not increase up to the pressure in the range of the Se aean specified adjustment, Or the increased pressure is held as it is Judging condition 2 Pressure sensor of either P1 pump or P2 pump Is failed. Normally the pump pressures of P1 end p2 pumps gradually increase to 10-25MPa (it may be affected by operating oil temperature.) When the pump pressure does not increase; a. Identify the reason why the pressure does not increase, + Check that the relief valve operates normally, + Check that the hydraulic circuit is free from leak of pressure, + Check that the pressure sensor functions normally And so on. (8) Other precautions: 41) In the event of a failure, there is case where the adjusiment may not be performed normally. First serve the machine, and perform the adjustment work. 2)In the condition where large load is constantly applied to engine, the adjustment could not be performed normally. (Note) For machines equipped with ting magnet, turn the generator OFF, 13-25,13, MAINTENANCE STANDARD AND TEST PROCEDURE (6) When the adjustment of unloading valve only is performed; {*C* adjustment) {in the event where only unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading vaive only. Procedure 1) Tum starter switch ON keeping the work mode selactor switch on the gauge MULT DISPLAY cluster pressed, and hold it for 5~10 seconds, and then release it (EXAMPLE) {If the engine is started, the following indication is not displayed, Therefore do 10:25 not start the engine.) i [Hse 2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release ADJUST itand the screen for selection of adjustment type is displayed. And “ADJUST READY is displayed FEED When adjustment data is not entered in mechatro controller, "READY" is ova indicated. If the adjustment operation is once performed, "FIN" is indicated ‘And the lever lock solenoid is automatically released, disabling all operations. 3) Change the adjusting items with washer switch (4) and wiper switch (¥), and [ADIUST UNLOAD] select "ADJUST UNLOAD". (See Fig. 13-35) READY Like the output adjustment, when adjustment data is not entered in mechatro a controller, "READY" is indicated. If the adjustment operation is once va performed, "FIN" is indicated. 4) Press selector switch on gauge cluster to display "START ENG”. SoRxe “ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ns command voltage) are indicated, actor, = 5) Alter starting engine, press selector switch on gauge cluster and "MEMORY TEMORV ON UNLOAD" is indicated, the engine speed is automatically increased and the lemme ttt adjustment of unloading valve is performed bs icone “ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" keene {acceleration command current) are indicated. 6) When the unloading proportional valve operates to the specified value, the FINISH UNLOAD adjustment of unloading proportional valve automatically completes. "FINISH | evanesneco UNLOAD" is indicated, sion ‘The speed is shifted to the speed corresponding to acceleration potentiometer, JPR oe sn The value of adjusting current is indicated on the display of current of 1 anc P2 unloading proportional vaives. The adjusting range is usually 520~635mA. Stop the engine. (The adjusted data is automatically stored.) 13-26,13, MAINTENANCE STANDARD AND TEST PROCEDURE. 13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER (1) Engine emergency mode When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating ‘emergency acceleration (E-27) provided on the seat rear side. (Gee Fig. 13-34) Operating procedure: 1) Set the emergency acceleration to NORMAL position. 2) Start engine, 3} Turn the emergency acceleration to HI side and control the engine speed 4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping, Never increase the engine speed immediately after starting engine. Itis dangerous. To avoid this danger, repeat the above procedure, or the engine speed does not increase When the machine does not operate, set the emergency acceleration to NORMAL position. EE (2) Pump emergency mode In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is indicated on multi display provided on the gauge cluster, the full power control of pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to ‘emergency mods, making the operation with the power shift control of puma and the constant power control by means of self-pressure possible, But be careful that, at emergency mode, tie accuracy of inching becomes poor, the frequency of engine down is increased, and the engine stalls in LOW speed condition. | AACAUTION| The emergency mode should be used in only case of emergency. We recommend that the defective section Is repaired by troubleshooting as early as possible. 13-2713, MAINTENANCE STANDARD AND TEST PROCEDURE [MEMO] 13-2821. MECHATRO CONTROL SYSTEM TABLE OF CONTENTS 21.1 SUMMARY OF MECHATRO CONTROL SYSTEM. 2n44 214.2 244.3 244 2145 21.48 244.7 2148 21.1.9 24.41.10 244.41 24442 214.13 2hAt4 MECHATRO CONTROL SYSTEM IN GENERAL UNLOAD VALVE CONTROL. POSITIVE CONTROL & P-Q CONTROL BOOM UP CONFLUX CONTROL ARM IN RECIRCULATION & CONFLUX CONTROL, ‘ARM-IN ANTI-CAVITATION CONTROL ARM-OUT CONFLUX CONTROL 7 BUCKET DIGGING (DUMP) CONFLUX CONTROL BUCKET DIGGING ANTI-CAVITATION CONTROL... SWING PRIORITY CONTROL TRAVEL STRAIGHT CONTROL PRESSURE RELEASE CONTROL N&B SWITCH CONTROL (OPTION) OPTION CONFLUX CONTROL (OPTION). 24.2 MEGHATRO CONTROLLER. 24.24 21.22 21.23 2424 225 21.26 2127 24.28 SUMMARY OF MULTI DISPLAY SELF DIAGNOSIS DISPLAY. SERVICE DIAGNOSIS DISPLAY FUNCTION TROUBLE HISTORY DIAGNOSIS... TROUBLE DIAGNOSIS MODE SET PROCEDURE OF MAINTENANCE SCHEDULE ADJUSTING PROCEDURE OF DISPLAY MECHATRO CONTROL EQUIPMENT 21-1 Bd 21-4 21.6 BE 207 21-9 21-10 QA wn 2113 21-14 21-16 21-47 21-18 21-20 21.24 21-22 21-23, 24-23 21-28 21-30 21-40 2184 21-82 2-43 24-47 Book Code No. S5YN2118E0121, MECHATRO CONTROL SYSTEM E __tssue Date of issue ‘Applicable Machines Remarks )SK200-8 : YN11-45001~ S6YN2118E01 [_Fistediton | August 2008 |exrio.c-a var.06001~ (ASIA, OCE) 24-221. MECHATRO CONTROL SYSTEM PREFACE This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual summarizes the mechatro system and the (unction of the mechatro controller related apparaluses. Regarding the conditions before and after each conversion, refer to the hydraulic system and the electric system. 21-321. MECHATRO CONTROL SYSTEM 21.1. SUMMARY OF MECHATRO CONTROL SYSTEM 24.1.4 MECHATRO CONTROL SYSTEM IN GENERAL ELECTRIC ‘CONTROLLER INPUT SIGNAL, HYDRAULIC PILOT SECONDARY PRESSURE | VOLTAGE OUTPUT 1 ‘SOLENOID PROPORTION VALVE SECONDARY PRESCURE 'SQENOO PROPORTIONAL VALVE PRBUAY PRESSURE UA CRCUT PILOT VALVE: FoRATT oie Q sen |GAUGE CLUSTER Loo oseuy PSE ron ss once eons ta once coueren green canoe senior ioe zien hirer ee pect le ACCEL DIAL Se48 928 SERIAL COMMUNICATION ca MECHATRO CONTROLLER us ENGINE INJECTOR seecv senso} Mm sel] Pov-P2 HIGH PRESSURE SENSOR. (FOR PtP 2pes) Mm NeECTOR QO ] :516 SPEED SENSOR can conmuntcanion | © ‘Loweressure sensor | a +--+ ENGINE CONTROLLER, © aT es HAVEL Sn) ENGINE SEED coo corer eon an 7" BROPORTIONSL COiRiAIGCiReNT, ea Bitrcencr wove xccet oi << ACCEL DIAL POTENTIOMETER: 24-424. MECHATRO CONTROL SYSTEM 1 sez © JAR OUT reg) OUNP DOWN FORWARD FORWARD LEFT ARM OUT f ® VLe@ @ | @ @ sv-13 8 8) 8) |32 2! 8 2 ze 2 Pane g 5 ° 5 2] e 5 @ S/S lz] §] 5 [88 £ 5 2 z\@ 8| 5 i me | 2) 8 |2lalis| zZlelele]2] a l3e | 3 3 3/2/e8/.2)2]/8]21]s] 2 22 2 {e8/.2/2/8|2)2)2 | £) 2 |S|@leseb) 2] 2/4) 8) 8 fe | © | Pip2 & | (i) (3) (8) a oxcons UP | Reverse reverse | RGHT anes / w | SOLENOID VALVE i3_ Zo ce 7 i Oo] [Drcot SWING MOTOR PAIENG RELEASE ©) h t eee EEE * f tf "Ave: MOTOR TZ GREED Sse i BOOM CYLINDER, BRON EEorcumon Boow eaten w os B eg 1 . 8) e|2/8 EF} 8 oS olBioe|]4 a 3 2) /)2|¢ Slelelele| ales = s1eyalslzelalel= s/2/2/5/2/2/2|& glzle#lsele]2@] a] 3 smucrunoen few SuTenruux pov Jes fal Noses als = BUCKET CYUNDER DIGGING / DUMP CONFLUX ob bgeeel — 1 PROPORTIONAL VALVE SOLENOIDVALVE BLOCK ot 24-521, MECHATRO CONTROL SYSTEM 24.1.2. UNLOAD VALVE CONTROL + Zz 8 2 é g r @ 8 2 | le INES a & PL a evecrort| _ HB fl ors efl8 IvaLve elleffel gd glle//e]|2 Ellz||é z © zi/SliSilzs cor Ea) = a ULEIL 2] (2 [2 PLOT pLoT (EFT), Risen) Paanen valve O VALVE PILOT VALVE: PLOT VALVE = FOR TRAVEL Letel too PLOTSIGNAL | orb Jpeonontrons. WaLve pave PLOTSIGNAL | PROCESS __i paSORT ONAL VALE PSV. Fi: PROPORTIONAL VALVE SECONDARY PRESSURE (1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective low pressure sensors. (2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve. (3) Each untoad pressure proportional vaives output pilot secondary pressure according to the command output by mechatro controller and switches each unload spools. (4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating, 21-621. MECHATRO CONTROL SYSTEM 24.4.3 POSITIVE CONTROL & P-Q CONTROL e 8 E = ra e i oe ey Hue aliel|e ‘|| ele{]e le S218 @ az UlEt/ 8/2) 8 i. (een) irichr) | OPLOT CyALoT b QDvave O vave PILOT VALVE FOR TRAVEL sete Qarsre low iow IPRESSURE| PRESSURE lsensor | SENSOR Poa PEP. fpeoroRrioNaL bt PaOPorTioNAL fvatve conto) "| vatve ave. Re -| FRo=ozmonm VALE #8 pe ee PiLoF SNA PROCESS i PILOT SECONDARY PRESSURE [LN Ee pi-PRoPoRTENAL Ye SECONDARY PRESSING21. MECHATRO CONTROL SYSTEM (1) Positive control 1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve. 3) Each pump proportional valve outputs pilot secondary pressure according to the command output by ‘mechatro controller and changes the titing angle of each pump and controls the delivery rate 4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator, and consequently the working speed according to the lever manipulated movement will be obtained. (2) P-Q contro! 1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller and the mechatro controller processes pilot signal and operates the command according to the input voltage (load pressure). 2) The lower value between command vaiues calculated by positive control and operated value found by P-Q Control {operated value found in item 1)} is selected and is output to each pump proportional valve es command value. 3) Each pump proportional vaive outputs pilot secondary pressure according to the command output by mechatro controller and changes titing angle of each pump and controls the delivery rate. 4) With this operation, the delivery rate according to lever manipulated movernent is fed to actuator and consequently working speed will be obtained according to lever movernent. POSITIVE CONTROL P-Q CONTROL ett Po Pee y (BLOTSGNAL PROCESS) e F SIGRAL PROCESS 133 ' | 33 1 ag 33 ise i i BE t 1 ge" | fs” if2 | 182 I 2 a8 (a8 i | 28 i i : PUMP DELIVERY PRESSURE 24-824. MECHATRO CONTROL SYSTEM 21.1.4 BOOM UP CONFLUX CONTROL 2 4é 8 3 te z= 5 8 nae 8 8 5 8 # lsstecror-y HB ee = ble we “1 31/21) eg g g ails sI/2| = & g E Ballz 51/2) elle Elli] og We 2||& eye ge 7 & Pot Th | fae + | Low PRESSURE SENSOR PLOT SIGNAL | aie PROCESS: ifP2PuRe i Peer. i oaiie Pa UP PLOT SECONDARY PRESSURE | PLOTSIGNAL | PROCESS { [Pree L PeOLOeroNL ‘vate ror | UP ALOT SECONDARY PressuRE | PLOT SIGNAL ! PROCESS |JEzacoaD | FeStoRrona. | 1 Wave PS | UPPUOTSECONGRRY PressuRE i PLOTSIGNAL § aos FROCESS PROPORTIONAL wwecHatRO _:LuRveeuvo | controtter: pi: PROPORTIONAL VALVE SECONDARY PRESSURE (1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up contlux ‘spool and is input to low pressure sensor. (2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P't and P2 proportional valves and Pt and 2 unload proportional valves. (3) Each proportional valve outputs pilot proportional valve secondary pressure according fo the command output by mechatro controller and changes P'1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valve. (4) With original hydraulic pressure command, boom mein spool and boom up confiux spool are switched, and also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and consequently the delivery oll on P'1 pump side confluxes delivery oll on P2 pump side during boom up operation, 21-921, MECHATRO CONTROL SYSTEM 21.1.5 ARMIN RECIRCULATION & CONFLUX CONTROL | 2 8 3 sored f ha 8 8) 1 8| | Le 3 g tec = HSH 2448 7 He saroria [lets g as ene amas |& || | [5 All os WEEE Puor aS ge vow Tit rreseure, | oeessune ENON OD Sign a Punto Fi PILOT SIGNAL (tie PROCE: =e Lo SECONDARY PRESSURE PILOT SIGNAL DK process | EE paeese (eee ae a POPOMPPRESSURE = ECHATRO CONTROLLER | pr:PROPORTIONAL VALVE SECONDARY PRESSURE 21-1021, MECHATRO CONTROL SYSTEM (1) Recirculation and confiux (Low loading) 1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool and low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal according to the combined operation and outputs command, which is different from the arm-in independent operation, to P1 pump proportional vaive, P1 unload proportional valve and reverse proportional valve for arm-in 2 spool 3) Primary pressure of reverse proportional vaive for arm-in 2 spool is arm-in pilot secondary pressure and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls recirculation rate and conflux rate.) The other proportional vaives output proportional secondary pressure according to command from mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload valve. 4) The arm 1 spool is switched according to original oll pressure command, and P1, P2 pumps, P1, P2 unload spools and arm 2 spool are switched according to the command output by mechatro controller, and consequently the return oil from the arm cylinder rod side is recirculated in Pt ancl P2 pumps delivery oil during arm operation (2) Recirculation cut The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is raised during arm operation the mechatro controller processes pilot signal processing according to the pressure detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for arm-in 2 spool The reverse proportional valve for atm-in 2 spool outputs pilot secondary pressure according to the command output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation passage is blocked, 21-1424, MECHATRO CONTROL SYSTEM 24.1.6 ARM-IN ANTI-CAVITATION CONTROL, 5 4? 5/| 21/8 )] 2 : eel 8}| ei PILOT $ ge vA 2 #5 a Low eessure| Acc cea porEtmo 37 muorgona) eee ARUN PLOY SECONDARY PRESSURE : ai PILOT SIGNAL: _ ARUTNPILOT SECONDARY PRESSURE i ol : 8) ee) ee ave roan — “yeas? S500. $260. CoMaN ted a ENGINE SPEED (COMMAND VALUE) CHATRO CONTROLLER | pl: PROPORTIONAL VALVE ‘SECONDARY PRESSURE (1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low pressure sensor. (2) The engine speed command output by accel potentiometer is input to mechatro controller. (3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2 unload proportional vaive. (4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve for arm 2 spool (8) Each proportional valves output pilot secondary pressure according to each command output by mechatro controller, and consequently since the reverse proportional vaive for arm 2 spool is controlled to spoo! stroke according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump delivery rate is low due to low engine speed. 21-1224, MECHATRO CONTROL SYSTEM 24.1.7 ARM-OUT CONFLUX CONTROL 8 g = 4é le | Ile g rk z . e ise el} Lei] lel |i 8 a lseLecToR 4 Hh he 2 fH feos hwe |SITE Tie g glfs{/elts Elle {|= 2 = S||s SILEl Elle] |2 oe UES ai]8 2 sé | Low | Pressure © SENSOR See et PLOTSIGNAL eat PROCESS [PZPUHE Ae Se 1 OUT PLOT SECONDARY PRESSURE ferme | PROPORTIONAL "fave sae4 TTPTTOY SECONEARY PRESSURE Fanswaet [PZ UNLOAD FeoboeronaL : ‘aero | | sew GOTFTSECOTOR onessone | 1 pl i i PM} Frama I FeOReRta veorrao (WANeesu San OUR) i pROpORTIONAL vaLvE |" SECONDARY PRESSURE (1) On starting arm-out operation, arm-out operating pilot pressure switches arm 4 spool and arm 2 spool and is input to low pressure sensor. ‘The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P+ and P2 unload proportional valves Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valves. With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P+ pump side during erm-out operation. 2 @ 21-1321, MECHATRO CONTROL SYSTEM 21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL, 8 g k 5 e| hse £ Ley) e 8 & IseectoR - +] % = 4 ey bn pave || Sl] elle g @/al[8]fs wm /8]/8)/S|lol 2 #/(2//3][2} g PILOT & Ovaive LE] me Seema PLOT SIGNAL | | beopeeriona, LI La oT BRE BY PDT Secours ae ; i lavor sional | “NK _ P= i = "VRE Pavibs uc SE BO PT SECOUDIRYPRESSRE A PLOT siGnaL | Hl NE KET OSG BON FUG SC OONRY FRESH pi FanEsaAGr lpaocmrons [sae pave IMECHATRO| au essune|CONTROLLER pt: PROPORTIONAL VALVE 2 ‘SECONDARY PRESSURE (1) On starting bucket digging (cump) operation, bucket digging (dump) operating pilot pressure switches bucket spool and is input to low pressure sensor. (2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve. (8) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve. (4) The tandem passage is connected to P2 port because of the travel streight valve switched and P1 pump delivery olllconfluxes P2 pump delivery oil because of P2 unload valve switched. 24-1421. MECHATRO CONTROL SYSTEM 21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL, [|s | se g & 8| | Le é I ¢ eT) {1 ef] g 3 al alpeyle] |] wm |5|/2|) $}|2 z elle leiistle! || 5) (2) (5}/3h LEI 98 e{l#) || Pitot 3 gE | VALE = ma + saan | A PILOT SIGNAL | ETOIGEING PLOT SecoNDARY PRESSURE i PILOT SIGNAL, OCs. KET DIGGING PLOT SECONDARY PRESSURE t PILOT SIGNAL; P PROCESS PILOT SIGNAL m PROCESS FREE STR backer ‘BUOKET DISEING PLOT SECONDARY PRESSURE BUCKET DIGGING PLOT SEOCNDARY PRESSURE i ai i eNGo ave MECHATRO | CONTROLLER i: PROPORTIONAL VALVE SECONDARY PRESSURE 21-1521, MECHATRO CONTROL SYSTEM (1) On starting bucket digaing (dump) operation, bucket digging operating pilot pressure switches bucket spool and is input to low pressure sensor. (2) The engine speed command output by accel potentiometer is input to mechatro controller. (3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P71 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve. (4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output bby mechairo controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of control valve. (6) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unioad valve switched {6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary pressure, and actuate stroke limiter and then controls the stroke of bucket spool. The control of spool stroke makes the prevention of cavitation possible even if engine speed Is low and pump delivery rate is tow. (7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to contra! the stroke limit of bucket spool. 21-1621. MECHATRO CONTROL SYSTEM 21.410 SWING PRIORITY CONTROL FLW Pr UNLOAD T OOK L CONF Nee lsetecror| Jualve En = eUCKET ‘ARI 1 SPEED ‘TRAVEL LEf ARM 2 SPEED OPTION | teaver aici [soo P2UNLOAD TRAVEL STRAIGHT Low ) eressure | Sersom PILOT SIGNAL | PROCESS PINE PROPORTIONAL Vane POV LPR Peoporiowa. LH whtve av PEONCORS PROPORTIONAL VALVE PSV PROPORTIONAL biti PILOT SIGNAL S 84 PLOT BEOONOAT TERE STRAGAT eenauans BeoeoRTnn, VALVE Pe eeRERETON] | frsersemororow] eesSter is [Soar | pl: PROPORTIONAL VALVE SECONDARY PRESSURE (1) During arm-in operation, arm operating pilot secondary pressure switches arm spool andis input to low pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot secondary pressure switches swing spool and is input to low pressure sensor. (2) The output voltage of low pressure sensor is input to mechatro controller and the machatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P41 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool (3) Each proportional vaive outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P41 and P2 unioad spool, travel straight spool, arm 2 spool. (4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched enabling for two pump flow rates to be supplied fo the arm cylinder head side, and consequently the return oil ‘on arm oylinder rod side is recirculated into arm cylinder head side. {5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum speed drop possible, 211721, MECHATRO CONTROL SYSTEM 2A cPriowaL PILOT VALVE (ert) (eich) OF VALVE TRAVEL TRAVEL STRAIGHT CONTROL ; ccm veconreux J 1 PI UNLOAD - ] ew 8 & & lle seLecTor 3 & BHe we | Tere g #sl/e/2 erlaligllo| |2 z 8\|3 wad (5 ]/2)|2/}e, fs ee ULE}E} Leh l2 z Be PLOT PILOT a a Wave © VANE “ nooo TRAVEL STRAIGHT SIGNAL | por siowat \ PLOT SIGNAL Process AY PRESSURE Le PLOTSIGNAL =— ave oa “Ea a | LCT SECONDARY PRESSURE ‘SECONDARY PRESSURE PLor signa eeu [psooess ror crea I 24-18(1) Judgment travel straight 2 1) During travel operation (right and lef), pilot pressure switches each spool and is input to low pressure sensor 2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns travel straight signal on, 3) On turing travel straight signal on, the following commands are output to each proportional valve. on carrying out attachment system operation, Operation of each proportional valve (Basically attachment operation is actuated by Pt pump and travel operation is actuated by P2 pump in travel straight condition.) 1) 2 3) 4) 5) Travel straight proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating 24, MECHATRO CONTROL SYSTEM (Goom, arm, bucket, swing, option) pilot pressure during operation. P1 unload proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation P2 unload proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation, 4 pump proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation P2 pump proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation, ~ ATT aperatorl Boom | Am | Bucxet | Swing | Option In travel operation (P1} oO Oo in travel operation (P2) Oo Oo. oO. 21-1921. MECHATRO CONTROL SYSTEM 21.112 PRESSURE RELEASE CONTROL ppatssenetasmanesssinoaaa 4é hus Q BL LE 5 a ae) fat] tle é{] ailellallé wae |B Ells llel_ [Ff -e Weyelelis 3 ge GAUGE CLUSTER ot 3 ze be!) LS | ENGINE SPEE! ‘CONTROL PILOT SIGNAL f Ee ee es] PILOT SIGNAL | AES EE | PILOT SIGNAL PROCESS ieee PROTSIGHAL ‘pee process IIR ER oa secre NEY 4 "pr: PROPORTIONAL VALVE ONTROULER, "SECONDARY PRESSURE (1) Press "Enter SW" on gauge cluster and select switch change mode, Press enter SW of & ¥ switch displayed on pressure release control screen. After the characteris reversed, select control ON with ¥ switch and press “Enter SW", and the mechatro controller decides it as pressure release mode. (2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot accel potentiometer, etc.) the mechatro controller, 1). Outputs minimum tit angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum tit angle 2) Outputs command of pressure release and outputs cornmand of pressure release control to ECU and fixes, engine speed to pressure release control speed. 3) Outputs maximum commend to Pt and P2 unload valves and each pilot secondary pressure fixes P1 and 2 unload valves to the maximum opening (8) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump Pressure and displays "DRAINING HYD. PRESS" or "FAlL DRAIN HYD. PRESS" on gauge cluster. (4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching spoo! with the unload vaive opened 21-2021. MECHATRO CONTROL SYSTEM 21.413 N&B SWITCH CONTROL (OPTION) [B00 UP CONFLUX PRESSURE SENSOR las FOR BREAKER E29 OPTION ‘AR 1 SPEED swiNG [eee 1 PrUNLOAD TRAVEL RIGHT I 00 I BucKeT L ‘ARW2 SPEED {Teaver ser TRAVEL STRAIGHT P2.UNLOAD AMODE BMODE MecHATRO | CONTROLLER | 1: OUTPUT OF N&B SELECTOR SOLENOID (1) Nibbler circuit 1) Select A mode through gauge cluster. 2) Nibbler display appears on gauge cluster. 3) The return oil from the contro! vaive. 4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output. itis in normal when there is no output from sensor in A mode, and in cases of other than above, error display is output to gauge cluster. (2) Breaker circuit 41) Select B mode through gauge cluster. 2) Breaker display appears on gauge cluster. 3) The return oll from the breaker passes through selector valve and directly returns into hydraulic oll tank 4) When selecting 8 mode through gauge cluster, the breaker pressure sensor outputs signal Itis in normal when there is an output from sensor in 8 mode, and in cases of other than above, error display is cutput to gauge cluster. ler passes through selector valve and option spool and led to tank line of main 21-2121, MECHATRO CONTROL SYSTEM 24.1.44 OPTION CONFLUX CONTROL (OPTION) g g 3 3 5 7 ill. a Ell lg & 5 | Ue sHeh ets aH Hells a||z]|2 z fr £1/8// 8/2 Puorvayye St2}LeileL [LF VEEL § ge z 25 = ° [SRRLETCOWALER] ton pressure [SUCH g Sexson | Of BiLoT GNA. | ae ron nae ees : t OPTIONPLOT SECONDARY pressure ae % : Hee uot L PERE Preeernen i "[aeseoa : TONPLST SECORDARY PRESSURE | j BiLoT ston. | | i PX PROCESS "2 UNLOAD | : ae : ‘Teese : ONBROT SECOND pnessune | : PILOT SIGNAL euROD. : PROCESS. |PROPORTIONAL : Later i RONPOTSECORER PESSURE | : LOT SIONAL |p F chee : ese a: jMECHATRO _ 5): PROPORTIONAL VALYE paesguee__ | conrRouter ™ SESBuShar oReeS Re (1) Select the Conflux with the aid of Conflux/Single swit (2) On starting option operation, option operating pilot pressure switches option spool and Is input to low pressure sensor. (3) The output voltage of low pressure sensor is input io mechatro controller and the mechatro controller processes pilot signal and outputs command according fo the input voltage to P+ and P2 pump proportional valves, P1 and 2 unload pressure proportional valves and travel straight proportional valve. (4) Each proportional valves output pilot proportional valve secondary pressure according to the command output by mechatro controlier and changes P1 and P2 pump delivery rate and switches P4 and P2 unload valves and travel straight valve of the control valve {5) The parallel passage on P2 side is connected to P1 port because of the travel straight vaive switched and P41 pump delivery oll confluxes P2 pump delivery oil because of the P2 unload valve switched. 21-2221. MECHATRO CONTROL SYSTEM 21.2 MECHATRO CONTROLLER 24.24 SUMMARY OF MULTI DISPLAY Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. (1) Controts EMERGECY ACCEL DIAL SWING PARKING BRAKE RELEASE GAUGE, SAFETY Q fee’ 27 LEVER = =) RIGHT CONTROL = i WITH ATT | PAY (BE) NE | eranter siren 4 Loox | 0 ACCEL DIAL, Name. [Engine coolant temperature gauge Fuel level gauge Screen change switch Buzzer stop switch Work mode select switch Washer switch Wiper switch ‘Travel high speed, low speed select switch ‘Auto accel switch Select switch Multi displey (LCD) 21-2321, MECHATRO CONTROL SYSTEM (3) Screen selection by work made select switch Attar starting engine, “S* mode is usually set. ‘The work modes "S' ."H","B" and "A" are selected in order every time (5) is pressed Select efficient work mode according to the working condition and the purpose from the following table, ‘The selected mode is displayed on the left lower comer on multi display. + S mode: For standard digging work + H mode: For heavy duty digging work +B mode: For works with breaker + A mode: For works with crusher (nibbler) eB) Work mode Disay Contents ae rmoddessuilabe for stander digging and loading works and isin |uct seving end is maintained wel-belanced relations with workload oe "H modes suitable for heavy duty digging work which gives priory ho te word atthe high speed B mode For the work wit breaker, select “8 mode" wthout fal Amode |For the work with crusher (nibbler), select "A mode".21. MECHATRO CONTROL SYSTEM 1) Pump flow rate adjustment (A mode /B mode) Eos PEPE uvlit PCE PEPE screen change switch Buzzer stop switch PSS work mode sel Washer switch Wier switch Travel speed select switch [Auto accel switch elect switch switch |=|~|>[]a [ef fw go dy ca Fig. 21-4 According to some kind of attachment, itis required to change the flow rate for service circult. Change the flow rate in accordance with the procedure mentioned below. In this machine, last set flow rate has been stored and the initial low rate is 240L/min, The adjustment (increase or decrease) of flow rate is changeable by 10L/min step, Main screen, Attachment mode (A mode) i 7 a) 10:25 eto um rate cof in| => Enter 2 va (a) Increase/Decrease When the conflux switch is tuned ‘on, the double flow rate is displayed. 1. Turn starter key switch on and display main screen (a). 2. The display on the left lower corner of screen is changed in order of "MODE" switch (3) is pressed under the candition where main screen (a) is displayed. Select "A" and A mode screen is displayed, and select "B” and B mode screen is displayed 4, Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and each time the the screen (d) is displayed. in this congition, press FEED A (4)/'¥ (6) and the flow rate value increases or decreases. 5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value. 24-2521. MECHATRO CONTROL SYSTEM (4) MAINTENANCE SCREEN DISPLAYS This screen displays the remaining time to the end of recommended replacementichange interval specified for filter/oil, For the initial set value of recommenced replacement/change time, see the following table. Replacement interval item Default Engine oil ‘500 Hr Fuel filter 500 Hr Hydraulic oil filter 4,000 Hr 2,000 Hr }00 Hr Hydraulic oil This menu is available for confirmation of the following items. ‘The maintenance screen changes each time the screen change switch is pressed, +1. Remaining time display to the engine oil change: This display shows the remaining time to the coming engine oil change. 2. Remaining time display to the coming fuel filter replacement This display shows the remaining time to the coming engine fuel filter replacement, FUEL FILTER 3. Remaining time display to the coming hydraulic ol filter replacement This display shows the remaining time to the coming hydraulic oil iter replacement. 992Hr HYD FILTER, 4. Remaining time display to the coming hydraulic oil change pyre] This display shows the remaining time to the coming hydraulic ofl change. HYD. OIL =~ (Notice + The display automatically changes to the main screen, if switch is not operated for 20 seconds. + For the setting procedure of maintenance time to be performed to the coming oil change in each type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE 21-2621, MECHATRO CONTROL SYSTEM (5) Gauge cluster display After key is switched on and logo mark display disappears, screen for operator is displayed on mulli screen. The display functions of multi display are explained below. ‘CLOCK DISPLAY ‘SELF DIAGNOSIS / WARNING MULTI DISPLAY INDICATIONS: 1), Display function for operator Screen usually displayed during operation. 4.1 Clock display function Current time is displayed, 1.2 Self-diagnosis display........ When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays error code. 4.3 Waming display ....... When machine was thrown into dangerous siate, or was failed, displays warning contents with the symbol and statemont. (For warning contents, see items shown below.) 1.4 Machine condition display ....... Displays machine operating condition. 2) Display function for maintenance... Displays remaining time up to replacementichange of following items. (1) Engine oil 2) Fuel fier (3) Hydraulic ol! fter (4) Hydraulic oll 3) Failure history display function ...... Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence. 4) Mechatro adjustment display......... Displays procedure for adjustment of mechairo system like output adjustment and unload adjustment, etc 5) Service diagnosis display... Displays information like pressure sensor sensed value, proportional valve command, etc, output by mechatro controller 6) Failure diagnosis mode display function ........ Specifies failed section automatically for failures which are not detected by self diagnosis and displays the results. + Waming Eon REET] BYrwes (a) Avro stor Gy Heke | CHARGE ERROR [a Rarer GOST Bere] Gf aamce WAR FISH WARMUP A ovwvaren sem) WARM AUTO WARMING UP cpu EeRhwucarion | ©, aocccoanru SEF CHANGE ENG OL BeeMSIeeUT | G2) ENGINE sToP 21-2721. MECHATRO CONTROL SYSTEM 21.2.2 SELF DIAGNOSIS DISPLAY (1) Outline This function identifies abnormality of control I} signal like pressure, proportional vaive, etc. during machine operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector No, and pin No., refer to the section "C-1 Mechatro controller" explained later. Electric circuit diagram or harness is available to identify wire No. and wire color. (2) UO configuration Pressure sensor, Engine controller INPUT | Proportional vaive, Battery relay —| Selector valve (SOL) SERIAL COMMUNICATION P| Gauge cluster (Buzzer sound) CONTROL (3) Self diagnosis display items. As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with, the aid of error code. ‘Alphabet: Decide system failure occurred. 10:25] 5 COAG) ten ae 98 ae: Secte sle seton Gs 3 T—Last 1 cist Specifies failure type. EeSeaconE Tis alors symbol is played simultaneous th eror code during fabore agnosis — ee ee eS ee Sr = a= = ee Ee ee oe ee Prone tno TTT rar aaa [read oe Refer tenet p2ge (Engine) = - — ol ! etl | iff Breer eee “| | c | i : am ara | Srila a} = 221, MECHATRO CONTROL SYSTEM ERROR CODE OF ENGINE Sensor SySTEM POSSIBLE CAUSE Atoapherie pre sure sensor mahuraton, TaD. cent engine | Insuficint engine power Boos: pressure sensor maiuntion (4) 7_| Coolant temperature sensor malfuntion (LOW [Coolant temperature eanserm Fuel eomerstor [Accelerator sensor 2 maltinetion (HI) Iswirck, ReLay syste reheat aeult msfunevon (Open /¢ Preheat circu malfunction (°B short crcut IsuPPLy Pum sxsteK ‘Supply-pume abnormal pressure record {Supply ou ewer source ins short ‘Suoply pune SOV mefunetion (Ful dacharge rade) [Excessive common ral preséare INueoTor sysTEM injector conmmon { ground short Ovinder 4 contraution / lance ful lec sYSTEM EGR sovenoid | malfunetion (0 EGR solenoid malfunction Power source ine short) stick ot EGRIR sensor {circuit hgh nut [Tune ARCA Sra Ture charger ever Boost leNaive conomrion Engine over neat Engine overrun [GOMRTURIGATION | Ui00 [interruption of GAN comanicaion (Machi) [ECU charge eveuit lw ineut lecu system Monitoring (6 masifurction in CPU TUECTOR SYSTEM, injector correction cata corforaity a [SUPPLY PUMP SYSTEM i Bp ee [SUPPLY PUMP SYSTEM. Supply pump malfunction Ton octet “few eutsut Note) ‘The numbers in the column of "page for reference" show the related page in Chapter 51 Engine. 21-2921, MECHATRO CONTROL SYSTEM 21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION The current service diagnosis is dispiayed on mutt display based on the data received from mechatro controller. This section explains the operating procedure and examples of each screen. The values in display changes according to the conditions like engine speed, attachment position, etc. (1) Service diagnosis display screen operating procedure 1) G23 Tum starter switch ON keeping buzzer stop switch pressed 2) After logo mark is displayed, the screen changes in service diagnosis mode. The service diagnosis screen "Mode No.1", “Screen No.1" is displayed first. The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in "Screen No.1" ‘The screen number each mode can display differs. The screen number displayed by each mode is as follows. + Mode No.1 : Screen No.1~No.30 + Mode No.2: Screen No.1, Screen No.31~No.40. + Mode No.3: Screen No.1, Screen No.41~No.50 3) The screen changes each time each switch is pressed from now on. (3) Wesher switch: Screen gains by 1 in order. (No.2-+No.3->No.4~...) (2) wiper switch: Screen loses by 1 in order. (No.24—No.23-9No.22->..) {2 Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.4 (No.1->N0.29N0.3-9No.1—..) () Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to No.3, (No.3->No.2-9No.1No.3-...) 4) Turn key switch OFF and the display of service diagnosis mode is closed. 21-3021. MECHATRO CONTROL SYSTEM (2) Service diagnosis display screen (Example) The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low speed and lever to neutral position.) 1) Service diagnosis mode No.1 % oa ae r aa aE 24ER 0000 WeeRrconrter regan arson | |r swine ore iy ot Sua gente OFF fe en Iseruce Dua + sere oagnne mace Senor ie ae free ane * |e taess rman [Sa sessoser 2a —_||ro tad snore a boone went wat |[denatien av ah ses este esi heese Bor || pene 2m envoy | lle coow dite las encres. ine nom otpresnse ava seo tap tecae comet it vanserten ‘ico cee |icocerc wesc sxr ps Anwout Move” nw eos Sev bow stor tape rsa jes Heb “ay Pte we es Sle socks atoge nn ae sera sa ce sououtrur "hsv | AtelScputsersoeraes | les auckerdie ester ec vee cre ee et uN aw Semen Pee cnt ot Js rower boost fer we stuns compte Eee) Ise Pere comes Monastic ibe thaveury ‘Suich ec ser wo Pane covet ee sexwavein cone eset [sete ee Sere eee [see covet Setvaucincometr iby te [ee nisiPesuecrnet abe ese we low Bezen' Pear seve ze [serie ressecomen ae lew boven’ yew [sre Pome aie 21-3121. MECHATRO CONTROL SYSTEM ae ta a ae 7 FRO RSENS POV 6] fid'ie PRESS. SENSOR ae sums neaercnevommn ||P "sev szeu ser te renee lee eum r 7 Az. = eae itoamenertine| | stg cate ea searenpsironeedaie| [Pas 120 sonst Resource San searouprnoasronaer| [Pasy race Smet reanate PROPO.VALVE [eas 7 Boer te 5 seavenmeononenennwie|_|fPSsev rae sein oe ie MEAS. 600m8 14.50 mamlomensenetsrs] P20. oy 26 Serene wage /Pressrecomamied abe JE OFT RELIEF 2 [Se whe nenevas Gawhs in ton oom Sou fon to scenes 3 ison mano oad Siiveeooteom i lowoee mato Spe dnt a ——— or iuoer Seen los ta unroxoce cum rt oe [Sue parton Col same tsi ont net en faa [dues macance los sreavee Pee reer eee oF [Sure macaren | Se, Soi een 3 san erent ne oe lure nocisn p Methake ie tone a Seater a or foreseen Se ‘col eooma it sestmraremcremesaninsean| |[ort OFF loots macaton Se wane fssmaemcecacereces| [cd See are Soece Be Bee Shor accae Bit_ fre Shoe aoeacn ea PRP Dosce sours a Lesaniweitnninennvaue| [oh StF ower aces Poteet inn sarin Bee Shoe tore Iau aston Pct bina re See wore aca fs re as Se Sheraton aurea «at ccronenrinennanernn| [ost See [er ton Nea cata st fscccsiecemstrpact)| eae Ser uence Jrcownane soot be oun P2 et Ser lSuser nscsen Be ie ce Isr oer stoer moti, Bs_oet [wore mca [fuse amore Plscasomar etree : Sas oe ——— Ss lronaccrmnwe | Ue ed Sittren ve \artrs lier Ser torr macaton Sec eee | YER Se Eee’ Eevcerattive Sei oe less Se Shoe rece Frew vinow FSteratropettee nae | esr SEF enone fen Saucon on eeauisiyctcwmcsonn | [sce Ser lower ten ed enc Gs oer ier fae Socata Beare Bore Shorr taetos | et Soc vee ')IRO2T SISTAL OUTPUT Pe Gere Sor coue ore seat sree ee ore ctaba incu vets oer contac ies oe Senate Aeron won| oon ue Set Seat Tahoe sss Se nue sce 200.708. es sptrsior tee re Eee Seite | ene Sens Ser cores ace ins aun Se Se Bere eau eee Stan np wens re cows eters nar tie Sr Bee an lor Ss ore Sone wa Ser cose 2) fNo.t2 POTENTION 22 | oa BeGiTAL OUTPUT Noon Bi cou ore sevaveingnoer Sr sincionmccntmrne| [PO Sas SFr seule saa oe ore Saree eae et 3010 COMP. OFF Set vahie in computer See re cores co on Gone See Beate rae ek & nie lors om et Berea tens oe sounds fos done Seen pov ote er [Sect 21-3224. MECHATRO CONTROL SYSTEM — aa a a Jo's COMP OFF | Set ware in computer Pa eas 7 femme coy paetemeeetoren pow fa ee 7 ee oe Lom ie eee pow te Be ee ° pox te eae ge ge fesenree Noa? DionaL coeur 7 |°8| roe: ENG CONT. Besa —— rn loos Mee Ieesue wun JRECEWE COUNT. 160 Gounte number ef resenton eto. tee oe Seem fearon, feerexy eee an Barat |e pon a ene facet |e gee fees Ea eee. pun te eee Ee © [RASeee, on gee Leen ess faeces boar Cour OFF Set wauein comeuiar IENGPRESS. 20 Engel arre loow Cou Ore Stan reaper [sxeSrop “ore Erne sep aman fom ECU ae Eo Rae eae Beets RES an ‘Sow Moto Re OFF per nema ation ty Bees” Seeman, Soh S| REIS 2) Service diagnosis mode No.2 Fg sa er —y a me “Wino 7 [nese aoeRET [Bao Eero ree EER soon er aes ae eect ori eerncin tay | |S eta ees Sea oe Seas arian | | aes me |e emcees ae penn Beer ceases Skee | amieeace 31 (inoaT Booar [noe raver ET oe ee Eee aw rpscze ne seen? 2a fazeswesnes Esme: 32 essere fers, Sra rare Fee, oe mae Bi eiteet en Somes Ueresne — ecmntet ieee, [rece Bifearces [gsm ls3 soso on Somos senor jee TRAVEL “raane we pt ora esr Saint na (pba ad [Sct yea jafcewire eee POWER StaFT Thoma ower scant ime en cece Sire a Elie: 3% Raspes Ears fase See aa erga Ene? aa eatin Ens) ke emma Eres Bit rae Bee tm | Eeemaeces Ei Pcleet ne | Sawa: Binge et escaeeas Bepiers fest | Senate eee ee See Bete | Siaaeeret Baseaas den eevee Eyecare | geemacet amare |iatnetaeae, | YESS ae bs seainase son ergretenn | PGES we [Sire Bxgeecte [eee oo nee 21-3324. MECHATRO CONTROL SYSTEM 3) Service diagnosis mode No.3 —— ca = x nor 183 [c.43 MAGrANE-IHFORA EEkcocr a ee el eee ecm seen Sore Heer lee a Perec | | Se eeeaie cei ele SS lereons fwcewmevae | | ee Seen a, 8, oats Eraine spe none lgrete neo scueret Pessare a puna somes Engoe specs oreo ia SRST Levee bebo, Tete oe Soe tees te ie Pep case steson (5) ae a Oe lbd0u sar Page avers Lives Soe Som be sare 3 Ri asmer IBEG Be Be loeeser ar ee ere ie Te ae ois eee Ones nick a_i dor ge acre 21-3421, MECHATRO CONTROL SYSTEM (3) Service diagnosis data list Preface and precaution ‘The following is the data decided as normal status ater service diagnosis for every operation. Use these data to decide normal/abnormal status. + The values in following display are reference values with standard attachment attached machine. + The value of pressure sensor is calculated taking variation into accounts. When compared to performance check reference criteria, measure it with the aid of calibrated measuring instrument. + The current of proportional valve is not the measured value, but command value. The measured value should be confirmed by the value in the displayed value for each proportional valve. + The current value of pump proportional valve is reference value because it varies according to pump pressure and adjusted torque value. + The value in display during operation shows the value in steady state, rather than, at start of operation. * Check on machine after sufficiently warming up machine. + The value in display may differ according to software version. Contact our dealer/distributor. (Operation No.1 : No operation [Operation No.2 : No operation H mode Hi idle |S mode Hi idle No.32 ARM, SWING 7 | |Nos2 ARM, SWING : C+ PIL-PRES 0.24.5 M C4 P1-PRES 02-45M C2 P2-PRES 02-15 M ©-2 P2-PRES 02-1.6M E41 PLPSV soma | | E41 P1psV 250 mA | £2 P2PSV a60mA | | £2 P2PSV soma | D-t_ PT-UL(BPC) 750 mA D4 Pt-UL(@PC) 750 mA D2 P2UL(BPC) 750 mA D2 P2-UL(BPC) 750 mA D-3 S-TRAVEL 350 mA D3. S-TRAVEL 350 mA D6 ARMAN-2 750 mA D6 ARMN-2 750 mA 8-3 ARM OUT oom | | 83 ARMOUT oom | B44 ARMIN 0.0M Bs ARMIN oom | B-1 BOOMRAISE 0.0M B-1 BOOM RAISE oom | 87 SWING 00M B7 SWING oom | G-3_ ENG SPEED 1970~2030 G3 ENG SPEED 1770~1830 POWER SHIFT mA POWER SHIFT Oma ‘Operation No.5 Boom up in full lever operation & relief [Operation No.t: Boom up in fll lever operation & in operation H mode Hi idle Hi mode Hi ite | |No.31 BOOM No.31 BOOM Hee | | C1 PLPRES 33.0-26.8 M C1 PL-PRES 11.0~16.0 M | 0-2 P2PRES 33.0~35.8 M C2 P2-PRES 11.0~16.0M E4 PrPsv 415-525 mA E41 PLPSV 560~750 ma £2 P2PSV 416-625 mA E2 P2Psv ‘560-750 mA D-1 Pt-UL(BPC) 360 mA D-+ PH-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA D-2_ P2-UL(BPC) 360 ma 8-1 BOOM RAISE 30M 8-1 BOOM RAISE 3.0M | 8.2 BOOM LOWER 00M 8.2 BOOMLOWER oom | G3 ENG SPEED 1970~2060 G3 ENG SPEED 1970~2060 POWER SHIFT Oma POWER SHIFT Oma 21-3521, MECHATRO CONTROL SYSTEM [Operation No.5: Boom down in full lever operation & in| operation H mode Hi ile No.31 BOOM C41 PL-PRES 12.5~16.0 M C2 P2-PRES 0.21.5 M E+ PLPsV 600~617 ma £2 P2psy 360. mA D-1 P1-UL(BPC) 427-477 mA D2 P2UL{(BPC) 750 mA B41 BOOM RAISE oom 8:2 BOOM LOWER 3.0M | G-3 ENG SPEED 1970-2060 POWER SHIFT Oma [Operation No 6 : Armmin in fulllever operation & relief] _ [Operation No.7 : Armin in full lever operation & in operation] H mode Hi idle H mode Hie No.32 ARM, SWING INo.32 ARM, SWING C1 P1PRES 33.0-35.8 M C1 P1-PRES 125~16.5 M C2 P2-PRES 33.0-35.8 M C2 P2PRES 12.5-16.5 M E41 P4-PSV 415~525mA | | E4 Pi-PSV 550-750 mA £2 P2.PSV 415~525 mA £2 P2PSV 550-750 mA D-1 PA1-UL(BPC) 360mA | | D+ P1-UL(BPC) 360 mA D2 P2-UL(BPC) 360 mA, D2 P2-UL(@PC) 360 mA D-3. S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA D-6 ARMAIN-2 200 mA D-6 ARM-IN-2 400 mA B39 ARMOUT oom 33 ARM OUT 00M B44 ARMIN 30M B4 ARMIN 30M B-1 BOOMRAISE 00M B41 BOOM RAISE oom 87 SWING 0.0M 87 SWING 00M | G3 ENG SPEED 41970-2080 G3 ENG SPEED 1970~2080 | POWER SHIFT Oma POWER SHIFT oma 21-3621. MECHATRO CONTROL SYSTEM [operation Nos ‘Aarau in full over operation & raliet [Operation No.9 ‘Arm-out in full lever operation & in operation H mode Hi ile H mode Hite No.52 ARM, SWING No.3? ARM, SWING Cl P1-PRES 33.0-95.8 M CA PLPRES 15.0-22.0 M 6-2 P2PRES 33.0-95.8 M C-2 P2-PRES 15.0-22.0M Et PtPSV 415-526 mA E41 PLPsVv 488-677 mA E-2 P2PSV 418-525 mA £2 P2PSV 488-677 mA De PA-UL(BPC) 360 mA D+ Pt-UL(BPO) 360 mA D2 P2UL(BPC) 360 mA D2 P2UL(BPO) 360 mA D3 S-TRAVEL 350 mA D3 S-TRAVEL 350 ma D-6 ARMIN-2 7s0ma | | 0-6 ARM-IN-2 750 mA 8-3 ARM OUT 30M | 83 ARM OUT 30M B-4 ARM IN oom | | B4 ARMIN oom B-1 BOOMRAISE oom | | 81 BOOMRAISE 00M BT SWING oom 5-7 SWING oom G3 ENG SPEED 1970-2060 6-3 ENG SPEED 1970-2060 POWER SHIFT oma POWER SHIFT Oma * Measure the values afier a lapse of 5 minutes or after release of low temperature mode * Measure the values after a lapse of & minutes or after release of low temperature mode [Operation No.0 ‘Swing in full lever operation & relief [Operation No.1 ‘Swing in full lever operation & in operation | H made Hi ile IH mode Hi idle No.S2ARM, SWING INo.32 ARM, SWING C-1 PL-PRES 0.2-1.5M C+ PL-PRES O21.6M | C2 P2-PRES 28.0-35.8 M 2 P2PRES 10.0-15.0 M E41 PL-PSV 350 mA E41 PLPsV 350 mA £2 P2Psv 628-750 mA £2 P2PSV 750 mA D-t P1-UL(BPC) 750 mA D+ PT-UL(BPC) 780 mA | 0.2 P2uL(ere) 360 mA D2 P2.UL(BPC) 360mA_ | 0-3. S-TRAVEL 350 mA D3 S-TRAVEL 350mA | D-6 ARM-IN2 750 mA D6 ARM-IN-2 750 mA | 8-3 ARMOUT oom 8-3 ARMOUT 00M 84 ARMIN 00M 8-4 ARMIN 0.0m B41 BOOM RAISE 00M B+ BOOMRAISE 0.0m B7 SWING 30m BT SWING 3.0M G3 ENG SPEED 1970-2060 G3 ENG SPEED 1970-2060 | POWER SHIFT Oma POWER SHIFT Oma 21-3721. MECHATRO CONTROL SYSTEM [Operation No.42 [Bucket digging in full lever operation & relief [Operation No.13 Bucket digging in full lever operation & in operation Oma H mode Hi idle H mode Hi idle |No.33 BUCKET No.33 BUCKET | C1 P1-PRES 33,0~35.8 M C1 PL-PRES 4.0-8.0M C2 P2PRES 33.0-35.8 M C2 P2-PRES 4.0-8.0M | E41 Pt-Psv 418-525 mA E+ PtLPsy 650-750 mA E2 P2PSV 415-525 ma E2 P2PSV 540~563 mA 0-41 P1-UL(BPC} 360 mA D4 Pt-UL(BPC) 360 mA D-2_ P2-UL(BPC} 360 mA D-2_ P2-UL(BPC) 360 mA D-3 S-TRAVEL, 720 mA 0-3. S-TRAVEL 720 mA B-5 BUCKET DIG 30M 85 BUCKET DIG 3.0M 8.6 BUCKET DUMP 0.0m B86 BUCKET DUMP 00M G3 ENG SPEED 1970-2060 G3 ENG SPEED 1970~2060 POWER SHIFT POWER SHIFT oma [Operation No.14 Bucket dump in full lever operation & relief Operation No.15 Bucket dump in full lever operation & in operation 21-38 IH mode Hi idle H mode Hiidle No.3 BUCKET No.33 BUCKET C41 P1-PRES 33.0-35.8 M C1 PLPRES 6.0~15.0M C2 P2PRES 33.0-35.8 M C2 P2PRES 6.0-16.0M E41 P1-PSV 415-525 mA, E+ PLPsV 877-750 mA £2 P2-PSV aisagsma | | £2 p2-PSV 418-435 mA D-1 P1-UL(BPO) 360 mA D-1_ P1-UL(BPC) 360 mA D2 P2UL(EPC) 360mA | | 0-2 P2-UL(BPC) 360 mA D-3 S-TRAVEL 720 mA, | 0-3 STRAVEL 720 mA B5 BUCKET DIG 00M BS BUCKET DIG oom 8.6 BUCKET DUMP 3.0M 8-6 BUCKET DUMP 30m G3 ENG SPEED 1970-2060 G-3_ ENG SPEED 1970-2080 POWER SHIFT Oma POWER SHIFT Oma24. MECHATRO CONTROL SYSTEM ‘Operation No.16 Operation No.47 P2 side option in full lover operation & relief }P2 side option in full ever operation & reliet |A mode Hi idle B mode Hi idle No.35 OPT No.35 OPT C-1 PI-PRES 5-26.0M C41 PLPRES 0.24.5 M C2 P2-PRES 22.8-26.0M C2 P2-PRES 225-26.0 M E4 PLPsv 459-584 mA E41 P1LPsV 500 mA E2 P2PSV 459-584 ma 2 P2PSV 665-750 mA D4 P1-UL{BPC) 360 mA D4 Pt-UL(BPG) 750 mA D2 P2ULIBPC) 360 mA D2 P2-UL(BPC) 360 mA D3 S-TRAVEL 720 ma D3 S-TRAVEL 350 mA £3. OPT RELIEF oma £3 OPTRELIEF Oma B46 P1 OPT oom 846 P1OPT oom B47 P20PT 2.0-2.6 M B17 P20PT 20-26 M F4 OPT SELECT NIB F-4 OPT SELECT BRK DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF G-3_ ENG SPEED 1970-2060 G-3_ ENG SPEED 1970-2060 POWER SHIFT ama POWER SHIF oma “ Conflux switch is ON. Relief set pressure is value of —_* Conflux switch is OFF. Relief set pressure is valve of shipping. shipping, [Operation No.18 [Operation No.19 a ‘Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling H mode Hi idle H mode Hi idle No.34 TRAVEL 7 INo.24 TRAVLE C4 PL-PRES 6.0-12.0 M C4 PLPRES o215M | C2 P2PRES 02-15 C2 P2-PRES 50-120M | E41 PL-psy 750 mA E41 PL-PSV 350 mA £2 p2psv 350 mA 2 P2PSV 750 mA D+ P1-UL(BPC} 3e0ma |) | O41 Pr-UL(@PC) 750 ma 0-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 360 mA D3. S-TRAVEL 350 mA D3 S-TRAVEL 350 mA 8-9 TRAVEL(R) 2.0-2.5 M B9 TRAVEL(R) 00M B-10. TRAVEL(L) oom B10 TRAVEL(L) 2.0-2.5M PLPt 00M PiPt 00M Pip2 oom PiP2 00M G-3_ ENG SPEED 1970-2060 G3 ENG SPEED 1970-2060 POWER SHIFT oma POWER SHIFT OmA 21-3921, MECHATRO CONTROL SYSTEM 21.24 TROUBLE HISTORY DIAGNOSIS ‘The items of error detected by mechatro controller saff diagnosis function are stored in mechatro controller as one Cf history. And the errors are able to be indicated on the mull display The warning content is indicated partially in "Travel history screen’ The error code for self diagnosis is stored (1) How to display 41) Turn starter switch on, 2) Press buzzer stop switch for 10 seconds continuously § times and the trouble history screen is displayed (Example) No errors NO ERROR lioasene Fone g500Hr GO33 Error detected in the past 3000Hr P1211 co13 1600Hr 3). Transmit trouble history data (One or many) and hour meter to gauge cluster. + Hour meter and 4 failure data are displayed on screen + Incase of more than 4 failure data, 4 data is displayed ata time for 10 seconds by turns 4), Paging (Up and down) + Press washer switch (JA), and the item moves upward. + Press wiper switch (¥), and the item moves downward 5) Tur starter switch off, and the display is disappeared (2) How to delete contents of trouble history 1) Display trouble history screen, 2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more. 3) When "NO ERROR is displayed, the deletion is completed 4) Turn starter switch off Crete) All the stored items are erased. Itis impossible to erase data partially. 21-4021. MECHATRO CONTROL SYSTEM 21.2.5 TROUBLE DIAGNOSIS MODE The recent control system includes many electrical systems and it makes troubleshooting very dificut. The failure diagnosis mode is used to automatically specify the failed sections for the falures which can not be detected through the use of self diagnosis function (the failure can be specified through the use of error code) like disconnection and abnormal output. This is useful to save the time for troubleshooting, (1) Function ‘There are two types of trouble diagnosis mode. 1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine system, 2) Trouble diagnosis mode 2: Used to diagnose pilot system. In any mode, with the attachment not moved, both directional valve and proportional valve are automatically actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition ort feiled condition of the system. For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE". 21-4121. MECHATRO CONTROL SYSTEM 24.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE This machine is equipped with mult-display which allows confirmation of remaining time to the coming replacement/ Change time of engine oil, fuel filter, hydraulic oil fiter and hydraulic oil, therefore when the remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic fiter, hydraulic oil, etc. and perform the initial setting by the following order. oe Screen change Buzzer stop KPSS work mode ico) ‘itch switch Select itch 2 r > 6 6S ee ee ‘switch = Engh ol 500 Hr + Flor: 500 He 2 fw wy Interval of replacement of parts is mentioned below, + Hydraulic iter: 4,000 Fr a owes + Hydraulic ol : 2,000 Hr (ASIA) a ee) 5,000 Hr (OCEANIA) Procedure| Operating Procedure Display on Multdisplay Alter soveral seconds, [40.55 | display is changesto__ 10:25 clock autmaticaly, 1 Turn starter key switch on, IKOBELCO} ores seven crags 250 HF ENGINE O1L Am Press "(@)}" switch press once display 2 |shange switch on the switch panel once. And the clock display changes to the display of remaining time for coming engine oil change. Press * 3" switch press once select Barr g__ [Switch once and the display for the engine ct Sw oil change reverses Sice mere, 2] ENGINE OR : ees va When required to adjust the interval to the coming | change time by 10 hours, press "[5] a" switch and the time tothe coming engine oil change is | Fyne on. added. Press *[22) ¥" switch and the te tothe | | mem, coming engine ol change is reduced opecraintnatis YH | changed with each Hr pressing of switch, | ENGINE OL i ea wu When desired to return to the initial sat time, 500 Hr press "[E)" buzzer stop switch once [To set the desired interval Press "{&=3)" select switch once and the set || ENSINEOL [press the select switch | _ENOINE OL time is stored ane va fe Hm Chote) 1._ Alter caplaying the display for seting by pressing the splay change svc, set the respective maintenance time for ue tr, hyéraule of iter and hydraute ol while repeating the procedure 2 to 5 2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not sound. 21-4224, MECHATRO CONTROL SYSTEM 21.2.7 ADJUSTING PROCEDURE OF DISPLAY (1) For operator 1) Auto idling stop No. Switchs 1__|Scroen change switch 2_[Buzzer stop switch 3 |KPSS work mode select switch 4_[Washer switch 5_ [Wiper switch : 7 7 8 ~ me Sf Aw. Sree ‘Travel speed select switch cet SKY ‘Aulo accel switch f 6 8 7 8 ‘Select switch a Fig. 24-2 Main screen @ o - e J = -+-+--{ [AUTO IDLING STOP wa (a. TORO WaraOF “NUTOTOLE STOP ATO TOE STOP OFF OFF on ree0/< reso! 2 val va © AUTO IDLE STOP ie va 1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCKICONTRAST* select screen (tb) 2. Press select switch (8) again and display "AUTO WARM-UP OFF” screen (0) 3. In operation of FEED 4 (4), the “AUTO IDLE STOP OFF" screen () is displayed, 4. In operation of FEED 4 (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen {e) is displayed. 5. Switch from "OFF" to "ON" in operation of FEED A (4) and set it by pressing selector switch (8). 6. When auto idling is functioning, the “AUTO IDLE STOP" is displayed on the multi-display. 7, Tum starter kay switch off once and store the auto idling stop setting as. a memory, 21-4321. MECHATRO CONTROL SYSTEM 2) Clock Adjustment Switches No. ‘Switches ronnie nse Ta Jauzzer Stop Switch 4 /| 3 [RPS Work Mose SanctSaoy ———— rie / 4_ [Washer Switch 5_|Wiper Switch __6 [Travel Speed Select Switch 7 “3 ‘Auto Accel Switch Select Switch Main screen CLOCKICONTRAST Select Yearitionth/DayiHour/Minute_Increase/Decrese 1. Tum starter key switch on and display main screen (a) for operator, and then press select switch (8) and display "SWITCH STATUS CLOCK/CONTRAST” select screen (b). 2, In operations of FEED 4 (4) and FEED ¥ (6), move cursor to "CLOCK/GONTRAST" screen (c) and then press select switch (8) and the “ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed. 3. In operations of FEED & (4) and FEED ¥ (5), move cursor to "ADJUST CLOCK" and then press select switch (8] and the "ADJUST CLOCK" sereen (e) is displayed. 4. Select any of "YeVeD+HelM" in operation of FEED 4 (4) and FEED (5) and vary the values in operations of FEED A (4) and FEED Y (8) 5. Aller adjustment, press select switch (6) and the adjusted values are slored es memory and time setting is completed, and then the screen returns to main screen (a). 21-4421. MECHATRO CONTROL SYSTEM 3) Contrast Adjustment Switches No. Main sor 10:25 |= i 1 [Screen Change Switch Buzzer Stop Switch IKPSS Work Mode Select Switch Washer Switch Wiper Switch Travel Speed Select Switch _ [Auto Accel Switch [Select Switch 5 wey 7 2] Switches ‘CLOCKICONTRAST ie Aaa a “Adjustabl T Aguile rarg° | ncreaserDocreate (Geta 5855 Turn starter key switch on and display main screen (a), and press select switch (8) end display "SWITCH STATUS CLOCK CONTRAST" select screen (b). In operations of FEED 4& (4) and FEED W (5), move cursor to “SWITCH STATUS CLOCK CONTRAST" screen (c) and then press select switch (8) and the “ADJUST CLOCK ADJ CONTRAST” screen (d) is displayed. In operations of FEED 4 (4) and FEED ¥ (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed Press select switch (8) and the "ADJ CONTRAST 58555" screen (f) is displayed. Vary the values by pressing the desired figure in operations of FEED .& (4) and FEED Y (6), The available setting range is in 9 steps from "11111" to "99990" [Example] 11111 (faint) ~> 99999 (clear) _* The intial set value is 55556. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is completed, and then the soreen returns to main screen (a). 24-4521, MECHATRO CONTROL SYSTEM (2) Function for service Following items are provided for adjustment of service function. Item CONTENTS Language Language selection Rise-up wiper [Wiper control change (When cab is changed) idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust P1 option pressure sensor [ON/OFF of self diagnosis for P1 option pressure sensor P2 option pressure sensor [ON/OFF of self diagnosis for P2 option pressure sensor [Swing alarm [ON/OFF of swing alarm (ON/OFF of adjustment for user) Left pedal for rotation of option Does left rotation pedal use? attachment (Unload valve does not actuate because P4 pump is equipped in EU.) (Optional flow rate limitation, relief pressure limitation, combination of return [Setting of optional equipment selector adjustment) [Engine speed ON/OFF of engine rpm display lane eoeieoa Racine the type of the engine speed of auto deceleration runs up |Change of starter mode IChange of start mode Cow temperature mode forcible | aaerature mode release release [Cylinders calibration injection adjust mode of engine Pressure release For pressure release 21-4621, MECHATRO CONTROL SYSTEM 21.2.8 | MECHATRO CONTROL EQUIPMENT (1) C-1 Mechatro controlier 1) Outside view oe ibe 1 Hh 12) 28 22 | cwio1 Niaz cN103. NTO ONi0S ONTOS. CNTO7_—CNT0B_CN00 27 216, ne Way, 6 iS 7 \za\ wion Fens | Gwicg] Gwier | ewiee 2 anata a8 te 20 As 46 ‘oxita "entog ERO “ence 2) List of connectors Connector No. | PinNo. | Pon name Function Inputfputput| Signal level cNtOT 1 GA wW, 2 Al [Boom up Input Os-4 5 3 =5VA Power output SV, 4 =5VA Power output SV. 5 ‘A2Z___|Boom down input 0.5-4.5V, 6 GA OV, 7 GA ov, s a3 [Armin Input 0s-45V 2 =5VA Power outoul BV, 10 +5VA. Power output 5V) tt A4___|Arm out Input 0.54.5, 12 GA ‘ov 13 GA ov 14 ‘AS [Bucket digging Input Dey 6 EVA Power outpul BV, 16, 45VA Bower output 5V, 7 ‘AB [Bucket dump Input 0.5-4.5V. 18 GA ov, 19 TOT |Gauge cluster Franomission| RS2G20 communication 20 BXOt Reception | RSZ30C communication 24 GP ov, 2 SHG? Shiels GND 23, Tx03__|Download Transmission) RS282C communication 24 RXDS Reception | RS232C communication 25, DL EARTH / OPEN(V) 26 ‘GP. ov 27 CANaT |e ECU CAN communication 28 CANLI _|&/G_ECU ‘CAN communication, 29 D020 [Spare Quiput_[-EARTH/OPEN, 30 Dot [Safety relay Output EARTH/OPEN, 34 Do22 [Spare Output_|EARTH/OPEN, DO Rotary fight (yellow) Output |__EARTH/OPEN, 33 DO-24 [Rotary light (green! Outpul_|_EARTH/OPEN, 34 0136 [Heavy itt [input EARTH/OPEN. 21-4721. MECHATRO CONTROL SYSTEM Connector No.[ Pin No. | Porname Function, inpalpuion] Signal level CNt102 7 GA OV, 2 ‘AB____|Travel right Input D5-45V) 3 BVA Power Guipul 6V 4 5VA Power output 5V 5 Ag. Travel loft Input 05-45 6 GA ov. 7 GA ov & ‘A10___|Accelation Input Osa 2. BVA Power Gutput SV 40 “=5VA Power output SV 1 ‘Ai3 —_|P1 option ‘input 0.5-4.5V 12 GA Ov 13 GA, ov 4 AId___|P2 option Input 05-45V 15, 5A Power cutout 5V 16 =5VA Power output SV. 7 ‘Az? [Spare Input O5A.5V 18 GA ov, 8 GA ov 20. A28___|Spare Input Os-45V 21 VA Power output 5, 22 D137 [Spare Input GND / OPEN. ConneclorNo.[ PimNo. | Port name Function, inpuvpapia] Signal evel CNI03 4 GA BV z A swing Input Os-45V 3 =5VA Power output SV 4 5VA. Power output SV 5 Ait___|Pt pump Input O54. 5V, € CA. ow 7 GA. ov. 8 ‘Ai2___|P2 pump Input O5-45v 9 BVA Power ouiput SV. 10, =5VA Power output 5V. it ‘15 [Boom angle Input O54. 5V, 2 GA ov 13 GA ov. 1a ‘A16___|Arm angle Input O5-45V, 6 +5VA Power output BV, 6 Resened 21-4824, MECHATRO CONTROL SYSTEM 2S 2 eae 3 (sensor analog output) 419. D5+ P41 pump ‘Output +0~800mA, a Cho [Eaey DD 1 wv 22 D10- [OPT changeable relief 1_| Output -0-800mA. 25 D7+ [Cab slow stop valve ‘Output +0-800mA. 28 Dat Jaren cushion Ouipat ‘0-800mA, 21-4921. MECHATRO CONTROL SYSTEM Connector No] FinNe_[ Pod name Funelion inguin] Signal evel CNI06 1 =28V [faery ny sveonsany ade | 0 20S 2 SHG Shsid GND 3 ++ [Aecsl meter A phase oper) | Output 928 1.5A 4 Fi acca! motoea phase epare) | Outout 2281 5A 5 F2t_—|Acoe! moter ® phase (spare) | Output av 5A 6 £2 |Accel motor 8 phase (spare) |_ Output 21 EA z ‘Oi Oi ieve (spare) 0 @ OLE @ Dis [OPT changeable relet2 | Output | 20-BoGma 10 Dit 0-800mA 1 ize [Spare Sutpat | +0-800mA 2 Diz. oma 78 Dis+ [Spare Dutpot |_+0-B00mA a OTe 0-800 5 Didy [Spare Suipat [20-B00mA 6 Dia. -0-800mA, i ‘GND [Baten oy ow. 15 Digs {Spare Sutpat O=en0A 0 Diz. -0-800mA, 20 Ets |E1G spoad sonsor inp WOVE zi Et ov. 22 SST Shed GND 23 ‘CANH2 Proportional wave expend unt CAN communication 24 CANES CAN communication Connector No-[Pi No] Porname Funston inputted] Signal iovel cNiO7 1 DiS [Rey swith (GLOW) input—_| ~~ ¥2aviOReN 2 18 [Water separetor Input| EARTH / OPEN 3 B19 €/G of pressure Input] EARTH OPEN 4 O11 [Airfiter input| EARTH OPEN 5 OL it Stroke snd cheske input_[ EARTH OPEN. 6 2 [Spare ingut”| EARTH OPEN. T 113 [EI coolant level input[__ EARTH TOPEN, 3 O14 [Spare ingut[ EARTH TOPEN, 2 D115 [Spare input_| EARTH OPEN, 10 120 [ECU main rela input EARTH OPEN 1 3138 [Spare input_| EARTH OPEN 2 DL-92 [Hen control nibbler input_| EARTH OBEN 13 D138 [Quick coupier input| EARTH OPEN i D139 Jetra pressure input [EARTH / OPEN 15 140 [Spare input_[ EARTH OPEN 16 DIai [Spare input | EARTH OPEN a7 Reserved 21-5021. MECHATRO CONTROL SYSTEM Connector No | PinNo._| Pom name Function, Tepubuipay] Signal level cNt0s a Di 2 [Key switch (ON) input 724V / OPEN. 2 Dia [Spare Input $24V OPEN. 3 DIS [Swing PIB release input ‘GND SOPEN 4 Di 6 EI start Input “+24 FOPEN 5 DIT] esensig a eedposted) Input GND SOPEN 5 Di 16 _|Wiper rise up’ Input ‘GND FOPEN 7 DI17___|Wiper reverse Input ‘GND FOPEN & DI 18 ATT boost Input GND FOPEN 2 I-19 |Nibbier open check SW__| Input GND JOPEN 10, DI-21 [Elevator cab up check Input +24 [OPEN iH Dr22__|Spare Input 424 LOPEN 2 0123 [Lever lock Input +24V [OPE 13 DI 24 [Hand controv rotation 7 Input [clamp open or close: GND / OPEN, ia DI 25 [Front window open or lose | — input ‘GND OPEN, 15 I-26 __|Hand control breaker input ‘GND OPEN. 16 DI 27 |Confluxisingle select Input cd DI28|Overioad select Input GND /OPEN| 18, ‘D130 [High reach (hovsi at favel)| Input ‘GND FOPEN, 12 Rosorved 20 CF, 21 i 33 |charge. put meV a= 22 Dies {Spare Input ¥24V OPEN 23 ras |Spare, Input “24 OPEN 24 Reserved Reserved 25 His [Accel signal 1 OB 26 Hz. ov. 27 a oe D-5v 28 Ha ov Connector Ne | PinNo | Por name: Function inpupuipad Signal level ‘CNTOS 1 DO 4 |Wiper are prevention ‘Output_| GND / OPEN, 2 OZ Wiper normal moving. ‘Quiput_| GND FOPEN. 3 DO_3_|Wiper reserve moving | Output | GND OPEN. 4 DO-4 [Washer motor ‘Ouiput_| GND /OPEN. 5 DOS [Bucket move imitation | Ouiput_| GND (OPEN. 6 DO6 [Reserved ‘Ouiput_[-GNO FOREN. T DO 42 [Rotary ight (RAD ‘Quiput_|_GND FOPEN, 8 DO13__[Swing flashor (RA) ‘Ouiput_| GND FOPEN. 2 DO 14__|Swing flasher (LH) ‘Quiput_|__ GND FOPEN. 10 DO 15 [Travel alarm, Quiput_ | GND FOPEN, i ‘DO 16 [Auto idle stop rela ‘Ouiput_ | GND / OPEN. 12 BO47__|Engine stop. ‘Ouiput_| GND/ OPEN. 3 O48 |Lever lock ‘Output | GND / OPEN. 14 DO19_|Exira pressure release | Ouiput_| GND /OPEN 15 Reserved 16 & IT controler ow 17 TxOZ [Tranmission| RS2300 communicaion 18. RXDZ Reception |RS2326 communication 19 RIS, Spare S220 communication 20 cis ‘Spare RS232C communication 24 SHG2 ‘Shiled GND. 22 DO_ 10 [Gab up and down swing vane] Sv. 2AVIOPEN. 21-5121. MECHATRO CONTROL SYSTEM (2) Gauge cluster (symbol C-2) 4) General view MULT! e BSELAY Leo ’ | 8: yi cootanr Va | ‘TEMPERATURE| eee gauee at FOELLEVEL FH cause waTED SE se cao HOUSING : 174044.2 TERMINAL : 173681-2 SOREN CHANGE! SWITCH ETC, BUZZER STOP SWITCH WORK MODE SWIHCH 2) Connector CN-600 (Harness side) No. item name Wire color [[ No. em name Wite color [Gauge cluster > Mechatro ]GnD +28 B Yellow / + |controtier (RS2320 White 5 eee ee it ion Black communication) rect connection) IMechairo controller > Gauge 2 Joluster (RS2320 Red 6 [GND Black |communication) ‘Source (*24V slartar switch 3 [Reserved aa 7 (Bee a 4 |Reserved Ee 2 (GND RS2320 see communication) 3) Function a. It processes signals by communication between the gauge cluster and the mechatro controller, displays them in lamps, displays them in LCDs and actuates the buzzer. b. Itoutputs coolant temperature signals, {uel level signals and panel switch signals to the mechatro controller through the communication port. 4) Summary of display and drive itern No. item Remarks 1 |Monitar display LCD dot 120x168 2 [Gauge dispiay (Coolant temp., Fuel level) [Stepping motor 3 [= 4 [Buzzer Piezo-slectricty type 5__|Screen change switch 6__ [Buzzer stop switch 7 [Work mode select switch 8 [Back light LED. 21-5221, MECHATRO CONTROL SYSTEM (3) Relay & fuse box (symbol E-1) 4) General view Inscte te prs wach are Used in alanderé spsision LOCATION OF RELAY & FUSE LABEL OF RELAY & FUSE BOX 21-5321, MECHATRO CONTROL SYSTEM 2). Circuit diagram21. MECHATRO CONTROL SYSTEM = | 15H pits e i ee | ae j a | MECMaTHD contotueno% ZH EP! SPF i | eee Baal | Rebate sey son tot 200 eg | | me Meats hsae tia te | fete ost tp ti ti it Lh eee Sime ven | i e | | | | fete notte z es Se RESET gs CoS in ee | | 21-5521, MECHATRO CONTROL SYSTEM 21-5624. MECHATRO CONTROL SYSTEM (4) High pressure sensor : YN52800048°1 ECONOSEAL SERIES MARKIE (#}> ‘SPOLES CAP, MATING HOUSINGIT74357-2 COMMON curPur is) POWER SOURCE (+) HOUSING PLASTIC POTTING pe aie Tightening torgue TASNM (64.2EA) STRUCTURE (5) Low pressure sensor : YX52800013P1 Tightening toroue 28.4~34.3N'm (21.7~25.3106) a) ECTRIC CONNECTING DIAGRAM (Ex. Construction of internal controler) 21-57 ‘SPECIFICATION PRESSURE RANGE :0~50 MPa POWER SOURCE VOLTAGE : 5.040.5V DC. OUTPUT : 4/10Vs-9/10Vs (Vs=5V DC 0.5~4.5V DC) INSURANCE RESISTANCE : 100M OR MORE (BETWEEN CASING AND ALL IN/OUT TERMINALS AT 50V DC MEGGER) ELECTRIC CONNECTING DIAGRAM (Ex. Construction of internal controler) Vout Vee ‘eND SPECIFICATION PRESSURE RANGE :0~3.0 MPa RATED VOLTAGE : 5.0+0.5V DC INSURANCE RESISTANCE : S0M9 OR MORE (BETWEEN BODY AND EACH TERMINAL AT 50V DC MEGGER)24. MECHATRO CONTROL SYSTEM [MEMO] 21-5822. HYDRAULIC SYSTEM ‘TABLE OF CONTENTS 22.1 SUMMARY. Seated a nnn B23 22.2 HYDRAULIC CIRCUITS AND COMPONENTS. HH 22d 22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS, 22-8 22.4 NEUTRAL CIRCUIT. 2.8 E 22.5 TRAVEL CIRCUIT 22-10 22.6 BUCKET CIRCUIT Seb sn DOAD 22.7 BOOM CIRCUIT illest eee a 22.14 22.8 SWING CIRCUIT soeoonnmnne : . eee a 22-18 22.9 ARM CIRCUIT escensnssstinnnnnnnin Feb il ii ttl s20 22.10 COMBINED CIRCUIT. - Z : : 22-26 22.11 PRESSURE DRAINING (RELEASING) CIRCUIT... peat 22-30 Book Code No. S5YN2218E01 22-422. HYDRAULIC SYSTEM Issue Date ofissue | __ Applicable Machi Remarks I t 7 'SK200-8 : YN11-45001~ SEYN2216E0T First edition | August, 2006 pet or |Sk210L0-8 : Ya11-06001~ (ASIA, OCE) 22-222.1 SUMMARY The hydrauife circuits are built up with the following functions and features in order to achieve easy operability, safety, mass volume handling and low fuel consumption, 22, HYDRAULIC SYSTEM ‘Table22-1 Par pico Function | Features = Travel straight | Travel sright at combined operation -q [+ Tver 2sp60d change & Ao 15(ow) aed tun |e 12k ped change and ov speed ghee a ent ty § |e Auto parking brake |» automatic braking when parking © Ve Motor overrun protection | © Prevents overrunning of travel motor on the down hill slope. }@ Travel pilot operation |e Provents ‘hunting by the built in travel shockless mechanism | Je Reverse rotation protective function . paseoning fo prcilct ram swinging Baek when stops swinging. jp |* Swing priority cuit 1 Easy operation of stable swing speed, arm sarted evel, = | (simultaneous operation of arm in and swing motions)| swing press dianing F | |» Automatic swing perking brake +# Swing parking brake when operating aton a slope [TJ ryeraute pot contr system Light action wit operating lever B |B [+ Pict satty lock systom +# Cutout of plot circuit by safety lack lover. B | & |e Lock valve (boom / arm) ‘© Protect boom and arm from unexpected drop (Natural fal) & | & |» Hotding valvo for boom (Option) ‘# Prevention of boom falling when boom head side piping breaks 3 | _|e Mutt control valve (Oceania) tt + Changeable to 4 operating pattern with only 1 lover. | /* Pressurized hydraulic oll tank ‘© To prevent hydraulic oll from entering dust and to a promote self ton ably of par + Suction strainer + Remove dust on suction sie Line fiter pitt circuit To prevent pilot operating circuit from malfunctioning | € JeReturn circuit To prevent hydraulic ol from contamination |B |» cooing tycrauc ot by a cooler +o prevent hydraulic al rom being deteriorated + Pressure draining circuit '* Torelsase the main cicuit pressure fo iping repair work + Maia contol vai with optional vlve + Optional pining and sditionel work aro cacy | © Switching of return line for N&B machine in the cab | e Switching of return jine for N&B machine is able to | (Option) change with a switch in the cab. Electric flow contoied variable displacement pump|« Pump davey rae contl by sre onmerdie he le selenidpropornal ave oe vale dlplacemen! pu 'B | E |e Positive tow rate control ‘¢ Flow control by positive pilot control pressure 8 | © |e Hydraulics backup contro! ‘Backup control by hydraulic when the electric flow controtedt £ vatibleceplacerent pup fl © [= |e Boom up conthox reat ~~} Speed up of boom up operation Fete | E |e Arm confiux circuit © Speed up of arm operation B |B + Bucket contux circuit + For speed-up of bucket operation (digging & dump) + Optimum operation by work mode select (H.S/A.B) | Efcient operation in all work modes <5| « |e Auto accel '* Reduce fuel consumption and noise by lowering engine ze ge speed when control lever isin neutral position,22, HYDRAULIC SYSTEM 22.2 HYDRAULIC CIRCUITS AND COMPONENTS ‘STD. SCHEMATIC HYD. LINES YNO1Z00185P% (SE Asia)/ YNO1Z000161P1 (Oceania) Item Component name Part No. Model No. eee YNOVO0036F1 _|KVi12DTP (SE.Asia : without PTO.) YN10VO0040F1_|K3V1120TP (Oceania : with PTO) 2_[Control valve (main) YNSOVOOIO1F1_|KMX15YD_ '3_|Swing motor unit YNtsvo0036F1 _[IM5X130-CHB 4_ [Travel motor unit 7 YyNtsvo00a7F1 _ |GM3eve 5 _|[Boom cylinder (RH & LH) YNOWVOOISIF1 _|a85xo120x1355 | eal atinae sa YNOIVOOI7SF2 _|a95xo135x1558 (SE.ASIA)_ _| YNO1VOO175F1 _|995x0135x1558 (Oceania) Geechee YNOIVOO1SSF2 _|o80xa120%1080 (SE.Asia) YNOAVOO1SF* |o80x0120%1080 (Oceania) @_| Swivel joint YNS5VO0053F1_| @ [Pilot valve (ATT) YNSOVOOTNIF1 _[PV48K2 40 [Pilot vaive (travel) ‘YNG0V00105F1_[6TH6 NRZ 11_[inline fiter YNs0vo0020F4 _|¥-457400 42. [Suction strainer Ywsovo0004F7 _|¥-507400 [13 [Solenoid vaive assy YN35V00047F1 _|@KWESA-30 =H 14 [Retum filter He YNS2VO01008F3 _|FZ1F183A012A 15, [Air breather YN57V00004 BO210GA0GBA iianzsal 46. [Mult control valve (ever less) YNS0V001131_ [Australia : STD Multi control valve (with lever) YN3OVOO1I7F1 [New Zealand: STD 17 [Restrictor YN21v00005F1 [07361-00000 ‘The part numbers may be changed due to modification, 0 use only the numbers for references. 22-422.24 STANDARD 22. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03 22-592% LO LaZOLOOZLONA ort wash SBOE MOS may 717 noite van | oe is ot “BUNSEN 1IS AUVNIGHO NOUWOLIORAS ZZINOLSNO OL MOA WNOLO 40 NWA SANE OVOTHSAO LSNFOY 'HOLIMS H3AO3ONVHO MOT 3ONSNTENOD AB AIOTS STTONIS HO 3ONAMTENOD 2800H9 3 THLSWIaTEBIN 40 NOLLYOIdIOZES 01 DNIGHOODY UTES ONIN NSH oT 2 a XTRA aaa of = 340. xan STEN WOs STONS| = ‘oo. = NO, XTANOO] — eH JONOTIATNOD| a [ames | ang | anna [emoimrainamarera) instante ava 2a ovornes oronene | MRS | MES | 0S [ec ommn newer |e HENS TA Eom oni nousaTas ' arn tMioubodod HONSTOS 40 WHOS OND lololol loft On ere 5G) || ae “LINO CAVANVIS OL OGY OL G3SN SI LNDNIO OMNVACAH SIAL "E raz :10N ' 1 ZION [FSIZOOOAGENAT —_SAWATSMER |S ‘90000-08091 |Fs08000A0ENA, BATWA1OTd | 2S see beaoor anvadous | 1s GPLVABA |FsrOLOOADENA| SATA BOLOSTES | 08 SN BOON | “ON LEE sia [ON TazeioOZ}0NA | woneowoeds BRN (NolLdO) NOLLWOIsID3dS BBN zz'zz W3ISAS OINWHGAH ZZ.22. 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Aj@jes (z) Joquoo enjea peojun pue onjea no ssedfe (1) ‘Guimoo} 243 Soquosep UONDSS SIYL LINDHID WHLNAN = 9°27 Bt ‘wieiBie!p ynoulo oujoaje aun 0) .9/01 ‘Jenuew stu u sjoquufs |eou}99;9 ay) BuIpseB ay Sunesedo vey ynouro Aqpueys pue ynowo moy oun Buxeidsiq Sunjoxe pue ene u| plousjos pay Bunesedo 51 (Guronpe,) anyen feuomodoid piousjos uayy, anjen poy uoneiado anenyy u9} anig (isd 0167-521) ean 've-S “aunsseud enup duind ure, 6ue10 (isd szz) eat ¢ (ene 14 reuonsodoud Burpnjou1) ‘aunsseud yoUd Auewiig peu (isd $z4~98) ed S~65'0 (eneta jeuoniodoud Surpnjout) “eunssaid jould Auepuoseg, eiding (isd 98~r9) ea 6S°0~P9'0 “ynou dn eoyews “uma sai (isd 99) ean vp'0 ueU ssa) nou uleup ‘pee enig SLINDYID SIINVYGAH HOS GUYVGNVLS ONIGOD YO10D £7 WBLSAS OIINVUGAH Zz22. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03, Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position) 22-9oyeaq Supued jones, (g peo} yBty ye wumes paads ys} oyne pur wisiueyoau aBueyopesds des zmoryubIH (y ‘sdo}s 2010) eau! uay ‘@aJBA UOARIIABO HUB PUE anen jaIja4 SsapOOUS (E ojour o1nespAY ‘ayy jo uoHeyAK. syuanaid JeYI BATA HOBUD (z, adoys uo Buluuns Jeno Woy Jojo au sana (1 uonoun w NOILONN4 HOLOW TAAVEL = Y'S'2z. yo}our Jenen ay) sore}0: pue 40 J0 suod Ly “IY WOM, (g)1u)o{ anus Jo suod a9 yBnowyy (p) so}ou Jones, JO @pIs Ye] 84} UO UOd WA YORE U! SMO} JOU! janeT, Jo uojeiedo aut yim joods oxen omy BusGueyo fq suod zy pur Ly dung woy 0 Aenyop ous, + wojesed () AINOUIO NIVW TAAVHL = €'S'2z peads 1s} 24) oF 1yoeg uojsid 0918s paeds puz exp seysnd ainssaid 4]98 5J010u 84) “('Sd 090P) BAIN Gz enoge ses exnssaid ynouio urew 24) usym eneMoH, ‘2insseid 4198 sit Aq apow Sunjn paads pug euy ul un 0 o)0W au sasneo pure ‘uoIsid ales peeds puz 4) 0) eBessed jJ0 ot suado ‘(p) sojow anes oun Jouod g aur siatua ‘ew Hod wo pans} s| eunsseid PUBWLIOD PloUDIOS OY) LEY “2AjeA feUOIOdoud ‘ayy saBueyo pue peioxe sl (61) 20Ia ener Jeuoyodoid auf jo (g-AS) plousos aun ‘passeid si oisnjo aBne6 ayy Uo YOMS paxsew Hage! oun i uuonesedo ‘o)0U uetUedeIAsIp ayqeuen oy) jo @jSue Bunn e 0} eunsseud jes ay) pue einsseud joy Arewud aun syenuoo Uiny ul yoi4 plouajos [nen peeds-z ou) salIoxe 11 “panss! s1 feuBis ouIoaj@ Ue ‘Pauuny s1 YOuMNS OU 4 eidiouug -youms yum paeds sojow janes aBUeyD sesoding NOLLONNS NuN.au G3adS 151 OLNV ANY LINDHIO ©) (2) w NVWNOD GIONS10S TaAVHLGaadSz z'S'zz ‘pis 38010 Ut [oods Bulpeowun ey) soyouas suod 20d pur ad UO paLOXe sey YoIYMenyer yeuotuodosd wos, ainsseud Arepuocas ou, “uonysod e2nau 1949] 849 Ut UOHReedo oUt ox “epIs ASO19 Uo [oods ino ssed-Aq oul spIoy suod zdgag pue dad uo penexe sey YoIy anjen jeuoryodord woyy sunsseud Arepuooes ou. (2) enfen joxu09 u peprnoud suod ead pur 2dgid ‘9d ‘ded 0} Pe) S! (B-ASd) enier Surpeojun Zq pue (-ASd) eareA Buipeojun Id Ul paianap ainsseid Arepuoces out (g ‘opis asvaioul ayes Moy, Aronyap ey} uo duund oy) Bunenioe ‘soyeinBos dduind uo wexe (2d-ASd) @nyen yeuotnodoid und 2d pue (1d-ASd) @njen peuotjodoid duind td Aq indino sainssoud Arepuooes ou, (y (G-ASd) 2neA Burpeowun ze pue (@-ASd) eAVeA BuIpeO|UN Ld OF ndiNO s1WueLIND puewuioo oy) awn swes ay) 18 PUP (Ze-ASA) ‘enjea euomodoid duind za pue (Le-ASd) ‘enjen jeuosuodoid duind 1 0} 8121 Moy Jo ‘982810U) ay} 0} Sulpuodsa1ioo yuauino syndino pu Bulsseooid jeubis surioLed sei}o11U09 onjeyseus ay, Yej/0U09 OAeYOOUI OWL induy 5] a6e}0n jndino sosuas einsseid moj au (E "ynou19 UFewI @L4| SOUOUMS PUR ‘Jods JeneN ‘uy sanoU (2) enieA jonuoD ey) Jo Suod Wd ue aye 0} smoy unsaid Aiepuodes oud SUL (2 (01-2) (638) siosues ainsseid ‘mo| oy} uodn sje pue suod g ‘g ain yo no ‘seuioo ‘peloe[es | saunsseid a4} Jo se4Bly ou, (01) vd $0 shod | ‘g 24) Jo 1n9 sausoo einssesd jeuomodoid yoyd Arepuodes ay ‘suonows puenuo} pur yoy ‘1yBu janes 10} payesedo s}uisiueyoau Suidurep ym sana) AMEN aUp ys (L sowuosieyoeyy (2) uorjerado ssepjooys pue e010; Bujeiedo 14617 asoding (1) AINoUID NOLWHadO SNOaNVITAWIS LOd GHVMHOS TAAVEL = 'S'2z ‘uonfouny 10j0w @AeLy. (p) novo ure janeuy (€) Uuoyouny winjeu paeds-1 ‘cane pue ynouro puewiWoD ploUd}os ane poods z (Z) 1unoulp uonesedo snoaueynu's joy preMuO} janes] (4) ‘BuIMo|}o} By) SaquUOsEp UONOSS SY ALINDHIO TAAVHL §=S'2e O1-zz WALSAS OFINVEGAH ‘zz22, HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03 Fig, 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation. 22-1122. HYDRAULIC SYSTEM 22-12 22.6 BUCKET CIRCUIT This section describes the following, (1) Bucket digging pilot circuit (2) Auto accel operation (3) Flow control in the work mode (4) Bucket digging travel straight main circuit (6) Bucket spool stroke limiter 22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING (1) Mechatronics 1) When the operation for bucket digging is performed, the pilot proportional secondary pressure is delivered through port 1 of the right pilot V (9), flows to PAc port, and acts on the low pressure sensor (SE-1), and at the same time the bucket spool is switched. 2) The voltage output by low pressure sensor inputs in mechatro controller. The mechatro controller performs signal processing and outputs current corresponding to the increase Cf pump flow rate to pump proportional valves: (PSV-P1) and (PSV-P2) on the P1 and P2 pump sides, and at the same time the command current is output to P1 unloading valve (PSV-0), P2 unloading valve (PSV-B) and travel straight proportional valve (PSV-C). In the following pages, the relation of operation of low pressure sensor to both the increase of pump flow rete and unloading proportional valve is the same, Therefore the explanation is omitted. 3) The secondary pressure output by Pt pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exerts on pump regulator, actuating the pump onto the delivery flow increase side. 4) The secondary pressure delivered in P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is led to PBp1, PCb, PBp2 and PCa ports provided in control valve (2). ‘The secondary pressure from proportional valve which has exerted on PBpt and PBp2 ports holds the by-pass cut spool on CLOSE side, like the operation in the lever neutral position. ‘The secondary pressure from proportional valve which has exerted on PCb and PCa ports, switches the unloading spool in CLOSE side. 5) The secondary pressure delivered in travel straight proportional valve (PSV-C) is led to PTb port provided in control valve (2) and shifts the travel straight valve one stage. 22.6.2 AUTO ACCELERATION OPERATION (1) Principle : Auto acceleration actuates according to signals from low pressure sensor. (2) Operation In the event where the sensor does not receive signal for 4 seconds or more even though the acceleration dil is set to MAX position, the engine speed should be raised to 10001pm. - When the pressure 0.6MPa (87psi) is input to low pressure sensor in STD specification (travel, bucket, swing, arm), proportional voltage from low pressure sensor inputs in mechatro controller, and then the engine speed returns to the dial set position corresponding to the lever operation. 225.3 STAND-BY CURRENT CONSTANT CONTROL (1) Principle : When the engine speed is intermediate speed or lower, command current value to have the pump, delivery rate constant is output. (2) Operation Even if the engine speed specified by acceleration potentiometer is low speed, as the delivery rate corresponds to the intermediate speed, the actuator moves earlier than the movement ‘equivalent to the control lever angle rate in light, load operation. 22.8.4 BUCKET DIGGING AND TRAVEL STRAIGHT CONFLUENCE (CONFLUX) MAIN CIRCUIT (1) Operation : 1) The oil delivered through A1 port of Pt pump. goes into P1 port of C/V (2), opens load check valve LCc through parallel circuit and enters in bucket spool. 2) Onthe other hand, the oil delivered through P2 port of P2 pump goes into P2 port of CIV (2), confluences with oil from P1 pump through travel straight valve, and goes into bucket spool. (Confluence of oil from 2 pumps) 8) With the function of pilot circuit, the oil flow is switched from bucket spool, and is fed into bucket cylinder head side through AC port of C/ V (2). On the other hand, the return oil from cylinder rod (R) side is throttled by bucket spool and retums to tank circuit from BC port of C/V @). References * In bucket dumping operation, the travel straight valve also switches like digging operation, resulting in confluence with travel straight. + When the bucket operation and other operation are simultaneously performed, the travel straight, valve does not actuate, resulting in single flow of bucket circuit 22.6.8 BUCKET SPOOL STROKE LIMITER (1) Purpose : To secure simultaneous operability of boom and arm on boosting up attachment pressure (Pump flow rate decreases.) and to prevent cavitations at low engine speed (2) Operation ‘On boosting up attachment pressure, pilot primary pressure exerts on PCc port of C/V(2) through attachment booster solenoid valve, operates stroke limiter of bucket spool, and throttle oll path of spool. As a result, P1 pump pressure increases, making the simultaneous operation of boom up and bucket digging possible. Even though the engine speed is low, similarly the cavitations can be prevented by actuating the stroke limiter.22. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03 Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Travel straight conflux), Auto-accelation and Standby flow rate constant control 22-1322. HYDRAULIC SYSTEM 22-14 22.7 BOOM CIRCUIT This section describes the boom raise conflux ‘operation. (1) Boom up pilot circuit (2) Boom up 2 pumps conflux main circuit in C/V 22.7.1 BOOMRAISE PILOT CIRCUIT (1) Operation 41) If boom up operation is performed, the secondary pilot proportional pressure from the right pilot valve (10) gets out of port 9 and acts upon the low pressure sensor (SEQ). At the same time, the pressure acts upon the PAb and PB1 ports. 2) The secondary pressure which enters the PAb port of C/V (2) shifts the boom spool. The secondary pressure which enters the PB1 port shifts the boom conflux spool. 22.7.2 BOOM UP 2 PUMPS CONFLUX MAIN CIRCUIT IN CIV (1) Purpose Boom up speed up (2) Principle : Confluxing oil from 2 pumps. (3) Operation 41) The oil delivered through A1 port of P1 pump, flows into C/V (2) P1 port, and branches into bypass circuit and parallel circuit. Since P1 unloading valve is closed, the boom spool is moved and bypass circuit is closed, the oil opens load check valve LCb through parallel circuit and flows into boom spool. 2). Then the oil passes through boom spool, opens lock valve of boom lock valve CRb, and is led into H side of boom cylinder through C/V (2) Ab port 8) Meanwhile, the oil delivered from the A2 port of the P2 pump enters the P2 port of C/V (2) and due to shut off the P2 unloading valve, the oil then passes through the parallel circuit and via the restrictor on the circumference of the boom conflux spool, pushes the load check valve CCb open from the boom contlux circuit, and combines the oil delivered by the P1 pump internally. 4) The retum oil from boom cylinder R side flows into tank circuit through boom spool from C/V (2) Bb port.22. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03 Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function. 22-1522. HYDRAULIC SYSTEM 22-16 This section describes boom lower operation, (1) Boom down pilot circuit (2) Prevention of natural fall by lock valve and actuation at lowering (8) Constant recirculation function of boom down main circuit 22.7.3 BOOM DOWN PILOT CIRCUIT (1) Operation 41) Ifthe boom down operation is performed, the secondary pilot proportional pressure comes ut of portéC of the right pilot valve (9) and acts upon the low pressure sensor (SE-4). ‘At the same time, the pressure acts upon the PBb port of C/V (2). 2) The voltage output of the low pressure sensor {SE-4) enters the mechatro controller and processed in it. 3) Then, the proportion! secondary pressure fed into C/V (2) PBb port and branches off in two lines and switches boom spool and releases boom lock valve, 22.74 PREVENTION OF NATURAL FALL BY LOCK VALVE AND ACTUATION AT LOWERING (1) Purpose Prevention of natural fall when the lever is neutral (2) Principle : The oil is prevented from returning to the boom ‘spool by the poppet seat of the boom lock valve. (3) Operation In the boom down action, the selector valve is changed over by the secondary proportional pressure of PBb port. Then the poppet spring chamber of the lock valve CRb gets through the drain line (Dr) and makes the lock valve poppet open When the boom lever is at neutral, the drain line on the lock valve CRb poppet spring chamber is closed which causes the poppet closed. The result is that the oil returning from the boom cylinder head (H) to the boom spool is held and makes the leak from the boom spool zero. Thus the boom cylinder is prevented from making a natural fall. 22.7.5 CONSTANT RECIRCULATION FUNCTION OF BOOM DOWN MAIN CIRCUIT (1) Purpose Prevention of cavitation during boom lowering motion. (2) Principle : ‘The oll retuming from the boom cylinder head (H) is recirculated to the rod (R). (8) Operation When the oil is supplied to the boom cylinder rod (A) side during boom down operation, the boom moves faster than it should do in some cases by the self weight of the attachment. ‘On that occasion, the circuit pressure on the rod (R) side is on the negative side, The oil supplied to the boom cylinder rod (R) flows into the At port of the P1 pump and the Pt port of CNV, The oll then passes through the boom spool and goes out of the Bb port On that occasion, the oll returing from the head (H) goes through the recirculation path in the boom ‘spool, pushes the check valve in the spool open, is recirculated to the Bb port and is supplied to the rod (R). When the (R) pressure is larger than the head (H) pressure, the check valve in spool closes. Thereupon, the recirculation is stopped.22. HYDRAULIC SYSTEM ze Sitinoer 6 YNO1Z00185P1 01 YNO1Z00161P1 03 Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling. 22-1722. HYDRAULIC SYSTEM 22-18 22.8 SWING CIRCUIT This section describes the following operations. (1) Swing left pilot circuit (2) Swing auto parking brake (3) Swing main circuit (4) Swing motor circuit 22.8.1 PILOT CIRCUIT FOR LEFT SWING (1) Operation : 1) When the left swing operation is performed, the pilot proportional secondary pressure is delivered through port (5) of left pilot V (9), and the secondaty pressure acts on PBs port of C/ V (2), and simultaneously flows out from Pss port of G/V and acts on low pressure sensor (SE-5), 2) The voltage output by the low pressure sensor is inputin the mechatro controller, and is signal- processed. 8) Then, the secondary pressure led into PBs port of CV (2) switches the swing spool. 22.8.2 SWING AUTO PARKING BRAKE (1) Purpose ‘Swing lock in neutral position and parking (2) Principle Release mechanical brake only when required to operate swing and arm in (8) Operation : 1) The swing parking system excites the swing parking SOL (SV-1) usually if the key switch is turned on and works by the action of the mechanical brake 2) The mechanical brake is released if the swing parking solenoid is de-excited only when the secondary operating pressure in the swing and arm in actions acts upon any of the low pressure sensors (SE-5, 7) 3) The swing parking solenoid (SV-1) is excited five seconds after the pressure of the swing low pressure sensors (SE-5) is reduced to zero. In the case of arm in operation, the swing parking solenoid (SV-1) is excited the moment the pressure of the arm in low pressure sensor (SE-7) is reduced to zero. This causes the mechanical brake to operate. 22.83 SWING MAIN CIRCUIT (1) Operation ‘The oil delivered from the A2 port of the P2 pump enters the P2 port of C/V (2) andis branched off into the bypass line and the parallel circuit, However, since the bypass line is closed as the swing spool is shifted, the oil pushes the load check valve LCs open through the parallel circuit, enters the B port of the swing motor via the Bs port of C/V (2), and rotates the swing motor counterclockwise, 22.8.4 SWING MOTOR CIRCUIT (1) Anti cavitation circuit at swing deceleration (2) Shockless relief valve that prevents the swing motor from being reversed.22. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03 Fig. 22-6 SWING CIRCUIT : Swing operation (LH) 22-1922. HYDRAULIC SYSTEM 22-20 22.9 ARM CIRCUIT This section describes the following operations. (1) Arm in, light-load operating pilot circuit (2) Armin, ight-load variable normal recirculation main circuit / internal conflux main circuit 22.9.1 ARMIN, LIGHT-LOAD OPERATING PILOT CIRCUIT (1) Purpose ‘Speed-up and Anticavitation when the arm is at light loaded. (2) Principle : The oil returning from the arm cylinder rod (R) is recirculated variably to the head (H) at arm 2 spool incn. (3) Operation 1) When the arm in operation is performed, the secondary pilot proportional pressure gets out of port7 of the left pilot valve (9) and acts upon the low pressure sensor (SE-7). ‘At the same time, the pressure is branched off in two flows, acts upon the Paat port and the Lc? port, changes over the arm spool and the atm lock valve CRar. releases. 2) The output voltage by the low pressure sensor is input into mechatro controller, and is pilot signal-processed, and is output to P1, P2 pump proportional valve (PSV-P1), (PSV-P2)andarm 2 inverse proportional valve (PSV-A) 8) The secondary pressure from pilot proportional valve, which is reduced by arm 2 inverse proportional valve (PSV-A) switches arm 2 spool 22.9.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL RECIRCULATION, INTERNAL CONFLUX MAIN CIRCUIT (1) Operation : 1) The P2 pump delivery oil flows in travel left section through P2 port of C/V (2) and is branched off in by-pass circuit and parallel circuit, but because arm 1 spoolis switched, the delivery oll which goes through parallel circuit opens load check valve LCa and is flowed into arm + spool. 2) Onthe other hand, P1 pump delivery ol lows in Pt port of C/V (2), and the flows in travel straight section and travel right tandem path. Then because arm 2 spool was switched, the delivery oll opens load check valve LCAT2, goes through arm 2 spool, and confluences nw From arm out —>} Pv with P2 pump delivery oil in the valve section, and then is flowed into arm cylinder head (H) side through Aa port of C/V (2) 3) The return oil from arm cylinder (R) side flows in Ba port of C/V (2) and passes through the Ba port because the arm lock valve CRar is open, and is flowed into arm 2 spoo! through arm 1 spool 4) Because arm 2 spool is switched to normal recirculation position, causing restriction of passage to tank, the retum oil from arm oylinder (A) side flows into arm cylinder (H) side. + Because, at light load, the pressure in cylinder rod (R) side is higher than that in the head (H) side, it opens the check valve housed-in arm 2 spool and is recirculated in the head (H) side, resulting in the speed up of arm-in operation at light load. 5) Cavitations prevention control in arm-in operation Command current is output to arm 2 solenoid proportional valve by signal processing of E/G speed and arm-in pilot pressure, accordingly the arm 2 spool is switched to neutral (cavitations prevention) position, resulting in cavitations prevention. Position of arm 2 spool Neal positon [anicavtaton poston Reckodaton Nt Pik lision From arm 2 inverse proportional vave Reference In light-load arm-in operation (normal recirculation, conflux), when the attachment to which the circuitin P1 pump side is applied is operated, the meter-in path of arm 2 spool is closed, resulting in single flow operation. [Spool positon at arm in, light oad ard combined operation [ve poston not shown in hyéraulic agra) Neutral gostion} _Melern passage gta Normal recteulation epson22. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03 Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function 22-2122, HYDRAULIC SYSTEM. 22-22 This section describes the following operations. (3) Arm in, heavy load operating pilot circuit (recirculation cut) (4) Arm in, heavy load operating sequence confluxed main circuit 22.9.3 ARMIN, HEAVY LOAD OPERATING PILOT CIRCUIT (1) Operation 1) Inarmin operation, when the heavy loading is applied to arm and the P2 pump pressure increases to the set pressure, the voltage output by P2 pump pressure sensor (SE-23) is converted to signal (signal processing) by mechatro controller, consequently the current of arm 2 solenoid proportional valve is controlled according to the load pressure and the atm variable recirculation is cut. When the recirculation is cut, internal confluence is held similarly to that in light load operation. 2) Left pilot valve actuation due to arm-in operation is equivalent to that at light load operation 22.9.4 ARMIN, HEAVY LOAD OPERATING RECIRCULATION CUT MAIN CIRCUIT (1) Purpose ‘Speed up for arm in operation (2) Principle Cut the recirculation and reduce rod pressure. (8) Operation 1) P2 pump delivery oil flows in the travel left section through P2 port of C/V (2) and branched off in by-pass circuit and parallel circuit. Consequently the arm spool is switched and pushes and opens load check valve LCa through parallel circuit, and flows in the arm spool 2) Onthe other hand, P1 pump delivery oilflows in P1 port of C/V (2), and flow in travel right tandem passage through travel straight section. ‘Then because arm 2 spool was switched, the delivery oil opens load check valve LCAT2, and confluences with P2 pump delivery oll in the valve section, and is flowed into arm cylinder head (H) side through Aa port of C/V(2), 3). The return oil from arm cylinder (R) side flows, in Ba port of C/V(2) and is flowed to arm lock valve CRar, but because the arm lock valve CRaris open, the retum oll goes through atm lock valve CRar and flows in arm 2 spool. 4) The retum oil returns directly into tank circuit because arm 2 spool is switched to recirculation cut position. Position of arm 2 spool Noutal postion wea From am 2 inverse proportonal valve22. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03 Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function 22-2322. HYDRAULIC SYSTEM 22-24 This section describes the following operations. (8) Arm out pilot circuit (6) Arm out 2 pumps conflux main circuit (7) Natural fall protection with arm lock valve 22.9.5 ARM OUT PILOT CIRCUIT (1) Operation : 1) When the arm out operation is performed, the secondary pilot proportional pressure gets out of port 8 of the left pilot valve (9), and acts upon the low pressure sensor (SE-8). At the same time, the oil is branched off in two flows and act, Upon the PBat and Pba2 ports of C/V (2). 2) The operating proportional secondary pressure flowed in Pbat port of C/V (2) switches the arm 1 spool. 3) Then, the operating secondary pressure flowed in PBa2 port of C/V (2) switches the arm 2 spool valve. 22.9.6 ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT (1) Purpose: ‘Arm out operation speed up. (2) Principle The oil delivered by the P1 pump is confluxed with that delivered by the P2 pump in C/V (2), (8) Operation 1) P1 pump delivery oil opens load check valve (LCAT2) by switching arm 2 spool and contluxes with P2 pump delivery oil just short of the atm lock valve. 2) And, P2 pump delivery ol flows through arm 1 spool and confluences with P1 delivery oll, ‘opens lock valve of arm lock valve CRar with {ree flow and is flowed into atm cylinder rod (R) side through Ba port of C/V(2) 8) On the other hand, the return oil from arm cylinder (H) side flows in Aa port, and retums into tank circuit through arm 1 spool and arm 2 Spool The return tine which does not pass through boost check valve is used for this return circuit to reduce the pressure loss. 22.9.7 NATURAL FALL PROTECTION WITH ARM LOCK VALVE (1) Purpose To prevent the arm from falling naturally by the weight of the arm and bucket (2) Principle Complete seat of the return circuit against the arm spool of the arm cylinder (R) side circuit (3) Operation 1) When the secondary pressure for arm ‘operation disappears and the arm cylinder stops, the pressure on the rod (R) side passes through the selector of the lock valve from the Ba port of C/V, acts the back pressure on the lock valve CRar and seats the lock valve. 2). Since the oil flow into the arm spool from the lock valve is shut off completely, natural fall of the arm due to oil leaks through the arm spool is prevented,22. HYDRAULIC SYSTEM. YNO1Z00185P1 01 YNO1Z00161P1 03 Fig, 22-9 ARM CIRCUIT : Arm out operation, Confluence function 22-2522. HYDRAULIC SYSTEM 22-26 22.10 COMBINED CIRCUIT This section describes only the difference in combined operation. (1) Boom up / travel, pilot circuit (2) Boom up travel, main circit 2.10.1 BOOM UP/ TRAVEL, PILOT CIRCUIT (1) Operation 41) The mechatro controller outputs command current to travel straight solenoid proportional valve after signal processing, and the solenoid valve outputs secondary pressure and acts on PTb port of C/V (2), 2) Then the pressure of PTD port switches the travel straight valve one step. 22.10.2 BOOM UP/ TRAVEL, MAIN CIRCUIT (1) Purpose To insure straight travel movement during travel operation even if the attachment is operated. (2) Principle ‘The travel action and the attachment action are actuated by separate pumps. (3) Operation 1) Pt pump delivery oil lows through P1 port of C/ ‘V(2) and branches off in P1 parallel citcuit and travel straight spool P2 pump delivery oil flows through P2 port of C/ V(2) and branches off in P2 tandem circuit and travel straight spool. 2) The delivery oil flowed into P1 parallel circuit of 1 pump opens check valve CT1 and LCb and flows in boom spool, which exerts on boom up operation. The delivery oll flowed into travel straight spool of Pt pump opens check valve CT2 because the travel straight spool is shifted, and flows in boom contlux spool and exerts on boom up ‘operation with the internal oil conflux. (in travel straight operation, P1 pump delivery oil exerts on swing operation of attachment.) 3) The delivery oll flowed into P2 tandem cirouit of 2 pump flows in left travel spool to travel leftward The delivery oil flowed into travel straight spool of P2 pump flows in right travel spool because the travel straight spool is shitted and exerts on the right travel operation. (in travel straight operation, P2 pump delivery oil exerts on travel operation.) 4) However, a portion of the flows led to the travel straight spool notch restriction. The speed of attachments lke travel, boom, etc. is adjusted by the circuit of rostrictionFig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function. 22. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 0322. HYDRAULIC SYSTEM 22-28 In this section, the independent operation is omitted and describes difference in combined operation. (3) Swing / Arm in light load, pilot circuit (4) Swing / Arm in, swing priority main circuit 2.10.3 SWING/ ARM IN LIGHT LOAD, PILOT CIRCUIT (1) Operation : 41) On operating swing (left) and arm in motions simultaneously, mechatro controller outputs command current to travel straight solenoid proportional valve (PSV-C) and arm 2 solenoid inverse proportional valve according to signal processing, and this proportional valve outputs secondary pressure, which acts on PTb port and PAa2 port of C/V(2). 2). PTb port pressure switches the travel straight ‘spool 2 steps, and the PAa2 port pressure switches the arm 2 spool to the forced recirculation position. 2.10.4 SWING/ ARMIN, SWING PRIORITY MAIN CIRCUIT (1) Purpose Stable swing speed. (2) Principle Raise the oil pressure flowing to arm cylinder, and give a priority of the delivery of P2 pump to swing operation. (8) Operation 1) The swing main circuit operates with P2 pump flow. But on P2 pump circuit side, the flow goes to the swing circuit and arm circuit simultaneously because the swing circuit and ‘arm circuit are parallel, Then since the return oll from arm cylinder rod (R) side is restricted in the arm 2 spool because the arm 2 spool is switched to forced recirculation position, the pressure of return oil is raised, causing the rise of circuit pressure on the arm cylinder head (H) side. 2) Atthe same time meter-in of arm 2 spool closes and arm in contlux is therefore cancelled, and delivery oil from P2 pump and P1 pump are combined in the parallel circuit on P2 pump side because the travel straight spool was switched. The contlux oil of P1 and P2 delivery oil in high pressure flows in swing side taking priority over allothers. This operation is called "Swing Priority Circuit Position of arm 2 spool lewval poston] Mele passage Nealposton| (Close) co RCA oy / Nonna reason option 722. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03 Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function 22-2922. HYDRAULIC SYSTEM 22-30 22.11 PRESSURE DRAINING (RELEASING) CIRCUIT “This section describes the following operations. (1) Pressure drain (releasing) pilot circuit (2) Pressure drain (releasing) main circuit 2.11.1 PRESSURE RELIEVING PILOT CIRCUIT (1) Purpose : To release the pressure in main circuit for piping repair works. (2) Principle : After the mode is switched to "Pressure Relief Mode" with switch on gauge cluster, mechatro controller outputs the following commands. 1) Minimum titing command value to pump proportional valve (PSV-P1, PSV-P2). 2) Output "Pressure relief control speed command value" at ECU. (Electric system) 3) Stand-by command value to P1, P2 unloading proportional valves How to switch to "Pressure relief mode" 4) Press selector switch (3) on gauge cluster, and "SWITCH" sereen is displayed. After checking the letter "SWITCH" is reversed in black and white, press the selector switch again 2) The adjustment mode screen is displayed, then press (¥ ) switch or (&) switch, and "DRAIN HYD. OFF" screen appears, 8) Press selector switch, the screen changes in "DRAIN HYD. ON" screen. After checking the letter "SWITCH is reversed in black and white, press the selector switch again (8) Operation 1) Pump proportional valve reduces the pump flow rate to the minimum. 2). Unloading proportional valves (PSV-D, PSV-B) output secondary pressure and the secondary pressure flows in Cb, PCa ports of C/V(2) and switches the P1, P2 unloading valves to OPEN position. 22.1.2 PRESSURE RELEASE MAIN CIRCUIT (1) Operation When the operating leveris shifted to neutral during engine running, "DRAINING HYD. PRESS.” is displayed on the gauge cluster while the mode switch is changed to pressure relieving mode. In this time the intermittent buzzer sounds continuously. When right and left operating levers are operated 4 oF 5 times to their full stroke, pressure is relieved. Alter draining pressure is completed, turn off the starter key and buzzer sound stops. If the pump pressure is determined to be more than 1 MPa (145 psi) by the output value of the high pressure sensor or the high pressure sensors (SE-22,23) are broken, "FAIL DRAIN HYD. PRESS" is displayed and the buzzer sounds continuously. In that case, also the buzzer is not stopped unless the engine key is turned to OFF. Repeat the pressure releasing procedure once again. (2) Hydraulics Ifthe travel straight valve is turned to the pressure release position, the oll delivered by each pump is unloaded to the tank passage. If the spools are switched by pilot operation, the remaining pressure from the actuators may be relieved to the tank Circuit, i.e. the main circuit pressure may be released.22. HYDRAULIC SYSTEM YNO1Z00185P1 01 YNO1Z00161P1 03 Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode. 22-3122. HYDRAULIC SYSTEM [MEMO] 22-3223. ELECTRIC SYSTEM 23.1. ELECTRIC CIRCUIT DIAGRAM : seis Haas APPLIGABLE YN1-45001- sions 28 bE « bee fg2 MACHINE No. YQ11-06001- ogg 2 8 ges FS 2. Sa, ficke eran. ‘8:ENGINE comROULER vowanness bo 2 § $8.5 & , gs Sase2ckS a r ced ge & 2 ackh 2 Bey seoectee ssn [ey Laer i 3a HSS & soa @ 388 kbsase eo 2 [a wsn ] eng sree senso eee ete igor & Ta mse) Bee | ferhpeiiyaysy Ff a ae we 0 i ig as 4 48998) ee sofa TT | es T ~t Yl Psv.et PUMP 1 6 [HARNESS YN13E01444P2) 1 [ECUHARNESS Cae 3 cur 6 | CABLE: LE13E01006P1/ 1 |FLOORGROUND Cur tbe prea 37 | CABLE LC13801180P2| 1 |GROWRELAY-STARTERRELAY tea: 38 | CABLE L@13E01100P1| 1 [ENGINE GROUNDING ENGINE SPEED SENSOR 52_| HARNESS LC13E01193P1| 1 |ARCLEANER x1 t TOWARNESSOF ENGINE INSTALL THE CABLES TO TERMINALS Ba sarren cate SO AS TO AVOID INTERFERENCE panes STARTER CABLE WITH GAP AND BRACKET fite|_ CONNECT sems BOLT AFTER [BATTERY [CHECKING NO PAINTS HERE No’ TO ATT HARNESS ~ 9 BATTERY RELAY CABLE Ap FOCWHITE TAPING, PosmTion cur GPP HARNESS NOME HARNESS IN Nat ‘OF INSULATION, TO RADIATOR COOLANT LEVEL Sw. 4 BATTERY CABLE NOTE 1 TOENG ROOM RIGHT ee DETAIL OF BATTERY LEFT ROTATING SvITCH WORN swarch (AH) lartacenrso0st smi] loc-e converter IWASHER MOTOR IT CONTROLLER INBBLER OPEN SwaTCH IMBOLER CLOSE switcH cup. FIX WHITE TAPING, POSITION “a CUP = IFLooR HARNESS GROUND ae 5 Tocas cule cup FIX WHITE TAPING ji POSITION TOSOLENOD TO ARELTER CLOGGING SW. FIX AHARNESS TO THE PLATE cur: TO ENGINE BATTERY RELAY BOX ‘TO PRESS SENSOR : SWING UPP HARNESS: ‘ores: (I) TIGHTENING TORQUE OF BATTERY TERMINALS ARE 3.48, (2 TIGHTENING TORQUE OF GROUNDING CABLES ARE 10.7N-M. (@) UNLESS OTHERWISE SPECIFIED TIGHTENING TORQUE IS SHOWN BELOW, MB :235Nm M10: 48:1N‘M () UNLESS OTHERWISE SPECIFIED, THE INSTALLING PROCEDURE IS SHOWN BELOW. cu (PLACE Tee suITOP CORRUGATED TOBE |B SNTWARS AND INSTALL oer our Coe cas . Se, sens occr DRIER MaRNEss ene bout Soe S820" uPren Hannes TORECe VE To BATT RELAY 80x SENS BOLT Seu EME de cr ENGINE GROUNDING CABLE Scones tak ECU HARNESS 1x WHITE TAPING POSITION 23-1223. ELECTRIC SYSTEM 23.36 UPPER HARNESS ASSY (2/6) F TERMINAL } TIGHTENING TORQUE 3.43Nm (2.5 Ib) | USE NUT OF ATTACHED. “_S TERMINAL | GLOW RELAY sven EXTRA PRESS SOL. (OPT) S620 GLOW RELAY- STARTER RELAY TIE UP HART PRESS SENSOR GLOW RELAY 37 Te eOLENo® VALVE SELECTOR DETECTION CONNECT TO i USING PLASTIC TIE eee 102 su ATTACHED f+ ate Ate ea, C TERMINAL | TIGHTENING TORQUE 3.8001» USE NUT OF ATTACHED @ TERMINAL | STARTER RELAY $628 PRESS SENSOR EXTRA PRESS (OPT) FOCWITH THE CLIP | STARTER RELAY ce srorgrors ~~ THE FUSE BOX COVER UPWARD. _ BUTTERY RELAY nevunémie cur cup / WEEK nee sno open een ors ees ‘SENS BOLT cue Tie UP THIS HOSE HERE axed i ‘WITH THE BRACKET| Vy eee RR STARTER ORBLE Barren cae DETAIL A (EXTRA SOL. INSTALL) Pam Tae Trax gun exaconnecror SAEs ae repens roneue PUMP P+ bad PROPORTIONAL SOL. , Sraaell FIKA HARNESS Toru xwnire renerosinon ore Prenat ee | of i BE _psvip2 HEE 7” PUMP P2 } FEET ona sou TIE UP CORRUGATED PART OF HARNESS WITH SOLENOID VALVE \._USING PLASTIC TIE FIX CONNECTOR (207 TOTHE BRACKET see i \\ E23 ! Press sensor: ~ Lf \\ PRESS SENSOR PUMP Pt cup PUMP PE Hepa ‘TIE UP CORRUGATED PART OF HARNESS WITH PRESSURE SENSOR ‘TOWATER SEPARATOR SW USING PLASTIC TIE VIEW 1X VIEW Vi (PUMP P1, P2 PROPORTIONAL SOL. INSTALL) (PRESS SENSOR : PUMP P1, P2 INSTALL) 23-13,23. ELECTRIC SYSTEM 23.3.6 UPPER HARNESS ASSY (3/6) C8: ENGINE CONTROLLER ain] st Lroald sap CONNECTOR —_/ 32° CONNECTOR 31P connector WITH CNTF TAG / WITH "CNSF" TAG WITH ON-SF*TAG 35P (A) CONNECTOR —_35P (B) CONNECTOR Wits on2F TAG WITH “CN4E" TAG VIEW VIE 0-1 : MECHATRO CONTROLLER WITH"CNa.2* ‘TAG OF ITEM cho. 16P CONNECTOR je 28 CONNECTOR VIEW XV oe ENGINE CONTROLLER wwe one | een ECU HARNESS PUT WHITE TAPING POSITION HERE. VIEWXI 23-14 “CNT.A" WITH TAG, CONNECTOR OF (CONNECT TO FLOOR HARNESS connect conuécror connecrconecror Xl me FLOOR HARNESS PUT WHITE TAPING CONNECT 1P CONNECTOR GROMMET. ‘TO CAB HARNESS (GND) UPPER HARNESS [ENGINE CONTROLLER) CONNECT GONNEGTOR WiTH"GNd-1" CONNECT CONNECTOR WITH "CNS" ‘TAG OF ITEM 1: HANNESS. ‘TAG OF ITEM 6 : HARNESS. +t: FUSE & RELAY BOX Et __ FUSE & RELAY BOX ca ~. MECHATRO CONTROLLER CONNECT THE "CNT-2" TAGGED CONNECTOR WITH FLOR HARNESS: wireront™ \e . 24 CONNECT WITH Sees rea HARKNESS, SUB HARNESS & : VAL, BLUE CONNECTOR TO x - ACCELERATION SETAQnTE THANG PART OF UPPER HARNESS oR ‘TO WHITE TAPING PART OF FLOCR HARNESS, ey EMERGENCY VOLUME. ANDFDTOFLODRMARNESS CLIP. CONNECT 1P CONNECTOR TO CAB SUB HARNESS R49 FLASHER RELAY FOCWHITE TAPING POSITION OF UPPER HARNESS AND ECU HARNESS TO THE FLOOR HARNESS WITH CLIP CLIP + cup | neueuPpeR Hannes, | FLOOR wanes. ECU HARNESS AND Gas SuBHaRNeSS FLOOR HARNESS ECU HARNESS GROUND os eet | Steyr Spee WARess orowo | XV ~ aADATOR coowt TTenTEN seus BOLT AFTER CHECK ONT sews eour HOPANTSHERE Sati nee sow 7 FOCUPPER HARNESS AND. Mogneaness Tone STAND IN CASE OF <_UNCONECTION, TE UP <2 HARNESS AND FIX ENGINE CONTROLLER” HARNESS CHECK CONNECTOR POSITION HERE CPPER HARNESS (B= a[Eou HaaNess GaoUND [>= J] ECU HARNESS GROUND [SHECKER (FOR OUTSIDE WONTOR] our FIX WHITE TAPING POSITION FIX THE CONNECTOR WITHOUT INTERFERENCE INAIR-CON DUCT (BS[rrenswaness gaouno FUSE & RELAY 20x {EVER LOCK SOLENOID Frusven RELAY "7: BOOST SOLENOID [P= elurenvamaiserowo Mave zerszos c0.0N00) | — en aness cao DECK WORK LIGHT (RH) [SWING PARKING SOLENOID) Soe eee |ENGINE ROOM LIGHT |RAGIATOR COOLANT LEVEL SW eee ee [SWING FLASHER 1) & REAR WORK LIGHT] |AIRFILTER CLOGGING SWATCH] eee a (P= T[ecu HaRNess GROUNO lgyncrusiR nS REARWERCUOKT| [P— | SUPPER HARNESS GaouNo | lUPPER HASHES G ENGINE CONTROLLER] waver seeanaron SwiTCH [RADATOR COOLANT LEVEL CONTROLLER] IBATTERY RELAY (COIL) lo100= oe [GLow RELAY (COR) [TRAVEL ALAROD | PRESSURE RELCASMG SL FOREXT FUSE & RELAY BOX CONNECTION23, ELECTRIC SYSTEM 23.3.6 UPPER HARNESS ASSY (4/6) ENGINE ROOM LIGHT wer rBanion cour eve. si A, _-BATTERY RELAY BOX y swe AIR FILTER CLOGGING SW UPPER HARNESS TIE UP CORRUGATED PART OF HARNESS VIEW IV. CUP WITH SWITCH USING PLASTIC TIE RADIATOR COOLANT LEVEL SW. INST TOAIR FILTER CLOGGING sw ‘CONNECT HARNESS OF AiR FILTER CLOGGING SW FIX A HARNESS OF CLIP ON GUARD f | z cue FIX WHITE TAPING POSITION FIXTO THE CLIP AIR FILTER CLOGGING SW. INST view x 23-41523, ELECTRIC SYSTEM 23.3.6 UPPER HARNESS ASSY (5/6) ENGHE ACCESSORIES @ sone AccESsonIeS ARESS g BREE 7 ENGINE GROUND CABLE [sRouNo}] ENGINE! TichTEN AFTER NUT CHECKING NO PAINTIS HERE 7 NOTE ALTERNATOR (8) $=. HTENING TORQUE UPPER HARNESS cup D ne PART OF ALTERNATOR B TERMINAL cup. FIX WHITE TAPING POSITION ENGINE SUB HARNESS” counneness” —_// eee FIX AGONNECTOR ON BRACKET VIEW IIL cur \ } To BATTERY RELAY 80x 7, ENGINE ACCESSORIES HARNESS 7 NA (USE THE CLIP OF ENGINE) ¢ FX A CONNECTOR Y ENGINE HARNESS ATTACHMENT CLIP ON BRACKET view XI DETAIL OF ALTERNATOR St cir CLP PLACE CLIP INWARD AS SHOWN IN DRAWING, AND CLAMP HARNESS AT WHITE TAPING. ro raRTER OTOR AN CLOW INSTALL THE RUBBER CAP DETAIL OF E / Peer TIGHTENING TORQUE ENGINE GROUND CABLE TIGHTENING TORQUE ~ 23.5Nm (17.3 BF) Uf Saree ee / SUSU” exon crow cane itr / / FIX WHITE TAPING i ann f\ \ Ou eR racer N f- y POSITION 7 TOGLoW our SENS BOLT FIXWHITE TAPING POSITION TIGHTENING TORQUE TIGHTENING TORQUE \ 2et5Nim (89-11 BF 255Nm (18.3 BFA) VIEW VII KA less BY 2 SE13 : i CLP ON BRACKET ENGINE SPEED SENSOR cum McliSTARTER MoTOR 7 eee 7 EXACONNECTOR TO BRACKET LTE ce PoE 3.5-55Nm (26-4. If) tsisklieh baad a CLIP UPPER HARNESS, TERMINAL FIX WHITE TAPING ‘cur POSITION FOC WHITE TAPING ae POSITION 4 DETAIL C DETAIL D DETAIL OF ENGINE SPEED 23-1623.3.6 UPPER HARNESS ASSY (6/6) Le DECK WORK UGHT (Re cur. se. FUEL SENSOR CONNECT it HARNES! INSIDE OF CAP VIEW v Psvo ones P1 UNLOAD 3 Bu suc PROPORTIONAL SOL TWO'SPEED SELECT SOL. proportional sou, TRAVELSTRAIGHT / PSV.A sya a PROPORTIONAL SOC. ARM TWO-SPEED INVERSE SWING PARKING BRAKE SOL PROPORTIONAL SOL. svt LEVER Lock Sot. 7 * ‘CLP 7 sey FIX WHITE TAPING POSITION ~ FIXWHITE TAPING POSITION ~~ DETAIL B (DETAIL OF PSV BLOCK) INSTALL THE “ALAR TAGGED CONNECTOR, (ON BRACKET cup cue FIX WHITE TAPING POSITION FIX A CONNECTOR TO THE BRACKET ‘Sw-28 = WATER SEPARATOR SW. VIEW VI, (DETAIL OF TRAVEL ALARM INSTALL) 23, ELECTRIC SYSTEM 23-1723. ELECTRIC SYSTEM 23.3.6-4 UPPER HARNESS (1/4) : YN13E01446P4 TO BE INSTALLED |TEM 2 CAP, oovore TES > Pree eesom in| RE FA] Ce! O4 See CN-146F sureuy 2 uc Shrnt press. se.zzeie b et on=1498 FUEL suPeLY Ht weavesetiat 310 e ¢i: 5 ora J -E = [| WHITE TAPING ; Zs x2 SEALING PLUG TO BE Soe ee SEPP) Yn inant / mite TAPING mien sano areeihecten i oe os L F SUE CN-136F we ef Jeet ay SMe ‘ueeLy InSTAL cre-6 @ieces) SEALING PUG TO BE aie (aa5e0rsison) 1 a wt 5 1oN252t TOMA-JML® SEALING PLUG TO 8E SEALING PLUG TO a Pus {To stagren soroR cN-701F ieee TPE TMSERTED IN TO ALL 3M a a seaLing oa Ja steel | oy Sane 2a $2WA-2H 7 8-3 yey-si aw | EERE ae : alee Fit “VE = ARAN SMES SEE encom a Oe ose gene gepe aeacag Vaasa SCNT TOF PRESS. SENSOR INSTAL CTB-3 PI 7 See Pree] or Extaa PRESS CEEED INSTAL CTB-3@PIECE insrai Cras (PIECES! i WORKIN nT ONW264F INSTAL CTB-6 (2P 1 eee No 143F o Geasuae on-255F aut SEED Pee 12EA- IMI SEALING PLUG TD BE 7 esd INSERTED INTO ALL i 3HA-JMEF SA aeme i EReE> © (ET) eeeeear eae Des see a WHTe TaPI a a pre I we a YI — x3 — a A 7 WHITE TAPING a PRESS. SENSOR: 3FA-MaS ‘WHITE TAPING uk y SEED 1 surety z a KS surpLY seas 4 curser gy trntal aa ure (> ga CN-251F 2MAT IME CTD stu ris 2098 sean e106 70 98 23-18 ‘9y-19:08T SELECTOR sou23.3.6-1 Z WHITE TAPING. A a 2 ‘ARM TWO-SFEED_ INVERSE PROPORT ONAL SOL. UPPER HARNESS (2/4) : YN13E01446P4 ai TE TAPING 2FACIMTS On 142F pav-re. Pune pa PROPORTIONAL SOL. cae (7034-1279) 0 aE INSTALLED ow peur e-10-Rece VER one ‘coos pr-999 esos twinge cancer 8 arama Seas i oie Elbe meuar eon oan aeysoeor Setar a aeta0S$3300 Cate Ibe su penne | Gree ce 5 aeacimns = a at a a 7 sane SWING PARKING psv-Pt Tasos CAP(TO24=1279) BRAKE SOL PUMP PI PROPORTIONAL P-7 Pee eee oo 1 Woe at sez F a3 aR EE scores ed cenon Froksveen seuecr sou [fi arenas He aMArsinNs ME i Gcitae Genuine uve 70,86 E838 Fi Ai Psy-H: INSERTED INTO ALL 3FA~JME+ FB Sisson auv-sey L acedun — PRORSTONML OL Base E aeansms agaven : Gecitte iS Eattenr neuay cu-2eue Sez Merete aRB80b4 ede wos oo. BSce ose TMG frarped] is Fee equine owe, 10 82 fe Goiibe INGERTED IN TO ALL a a areas DHRCIEY pocy na Bon co. MSRM, a oe glee REAR WORKING LIGHT seating puug 70 Be $6523 sewsog, 2 i. cNeisir NBEO IW ro'ace | ERESS, Se x dencste seach NERTED aa e Site 8 wire Teme sek pores za YA, Instat oTB-3 TSCE. msaniy SiR sensaren se a s POTN Sb Srreoaoae HA x engi E| aenmte FE) wanes orate os Senin uve 70 ee ‘en 202" i ‘nto 0 TRSERTED INTO ALL SW-16: FD soe Bec soon Lic eneise 2FS-0900 Ye Fe85829 50m ETL. 27: wii Te TAPING [ L Setkton cootaur eve. sx k araoune ‘oy APTER WwITE TAPING wite TAPING Bote comm |e ett 25 E13: 2FA-3ME+ “a FaageL sua aa A. sven CEs > te A : "fice sence een iu ROTARY LIGHT bea ee surrey an awn wn aNA-snt AL sequin uot 10 0 CODD wale ris 1 oe xD Taser ace GD fiat ne 23. ELECTRIC SYSTEM DOUBLE — CAP TO BE INSTALLED SPLICE GLO RELAY: INO} 24) Las08 2 pe 2. STARTER RELAY (COU) 2FY-090a iwy-sey ce-2s8M ar A-INaS cn 258F Reis EATERY RELAY eo) bes ‘SHING FLASHER Leet & eae wore Ng LIGHT CN 1456 aFA- aM WHITE TAP pny wen aMa-siaay SEALING PLUG TO BE INSERTED INTO ALL 23-1923. ELECTRIC SYSTEM 23.3.6-1 UPPER HARNESS (3/4) : YN13E01446P4 a wire TAPING TW. we VE. HE ae a Te nk hee Te TAP 12FA-o79oI A re TAPING a cree fi9 Fitdien weuy 19 wanes maccna ey ey oesi oy 150 | To uasness eySet ‘cao - suepuy viTH rstabuly vied (eet CREEL a Simi Tv sos-cors is i tee t= t ve : rs ; ale ary-p908 A Se] oF bp Seats] PT el eee sl 208s-nmoe0s (0) felt te ZT EE) ERE! at EL AT EE) eases peer cers [orl] ET RADIATOR COOLANT LEVEL P= ain eae 3iFA-040080 DaPA-o40NAD ivea-oaoune CONTROLLER ; SEE iorA-o4onPN 28EA-os00PM Enc toSe peat arena F a le cna t0SF cha toe couse Se] | seuice lel |- a LT feist ppeoe taea-oroue TNE coer 1 metvars0 cowTRoLLER rH Carre HAND CONTROL Spite od wre 0iN6 euLaz0e b eaawe oxo oF SENSES" Ghee Futoe 1 A ® baton: Is| is + "| oN=571F 77 JAPING 1 FA~CNA uatoe we ov6LE SPLICE Lavoe Lapos Pott B10 23-20 T4FA-O7OMLI N= 158° To FLOOR hawness. Ua cHA, cuss 72 sete faclifleslin} #F4-€CP eu 12eAcHO ena? 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ELECTRIC SYSTEM 23.36.2 BATTERY RELAY CABLE : YN13E01417P1 640 B 40 + ae aves TERUINA | CAP BCBIs BTC-135R (RED) CAP YAZAKI 7034-1283 TAPED IN TWO TURNS 23.3.6-3 BATTERY CABLE : YN13E01441P1 (50) g AVBOB TERMINAL 60816 (-) CAP BTC-135R (BLACK) 23.3.6-4 BATTERY GROUNDING CABLE : LC13E01144P1 CAP BTC-135L (BLACK) 23-22 300 J q S \ CORRUGATE TUBE TOBE INSTALLED cAP rerminaL BTC~1 35K (RED) 8Ca18 (+) 480 40 rm YZ —N\ A oB / / TERMINAL TERMINAL 60-8 BC816 ‘TAPED IN TWO TURNS 23.3.65 STARTER CABLE : YN13E01442P1 2000 TERMINAL 70 rermina, 22 Bo-sBL 80-8 WO cap AV60S INSTALL DOUBLE CORRUGATE YAZAKI 7004-1268, € Z, scare wy oly 1A Wire TABING yysTALL CORRUGATE TUBE ' Be 7 SUPPLY || LB CAP TO BE wir | |36) ‘SLOW BLOWN INSTALLED FUSE 100A cap YAZAKI 7038-1283 TERMINAL BA5O8 WIRE No.35 ‘TAPED DOUBLY TERMINAL | 4-6NS sAPIN WIRE No.36 siikd Jeo TWO TERMINALS ARE IN TOUCH WITH EACH OTHER TO THEIR BACK AND. BUNDLED BY TAPING, CAP TO BE INSTALLED DETAIL A,29. ELECTRIC SYSTEM ECU HARNESS (1/2): YN13E0144aP2 4a208 A208 LA208 RRR SEALING PLUG SUE SRRE fe U/ aFy-sH 16) Geo Pil acceteration WHITE TAPING Ll) EMERGENCY Pied) sracna cw) ch-2eaF TO FUSE & RELAY BOX WA oa We ih fa nD TO ENGINE aonacopones CONTROL : ‘Whe TAPING CONTROL Ra SEALING PLUG PP RP ET, BI: WHITE TAPING 1ary-se rr BECK MGELICEL OW, ate oe TEE i INSTALL DOUBLE CORRUGATE ee Fe TOHARNESS FLOOR cn-210 vaNano7OuLt opal cn-9F st 20FS=HH9808 (0) lek = Peer Beat we eeans SUMITOMO 6409-0075 “cer PLUG 2ors-HMosos (@) [SE] CNSOr celvla eke = husabers ares q SUMITOMO 6400-0071 TAPING =EELEE ES WE AY. | oN 11 WHITE TAPING sae 11962 ZA Za SHIELD UNCONNECTED WHITE TAPING 7 34FA-025/0408 aa pI ED ED ats 31FA-025/0408 35 18) FA-025/0808 s2FA~025/0009 35 (Al FA~025/0408 N=5F ou-aF ‘on=3e NF 6-8 “ENGINE CONTROLLER 23-2323, ELECTRIC SYSTEM 23,3.6-6 ECU HARNESS (2/2): YN13E01444P2 wiRe[wAE laine séze| enom [eoncovion) ro pime[wiRelyiae size] FROM fommection] To Tak] w_lavean, aed] co-ar Teor Gas] 7 vseo. sted Ou eat 3120| w_favesi_ aba] ona Ten=3F sae [ak aveso. sted On-7F ence 3126] w”wvvei_ ass] cn=eF enor a27 [6 _[aveso. Stee) eN=TF oneaF ais [e| SHEE Ponmar nar an | 6 [wvss0. Steel WTF chr si [Ge | 2 corer [ cn-oF Jen-30F 330 | we [avsso. Steal CN-7F tN-4F 3ig0]_W vat. 26a0)en-OF [Lena Bara) aL favsso. Stoo) cumer |p | Ova Sis [3 | SHIELDED Tonner enna are) RL fwsse. Seq] en-9r | —-— | on-4e sua |r| Cone) [en=0F euesar sare] aL fwvsse. sree) encan fe— | ewe Taal Ww favsSi. 2520) enor on-aF 3528] et _Jwvsse.sfeelon-a0F | —p— | ens aise] _w [avasr aee cnosF oor 3aza| an favson.£tre| en-a0F | —F— | on-5F aac] # Wwes 2seq) ence | FF | euro 3326| e8favsse. £20] n~30F | F— | cv gis |p| SHIELDED Toymoe en 33a) AL_favsse. sree] ennaor | —p— | cn=5F gaz [er] G*5he) [emer | => [on-a0r sae) RL Javsse, Sfselen=aoF[—p— | ows Geo]w_ pve). 260d anor enor 33ac] AL javese, stsqlen-a0r[ ——— [onan siz [a] SHIELDED [cher en=sF 3aaal re hvss0 Y5fed onmaF | =—y- Lower so) or | G*ehke [ener | Enn20F sna8) va_hwaso.Yored enmae | ———> [ow ar E10] 8 fwvese, 5fes|_p-2 PRBEREMIE| cn aor aa4c] vo jwss0Tafsq @n-zin| ———t [ona ee |e Javsetasea) pa | ——p fow-a0F 350 [a ]avsso. 81 lon-aeaF ena es"[ 8 favane. Tete] GN-aF en-aer 352 | 6 [avsso. Stsclona6eF Beir 6 | 6 lavss0. 5tsq]_cn=ie | ——t- [en-30F 353 [ aL [avsso. srcfon 264i eine er [s_[wvssi.2see| pa PREREEIY cnr 20 | Rw [AvsS0. Ste] oncom] ona €2 [_@ [avest 25e0] Poa | W——— | onar 521 [uy [avsso. sfeqfencainy oN-3F E28 _avaar. e500] pt _ PUREE cnor Tar |v] wwVS0 S00 [on-2im| onc ca | |avsse.7eree] P= enor Tea |e] S¥LELBE? [onan en eo-| 2 sso. Staal ouea0s| ——— [ew sue Gr] G*eone [ens lneoe Sa | 8 _|avss0.75tee) on=1F | ———— [en-sne 6 | R |aves0.75tea) en-1F | ———— ons CONNECTORS SELECTION TABLE so | lavsse. 28tsal onm1F | ——— |cn-sre ea _[PInvss0-Tates] CN=aF | — [onan Fomcice aa nee 66 |p [avsso.75¢s0| Cn-2F | ———— | CN-SRF_ eee eu renua ae |p Javsso. Stee] on-ar | ———— [on-enr 6p |e Tavsso. 75¢se] cn-6r | ———— | cn-sar Pee eee Pere Tig| ye [avsso. srsalcnciif| — [enceiw mama ano saa | P |avaso, 2sfae[ew=2 19] —y- encaar $08 | P_|ves0.76tae] en-af | ——} [on-ser roa see | P|avsso. votes] on-ar | ——- onc sar asa G2a | w_[avss0, 51 ee) ewan [———— Jen sar Ta aT [esse 26 w [avsso. Steel cn-2F | ———— [en-sar heat 62 | wy |avsso. Staal cn-2r | ———— [en-21m eet 13 [oR avaso. er sa) cn=oF ext ee yoe [Ge _favsso. Stee] en-1¥F| — | ewnie Naa 308 | Ww [Mvvso. 75s cu-7F [| ———=- | cn-2F ri2a343-1 sor) a] SHIELDED Fenore | — Ponca Tas fast see [oe] 2 cone: | ene7n [ee | ewer isso 300 |” 6 javeso. sraal on-or [——— ower Bie, |) a Pavey 309 | RY [aveS0. steal encer | ———— | ower rane 310 | ts [avsso. steal CN-aF | ———— J cn-eF asia a1 [an |aveso. sree] en-eF | ————"F encore Saas ame pais 220 | ow |aveso, sree] en=er | —— | en-oF ea 221 [4 [avsso, Steel cn-af | =—=— | enor eo a2e | aw [avsso. Stee] cho 1 — Tower en 323 | wi pveso. Stas en-enr] ——— | ows aia | aa TTA 3244] [AVSSO. Sisal cHosRr| ——y- | CN-9F sess aso] _[avsso. tsa] cnear | ——+" | ona Fareowa [rpc aes oe saie| 1 Javeso. steal eueve | ——e | ena fea i ree [| 23-24 23.3,6-36 FLOOR GROUNDING CABLE : LE13E01006P1 vases 5B ©) oe €) se fe 1PAM YAZAKI 7122-3010 23.3.6-:37 RELAY CABLE : LC13E01180P2 ‘TAPED DOUBLY ‘CAP TO BE INSTALLED. CAP ‘YAZAKI 7034-1280 Se = / TERMINAL TERMINAL HEAT STRINKAGE TUBE TOBE INSTALLED van 6NS 14-6NS 23.3,.6-38 ENGINE GROUNDING CABLE : LQ13E01100P1 260 TERMINAL Gane. BA708 Mes avgo3 cme CORRUGATED TuBETO BEINsTALLED —TELAIE 2336-82 AIR CLEANER HARNESS : LC13E01193P1 ai > cAlo4 = ca swe lee { YA. AIR FILTER CLOGGING . SWITCH WHITE TAPING p BED 2NA-CNA CONNECTORS SELECTION TABLE lconwectoe PART. NUMBER NAHE] MANUFUC,| (in WM) HOUSING | TERNINAL awarena | AMP | 172218-1 | 170a80-1 taroe awe | 17067=1 | 1P0002-6 Ceres ‘anp | t70aea-1 | 170003823. ELECTRIC SYSTEM 23.3.7 ENGINE HARNESS ASSY = ENGINEIHARAESS SEV LceEOnDaner| et Hagwess €oU) ENGINE HARNESS ASSY|LQ1GE00D10F1 | a Tn COUPREEIOR ENehE: seceeoRY ITEM PART NAME PARTNo. [QTY] REMARKS CLUTCH 1_ [HARNESS Loveeor01sP1| 1 [ENGINE SUB H HARNESS (UPP) ENGINE GROUND CABLE COOLANT THERMO SENSOR (ECU) FOCABARNESS WITH CLIP | ON BRACKET OF ENGINE ACCESSORY cup SEMS BOLT, FIX THE PLATE TO ENGINE BRACKET TIGHTENING TORQUE, 25.8Nm (18.8 Ff) ENGINE SUB HARNESS : UPPER HARNESS VIEW 1 CONNECT UPP HARNESS. M4 ‘STARTER MOTOR REMOVE AND GANCEL THE HARNESS OF ATTACHMENT FOR SC TERMINAL STARTER CABLE T | | | | ALTERNATOR TIGHTENING TORQUE. 28.8Nm (17.3 ft) ‘SEMBBOLT— LB TERMINAL TIGHTENING TORQUE 28:5 (173 F 1 ~ SEMS BOLT ALTERNATOR (L, R) TIGHTENING TORQUE Sandan 2.43.3 bef HARNESS (ENGINE SUB). HARNESS (UPP) — STARTER CABLE DETAIL A, DETAIL OF ALTERNATOR tet STARTER MOTOR (COOLANT THERMO SENSOR (ECU) cu SEMS BOLT cue SEM: a TIGHTENING TORQUE 9gNen(71 BFA) FIX AWHITE TAPING TIGHTENING TORQUE BS-44Nm (2-4-3. bF IS BOLT \ALTERNATOR / \ ALTERNATOR 23-2523. ELECTRIC SYSTEM 23.3.7.4 23-26 ENGINE SUB-HARNESS : LQ16E01015P1 2: ALTERNATOR | an) CN-24F a 4FS-090 ENGINE OIL PRESS. SW. (82580-86408) CN-23F 1EY-090E Z UPSIDE toe LA SEALING PLUG WHITE TAPING ENGINE COOLANT ‘THERMO SENSOR (FOR ECU) CN=25F 3F$-0901l (82580-87604) i) AMA- JM cN-21M TO UPP HARNESS CONNECTORS SELECTION TABLE lenwccron aR, AUNOER rig ManeUe, lew 8. woustne | reeniaas WiaEDWRE Twine size] rom [connection] To ee | w [Aexo, Tose | Pes Seng co [ va [aeKo. 755) Ov-24F cna saa [m [acra 7530 cuiczm aaa | «[aeno. 7550] on-25F once iw 548 | GY [AEKO. 752) CN=25° en=ziM \SEALING PLUG23. ELECTRIC SYSTEM 23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) UPPER HARNESS ASSY|LC13E00032F1 | (00) ae NOTE: 1. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS Pee: BOOM RAISING MADE INTO THE FOLLOWING ITEM] PARTNAME | PARTNo. lQTy/ REMARKS: PRESS SENSOR: ae + | HARNESS YNISE01449P3| 1 [FLOOR eee e& 4 | HARNESS LC13E01186P1| 1 |CAB SUB HARNESS TowasHeRmoToR 3.4 \ Paces ‘SENSOR Pe 9 | CABLE LE13E01005P1| 1 |FLOOR HARNESS GROUND Se2. ~R eee PRESS SENSOR sez, a BUCKET DUMP ~~ /_-- PRESS SENSOR xevsW, ARMIN see. swts PRESS SENSOR net ACCEL POTENTIO E+1 : FUSE & RELAY BOX ‘SW.4 KEY sWwiTCH 2 / [ SLA / cup ; im ul FASTEN HARNESS BY CLP ‘AB HARNESS. PSE amo chee, A STAND AHO PR AAENESS — ,WITHBRACKET OF MULT) Cue Bb ewes { NT a ‘ arr a ro() Si WITH CLP NOT USE CLIPCASEBYMULT! cise HARNESS DIVERGES \ re WHITE TAPING DETAIL A: A CASE OF MULTI Mi AT fe} / postion For Oceania) sat C/To waster moro i 7 ff FIXAHARNESS ON SENSOR BLOCK WITH CLIP oe TOWASHER MOTOR || CABSIDE COVER VIEW I PUSH CONTROL LEVER HOST FRONTWARD . [AND FOC THIS SLACK HARNESS WITH CLIP . Se wed Bbc \ swass OVER LOAD ALARN SELECT SW. Y \ nN \ HEAVYLIFT Sm, CONNECT SWITCH TO TAGGED see / 32 CE, | GOnMCT onto "OVER L' CONNECTOR PRESS SENSOR PRESS SENSOR ; \ TO TAGGED "HEAVY" ARM OUT ce 7 ge; BUCKETDUMP — Své13 connector / | ‘TRAVEL ALARM SW. \ R / prmineee BCowawone’| —INCASEOF TRAVEL wa se ALARM SPEC, ROTARY LIGHT Sw. PRESS SENSOR CONNECT siNiTCHTO CONNECT SWITCH TO TAGGED "ROTARY" BOOM LOWERING TAGGED "ALARM CONNECTOR DETAIL A: ACASE OF SENSOR TOWER CONNECTOR (For SE. Asia) a a (Forse. FIX AHARNESS _., FIXAHARNESS PART OF OF SW.SIDE | WHITE TAPING OF CLIP CLIP cup 70 CONNECTOR FIXA CLIP ONHOLE ‘SE-20 : PRESS SENSOR : Pi OPT nf roneuncronaue wrmmeauin Cs) TIGHTEN AFTER CHECKING NO PAINTHERE, | /// x3 CLIP ~ 7 A eecting mT A Fi EXACLP ON HOLE + sw20 Se odenccr wir eaRTH { TQRESS SENSOR, eaSTEN FLOOR HARNESS ~~ Wewow sang CABLE OF UPPER NE WASHER MOTOR WITH LEVER SW. a ‘sw33: FRAME a i HARNESS | — REVOLUTION RIGHT SW. (OPT) got eee (RED TAPING) feneresoueromcesl| eee Re Jr soos a $610: eons — FOR SIGHT (OF (LUE TAPING roe) : S SRAVEL Leer ’ ) srreoosr. (9 ie \ owen Peesdeheohr A esos conenrex GRAVEL RIGHT ye ! ey \ WASHER NOTOR a 5 \ TUNER : MS cup Set: e cur ri FIX WHITE TAPING. ees seo cur FHT TAPING SS Fiacimouwoie Rosman NS | Le DLS) Bavate apis Trouame nanos | OF SEATSIE ‘ mroearaporemerer | |\ cup \ EX WHITE TAPING POSITION 1 ‘TO THE FRONT SIDE OF FLOOR PLATE. 23-2723. ELECTRIC SYSTEM 23.3.8 UPPER HARNESS ASSY (FLOOR PLATE} (2/2) S A UN om es Sen edllen eg lice GS"| Fserneny aA swe2t 1 BOX \ ct er GO Sts ono ; ae ao \T-2" TAGGED alow ano case comnoueng >. SeineDin oMBET OMT ASCE, CONNECT To SWING Se guerten orn oN eam Xe. SES (CONNECT THE "CNT-4" TAGGED! CONNECTOR OF CAB HARNESS \~-~ swat “ITEM 1 HARNESS" Lever tock sw, WTH"TE! E22 -DC CONVERTER PUSH CONTROL LEVER MOST FRONTWARD. AND FOCTHIS SLACK connect ro ‘ HARNESS WTH CUP A y Dope CONVERTER ye GoREUE cue’ , BACK SIDE ae Nos Lo DETAIL OF WASHER MOTOR CONNECTION : ° our Sb Aro Rcut FIXWHITE TAPING instpan Postion cu’ 2 Use cuIP TO TE UP wire TOUNDER SROING PART OF HARNESS _/ FLooR 7 WITH BILOT HOSE TOGETHER ~ view mt a TorcontRouweR CONNECT THE "onT-4+ TAGGED HARNESS q SONNEGTOR WITH "ECU. HARNESS" ' ca 7 = CONNECT THE "ONT.3° TAGSED MECHATRO CONTROLLER| Fanci GONNECTOR OF CAB HARNESS My Box CONNECT THE "eND-1 CONNECT THE *on2.2" en ure anes eae Cur ce taonchternon TAGGED CONNECTOR WITH TAGGED CONNECTOR WITH : ¢ FOX WiTE TAPIN x 7 THE UP ITEM 1 HARNESS" Hire STEM HaAeWESS ITEM 1 HARNESS THEUP TEM HARNESS’ WITH {TO THE PLATE WITH CLIP FIX WHITE TAPING POSTON = FO TE PLATE Wine CUP 4 cap SUB HARNESS g CONNECT TO SWING ag I DETAIL OF FUSE & RELAY BOX CONNECTION PARKING RELEASE SW. ag FOX TO THE UPPER PART. 5 CONNECT THE toNT:2" OF PLATE WITH CUP AGED CONNECTOR ai aa SUPPER HARNESS” CONNECT THE “ONS2°TAGGED eer rue ene E SONNEGTOR WITH "TEM 4 HARNESS" : FAOGED CONNECTOR WITH cofneor THe "oNa-1 "heM1 HARNESS™ a JAGGED CONNEGTOR WITH SEM a HARNESS view Iv FLOOR HARNESS ! ra FX TOTHE LOWER PART im : OF uate wire CUP & orts UP CONNECTOR 22° CONNECTOR 280 CONNECTOR 22P CONNECTOR x6 UNGER FLOOR SECTION AA VIEW v 23-2823. ELECTRIC SYSTEM 23.3.8-1 FLOOR HARNESS (1/3) : YN13E01449P3 aeacnas extsore ((Bahe] x1 sea Ux : Press sensor ‘v. Rave Richt eran Neo} steno (a) mie TAPING supoLy wn ‘SHE ye AMP 4565123-1 WHITE TAPING NIGBLER OPEN 4 PRESSURE SW fF = {J surevy vert al Dean INE BI sta ee PRESS sensor = TRAVELLE*T TCT: lecbeoked feats! renee | speed = le b Cec tr . " SE-16: se20 AcE. POTENT PRESS SENSOR aEA-oTOMLI Fi on=308F TAPING AFTER 7 To edu atess sarap 3FA-HO8 pane wwe FAP Tele cle na / la A BIE 2 TH aE I Ben a T/A TEE 7 3FA-CNA parma lagae x / vnure 0INGwmuTeTAPIG ons gair as Jeg] iPanena voire FAP fa ume Tsurrer wre Te TAPING felt a QBIRE roypren anes surPLy vert el rae vue raring STE | EN SOM du est coy reacts coh ae 308 ; i Seuce A is aea-cna owas mas | eutisae Se PRESS swe cies s us TOFRAME SIO taser Noro theca IFASCN lA CID ene-1 E auacsuts ‘SEALING PLUG 10 8€ = == a JE —_, INSERTED INTO Att cerry eels ised Pee Bae ete eT 25) SiG RELEASE 6 =D GHEE Sey] ara-cua fatal] ‘cnveae 26 3FA-WOs aracnos = aEa-250 entiste ae ene" See: usoR, PRESS SENSOR. Stora pla or a aes mearour eocre cbrloded [ele aFA-Mas entrb0e encizse ae se x Press sensor Press Sensor Satie RES BueK=T OU aFA-uaS aFA-Hos eneiate enti abe se S83 Press sewson: Baza seysor BOOHLOWERNG — BOcwRaISNG FUSE & RELAY BOX 23-2923, ELECTRIC SYSTEM 233.84 FLOOR HARNESS (2/3): YN13E01449P3. aFA-oNA a tS eS) 2eAcoNs aea-ows sea-ona 7 sil [eal b0tsis? N= 503F ce-sozr || swit2 re Re FD Sekine aus SH18 sw40 shy aap *. 2. INDEPENDENT EIN br see se ora ce Seteth om ogre oe iad a ON-512F ne TAPING AFTER — SW.35 TAPING AFTER ‘TAPING AFTER, ‘arm arten| —/rapiva aren ___BUNDLED. HEAVY LIFT sw. stuoee8 Be BUNDLED, GUNES lan wes. x zx WE = er povee “epee WHITE TAPING FepingarTer A TAPING ace TARO ARED XB Tt ee tare chad i Te = boletfe Tel: ars-imose etcend sw28 ps onsoo a - NBLEROPENSHL 20F5. 40808 @r) B.7 : TUNER: ‘TRAVEL ALAR SAV) ‘ON-168F uPecy wis SUMITOMO 840.0808 = 29 vie TAP FA haben c.0se SW 2f5-1Mo90 2Fs-amDg0 aFs-wwoI0 fatal { Tes wmoso Gactbae® “Cnctose” | “Eacener Gnceaee ows ‘sw.20. ‘sw-20 JGREEN TAPING. ves Low SEVOLUION BOWER BOOST SH. RORY SW RIGHT eae owes teagan a: POWER BOOST SW. LEFT. bra-ing30 Co -MecHaTRO comnsoLteR caodats — sw = cyrioie cnoiaze aysi0e Wea FE LEFT ose 34FA-040 1PM, 22FA-O401PM 20FA-0408HD 22FA-0400H ae we RED TAPNG—Hl puuL-ramIG ee seetamide ea Bren toox om. [esloouste a en 30er cha dedatel fmiatetireted| — (fxt-la Een eon EE Dracena of lerube Sevolimow err aw Se eeckeey ECE pS [tres peaap extsose Fae) pare-awoso ee faa mel tefotd TR Pale [inference = del [ *GicSose (ebgenes hts iver] (ERT ELI ETS EEL ex sruce er ano sie ee 7 cuetoor vtreaPia dy eeacens \ ROUBLE! save wz a { ze a wen unvcowecren st Tors-o7NL! cnet tor rorrvarness 23-3023, ELECTRIC SYSTEM 23.3.8-4 FLOOR HARNESS (3/3) : YN13E01449P3, frie [wiRelvine size] Fron [comecrion| To wige[#RElwine size| FRon [cowection] To RET WIRE wiae size] FR0M [conection] 10 tanuetvane et eetan ROLE 4 | wa [AVSSO, 75seicn—S05F| cna-2 33 | Lak [AVSS0, 15 selcn-304F| len 102] B17 | wa |AvSSo. Taadfon-ao2F| jew=io2e| @ |v JAvSS0, 75s alcn-400F| cN2-2 514 | GO [AVSSO. 75 sq[cn-s02F| len=1028| ‘950 [ Bre lavas. 75ecfen=24F1 jen=1014 lsecran PART. OBER TIAL v8 [avss0. 75sslon-aoor] ——-= lon- roar] [517 |_P _[avaso. 75nelow=aoar leuciazr] [61] t_|aveso.7sedlenci26F em | nousine| tenine Ti0_[ va" [aveso. Tseslen-700r|"EEEIE on i7ie| ['s20"| RW] a/SSO_ See env 714 Jecuare] [gee Can avaso-veeclencizatl fume fee Tie | ve [aveeo. 7eecfow=700e] —tfoncisar] [Ser | LY AvSS0- Sec on-171F lencior| [aaa Larw [rrasoctesalensiarel fewcrors) teem ee [sro rs tic | ve [avsso, 15se] cna-2 | ———+ |en-160F| 540 [LG IAVSS0. J5selcN-51 941 ien=102F| 954 [ert [avss0. 78eclon-120e] ——— on-10 14 Serta mera} iiecrr Ta [waves 26 selen-a018 cna-2| [eean| Grojaveserseelowsioeel| ——-y-evceare] [gags favsso teedensis i]s fect] RE CS 12_ [ve |aveso. 75sqfon=110F cna? 5420] Gro |AVSS0. 75s- low-ooar| Ti [ve layss0. 75ea) on-ser en-TaF €_| a [avss0. 75ed|en-s01e| ——+- lew=s05F 13 | ye | Aveo. see len=eo0r| cN=72F €3_| 8 [aves 75ad{cn=s ae] ———f- len-eose 18_| RG [AvSS0. 7580] cN-12 len=500F 4 [8 [avssi, 25sefon-soor| ——+- lon-805F 1a | w| AvS0, 50 [on-coom| on-72F ee] 0 | Avssee | Pa GEE | 25 [we [avesi, 258 Tena eavae | ~ane —[iro00s-s ronee=r cancion | vatner fraa-aoiap venses0 Y-oost_YaEAC preacrvadve ai Sweceea [Mo _[ versio] Hoan 23, ELECTRIC SYSTEM 23-35,23, ELECTRIC SYSTEM 23.310 BOOM HARNESS ASSY BOOM HARNESS ASSY FYN15E00003F3] cm) iTEM| PART NAME PART No. [Q'TY| REMARKS: 4. [HARNESS YN15E0101302| 1 BOOM LIGHT 23.3.10-4 BOOM HARNESS : YN15E0101302 4250 CLAMP AT TAPING POSITION TO UPPER HARNESS: 6 catod ‘CAP : 7120-1010 TERMINAL : 7115-1050-02 23-36 T-AVO. 85sq (GREEN) 1PAM WHITE TAPING YAZAKI 7122-2810 TERMINAL : 7114-2020 23.311 BOOM CYL. LIGHT HARNESS (A) ASSY BOOM CYL. LIGHT HARNESS (A) ASSY| YN15€00012F1| con ITEM| PART NAME PART No. _|Q‘TY| REMARKS 1 [HARNESS YNi5E0101801] 1 FE conect 10 23.3.11.1 BOOM CYL. LIGHT HARNESS (A) : YN15E01018D1 1600 caios entoe | CONNECTORS SELECTION TABLE PART. NUMBER lconnecror fume; HANUFUG. HOUS! W (iN NUM? | TERMINAL Atos | YAZAK! |7120-8012)7113-1020-09 caios | vazaKi [7120-1010]7115-1050-0223.312 BOOM CYL. LIGHT HARNESS (B) ASSY BOOM CYL_LIGHT HARNESS (8) ASSY[LC11000287 | (es) eM PART NAME, PART No. _[@'Ty|_REMARKS 1 [HARNESS terteoross| + | CONNECT WITH CAB HARNESS CONNECT WITH NAME TUBE OF * CAB LIGHT" DETAIL bb (CASE OF CAB WORK LIGHT) 23. ELECTRIC SYSTEM R=45 BOOM CYL, WORK LIGHT RELAY 1 et b. |S FUSE & RELAY BOX ee IA 2><._ CAB SUB HARNESS noe CONNECT CONNECTOR WITH TCNGs TAG OF ITE 1 :HARNESS GONNECT CONNECTOR WITH CNI2 TAG OF ITEM 1 HARNESS FLOOR HARNESS: 7 ey CLIP. f WHITE TAPING SET i TO THIS POSITICN DETAIL aa LIGHT HARNESS CLI Pe FIX A UBP HARNESS BY CLIP. 23-3723. ELECTRIC SYSTEM 23.3121 BOOM CYL, LIGHT HARNESS (B) : LC11E01065P2 23.313 INSTALLING BOOM LIGHT TO FUSE & RELAY BOX INSTALLING BOOM LIGHT _|YN80E00011F1 | (04) PEE EEE ITEM| NAME PARTS No. QTY|_REMARKS oe RESERVE RELAY POWER RESERVE 1 [UiGHT ‘YNg0soo001F1 | 1 6FA-O70MLI 2FA~CNA ene cna DOUBLE SPLICE me TO CAB WORKING LIGHT Sit ~~ 3FA-ONA ~ zlel| "char SS £O} 7 POINT THIS LAMP TO BUCKET BOTTOM CENTER ae Sy INSTALL THE LAMP 60 THAT THE LIGHT BEAM POINTS THE TAPING eee OTTOM OF BUCKET, IN THE CONDITION THAT AREM IS [=|] oua-ewa EXTENDED FULLY (ARM OUT) AND BUCKET IS CLOSED FULLY. witTe TAPING =[:]] euacos 1 fine ad asit& | wine size | rou [cowecrion| ro ara | 0 [avaso.78se| one PRMESBLICE] “chia sre] 0 [wvss0. 1508] ene Tree eon | seu [avsso. 7500] cn-se [QULESELIE| nia \ a5_[ ay [avsso. t5ee| oni2 [= [ft oN Se pase hese EE Gra | THONTENING TORQUE 12940 e2 | 8 [avssi 28e0] one wt i (13.7 Fey l ; iff CONNECTORS SELECTION TABLE SECTION AA CAlos cars PART. NUMBER pat ay rownecro8 | wanuruc. ‘pela noUSING [TERMINAL TO BOOM CYLINDER LIGHT HARNESS cao | ane |170887-1 | 170002~8 coro | _ ane _|10889-1|170003-8 aficowa |_anP_[h72130-1] 1700322 Brae | ane [172132-1| 170032 SuAceNA | ANP [v72ia1~1) 170340-1 lrxcoroni] ane [7565-1 [i7aeatm 23-3823. ELECTRIC SYSTEM 23.3.4 INSTALLING UPPER LIGHT 23.3.15 INSTALLING CAB LIGHT INSTALLING UPPER LIGHT —_|YN80E00049F # | (01) INSTALLING CAB LIGHT YNOEOOOSEFt | (ox, ITEM| PART NAME PART No. _[QTY| REMARKS Tem PART NAME PART No. QTY, REMARKS 1 [LIGHT Yreosoo002F2| 1 | 4 [LIGHT YT@0s00002F2 | 7 6 | HARNESS yNo2co1760P1| 2 7_| SWITCH yNs0soo0s0D4] + 9 np (OPT WORK LIGHT RELAY COMNECT TOINST-PANEL wanes comvect wits cute Wants HARNESS. NOTE ITEM 1, TIGHTENING TORQUE 18.6N-m (13.7 IbFft) + MAIN HARNESS TIGHTENING ToRDUE PAINT PANGIN SEAL 3 seine Hert) raw stank Tie Sens sncruoweae Rae a ISTNOSCRET Hydraulic ports ig Paris ary Code Ports name Size Ise.AsialOceania 7,2 [Delivery port ‘SAE 6000psi 1” 1 [Main pump assy TT = B1_|Suction port ‘SAE 2500psi 2 12" 2. [Regulator assy 2) Dr [Drain port PF3/4-20 3 | Gear pump assy(for pilot) 1 | — — P8vt,2|Servo assist port PFAUA-13 4 | Solenoid proportional reducing valve] 2 | — _PH1,2 [Pressure sensor port__| PFS/8-17 5. |PTO unit = | 1 _atrat [Gauge port PFS a5 _|Gauge port PRAA-14 ‘A3_|Delivery port of gear pump | PF A/2-19 53 _|Suction port of gear pump |_PF3/4-20.6 Dr3_[Drain port of gear pump | PF3/8-15 Fig. 24-1 Hydraulic pump + regulator24, COMPONENTS SYSTEM (2) Hydraulic circuit diagram ron Solero proanional—>, | reducing valve (PSV-1) mmm ET \— PT0 gear case Fig. 24-2 Hydraulic circuit diagram of pump Main pump Item Gear pump SE. Asia Oceania ee Pump assy YN10V00036F1 | YNT0V00040F7 a Single Pump YN10V00043F1 YN10V00014F3 Pump model K3V112DTP1K9R-YTOK-HV |ZX10LGRZ2-07G Max displacement capacity oma 110x2 10 Revolution Rated min-+(Clodenise seen from shaft end) 2000 - Pressure Rated MPa (psi) oes 080) 5.0 (725) ATT boost pressure 37.8 (5480) Max. flow Limin (galimin) 220 (58) X 2 at 7.8MPa (1130 psi) 24 (6.5) Max. input horse power kw (PS) 114 (155) 3.4 (4.6) Max. input torque N-m (Ibf-ft) 544 (401) 14.7 (10.8) Part No YNI0VO1009F1 Model KR3G-YTOK-HV Regulator Controt function Electric flow contros, positive flow control, teal power central at emergeney made end power shit conte Others With sono proportional reducing vale (KORDESK1/80050 Weight f kg (lb) 144 (310) 443 (315) 24-424. COMPONENTS SYSTEM 24.1.1.2 HYDRAULIC PUMP 2411.21 CONSTRUCTION (1) Main pump SEVNA 709 592 Ayatmecmestonsnorwen 724 901 OOO 717 «tH 1g 7a2_\_ 244 \549 91 702 792 $34" Z P of ln 885 ON \ 58 LN Dt ion AS aa 74 —~ att Ros 40T 251 490 271 153 156 157 488 313 124 Tho 146 467 46 12 885 314 thn 728 Tar 728 Tightening torque emnumber] Twesdsze -—TaHHennSuS ii Mao) I aq 396 408. 29 (21) 728 / “407 [297727 aid (42) 286; BE va 2627) 467, PEE 74 (55) 468 [Fa 1701123) 490. PTE 6 / \ Bis | wae 240-177) 407° 325 = é 806 M6 130 (96) vews SECTIONS SECTIONeR 306 0 240177) SEAS) No. | Parts iy [No [Fars a | No Paris 111 | Drive shat) 314 [Valve plate (L) 72a [Bulag 1B PE 113 | Orive shaft (R) 326 | Sensor biock 1 | 105 [onnng 18 Prt 9 118 |Goar #1 326 | Cover + | 727 |onrng 18 Pi 3 128 | Roller bearing 401 [Socket bolt: z0x210 | 8 | 728 |O-ing 1B Pos 4 124 | Nese bearing 406_| Socket bolt: MBX20 4_| 732 |onring 18 Ps 2 727 [Bearing spacer 1 407 Socket bolt MBKS5 3 | 774 [Oi seal 1 141 | Cylinder biock 414 [Socket pott:n10x20 | & | 789 | Back up ring : P18 2 15% | Piston (466 |VP plug : PE1i4 2. | 792 |Back up ring 635 2 152 | Shoe | 467 |VP plug :PF3I8 2 Nut i848 2 158 | Rotainerplote | 60 |VP plug :Prava 4 Nut: M0 2 786 | Spherical bushing | 2 | 490 [Plug ;NPTFI/i6 4 Snap ring 2 4187 | cyinder spring 531 [Tilting pin axe 2 | Valve piate pin 2 241 | Shoe rate 532 |Servo piston :M28x2 | 2 | 885.| Spring pin 4 2:2 | Swash plate 534 | Stopper(.) 2 | 901 | ye bolt; m0 2 214 [Titing bushing |_2 | 836 |Stopper(S) 2 socket soraw:M16x35_| 2 251 | Swash plato suppor 546 |Specer 2” |[S52)| Set sorew ; M20 2 261 | Seal cover (F) 548 | Feed back pin 2 | 04 | Gear pump 1 274 | Pump casing 702 | O-ring 118 G3 2 | 05 |PTOune 1 312 | Vaive block O-ring 18 G25 2 313 | Valvo plato (R) Oring 18 14s 4 EJ The codes in a rectangle represent adjust screws, Do not tamper with the adjust screws as much as possible. Fig. 24-3 24-524, COMPONENTS SYSTEM (2) Gear pump (For pilot) 700 354 351 Suction port : PF3¢4 Tightening torque : 73.5N.m (64.2 Ibe) 433 ines eee 314 { 312 ~ : 732 307 ae l 850 No. Parts Q'ty || No. Parts: | Qty 307 |Poppet 1 || 364 [Front case [4 308 |seat 1 | | 433 [Flange socket; Max<40 | 2 309 |Ring 4 || 434 /Fiange socket; M855 2 310 |Spring 1 || 435 |Flange socket; MBx20 4 311 |Adjust screw: 1 466 |VP plug ; PF1/4 312 [Lock nut ; M1ax1.5, 1 || 700 [Ring He 354 |Driven gear 4 732 |O-ring ; 1B P16 1 355 | Filter 1 850 |Locking ring _ 24-624, COMPONENTS SYSTEM (3) PTO gear case (For Oceania) 125, rH OA we 126-\\ 826. No. Parts Qty [| No. Parts ary 118 [idle shatt + |] 435 [Fiange socket ; M10%20 4 117 |2nd gear 1 || 468 |vP plug ; Praia 1 118 |3rd gear 1 || 710 |o-ing : 18 G80 4 426 | Ball bearing 2 |] 711 |O-ring : 18 G85 1 126 [Roller bearing 4_|| 728 [o-ring : 48 P24 1 126 [Bearing spacer 2 || 625 [Snap ring 1 262 |Cover 2} | 826 |Snap ring 1 326 |Gear case 1 || 885 !Sprig pin 1 414 |Capscrew : M1020 4_|| 886 |Pin 2 24-724, COMPONENTS SYSTEM 2414.22 a OPERATION ‘The pump assy is equipped with two pumps arranged on the same axis that are connected with ‘gear (116) and distribute the rotating power to the gear trains on a different axis. Thus the engine rotation is transmitted to front shaft (111) that drives the two pumps and, at the same time, drives the auxiliary pump (OPT) arranged on another shaft The pump assy consists largely of the rotary group, the main part of the pump that makes rotary on; the swash plate group that changes the delivery rate; the valve block group that selects between oil suction and delivery ; and the PTO group (OPT) that transmits the drive power to the auxillary pump. Rotary group The rotary group consists of shatt(111), cylinder block (141), piston (151), shoe (182), plate (153), spherical bushing (156), and cylinder epring (157). The shaft is supported by bearings (123) and (124) at its both ends. The shoe, which is caulked to the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure, Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic balance. ‘The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and the spherical bushing, so thet it moves smoothly over the shoe plate. The oylinder block (141) is also pressed against valve plate (813) by the action of cylinder spring (157). PTO GEAR CASE [OCEANIA] AUXILIARY PUMP. (OPT) Fig. 24-4 Construction of hydraulic pump Fig. 24-5 Rotary group 24-824, COMPONENTS SYSTEM (1) Swash plate group The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing (214), titing pin (631), and servo piston (532). The swash plate is the cylindrical part that is formed on the opposite side of the shoe sliding surface and is supported by the swash plate support. The hydraulic force controlled by the regulator flows into the hydraulic chamber thatis provided on both sides of the servo piston. This moves the servo piston to the right and left, The result is that the swash plate swings on the swash plate support via the spherical part of the tilting pin and changes the titing angie (a) 2 Valve biock group The valve biack group consists of vaive block (312), valve plates (313 or 314), and valve plate pin (885). ‘The valve plates having two crescent-shaped ports, are installed to valve block (312) to feed oll and recycle it rom oylinder block (141). The oil switched over by the valve plate 's connected with the external pipe by way of the valve block, (3) PTO group (For Oceania) The PTO group is composed of 1st gear (116), 2nd gear (117) and Srd gear (118). The 2nd and the 3rd gear are supported by bearings (125) end (126) respectively and installed to the valve block Now, ifthe shattis driven by the engine, the cylinder block rotates together by the spline linkage. If the ‘swash plate is inclined, the pistons arranged in the cylinder biock make reciprocating motion with respect to the oylinder while rotating with the cylinder block. Ifwe keep an eye on a single piston, it makes @ motion away from the vaive plate (oil suction process) in the first 180'and a motion toward the valve plate (oil delivery process) in the remaining 180’. If the swash plate is not inclined (ero titing angle), the piston does not stroke i.e delivers no oi The shaft rotation is taken up by the ‘st gear (116) and transmitted to the 2nd gear (117) and the ard gear (118), in that order, to drive the gear pump that is linked to the ard gear. 24-9 Fig. 24-7 Valve block group "7 12624. COMPONENTS SYSTEM 241.1.3 REGULATOR 24.1.1.3.1 CONSTRUCTION 413 o79 ze i 438 q 656 —+ | a AT fo aL Arar QD Os 1 = a 438 My @ [ (924) at 20 722 sis 785 565 681 724 466,788 768 644 646 645 726 VIEWC SECTION B-B rn op 734 es 858 asa 815344. Lei 631 613 ars 888 132 ir AL Ir O 5! ett (OF os ed 622 621 623 ~Y 625 626 887 763 SECTION A-A A stort ara Smergency mace Tightening torque tem No.| Thread size fatteniaatoraue Nm 468 42413 i 29 438,439 | Me | 2 755 eS eee 466 PF 14 % 496__|_ NETRA 88 496 630 | M30x1.5 160 01 we |e 802 M10) 18 SECTION E-E SECTION D-D ig. 24-9 24-1024, COMPONENTS SYSTEM No, Paris ay [Ne Parts Gy [Wo Baris ay 412 [Socket bole: MexSo 2 |[628] Adjusting screw (6) 1 | 732 |Oxing 18 P16 ni 413 | Socket bot 8x70 2 | 629 Cover(c) 1 | 728 Joring 1 418 / Socket bot: MSx12 2 | 630 |Lock nut 00x15 1 | 734 |Oxing ;18 625 1 438 | Socket bot: Mx20 8 | 831 | Steeve (For PF) 1 | 763 [o-ring 18 P9 1 439 | Socket bolt; M6X25 5 _| 641 [Pitot cover 1_| 795 | o-ring :18 P11 z 466 |VP plug PFI/4 3} 42 |Spoo! + | 756 1 496 | Plug :NPTFV18 47 | 643 | Pict piston + | 787 4 541 [Seat 2 | 644 |Soring seat (a) + | 763 |o-ing 18 35 1 543 | Stopper t 2 | 645. Adjusting stem (2) + | 201 nus 1 548 [Ball 2_| 646 |Piot sorng +_| 202 nut :mi0 5 G01 [Casing 7 [681 [Sieawe + [844 [Snap ring 1 611 | Fees back lever + | 652 | spoot 1 | 826 {snap ring 4 612 | Levers) + | 683 | Spring coat + | 858 |Snap ring 2 613 |Lever (2) 1 654 | Return spring, 1 874 | Pin; @4X11.7L 1 614 | Futcrum plug 1_| 655 |set spring +_| 875 |pinsoaxe 2 615 [Adjusting plug 7} 656" [Block cover [676 [Pin ©6xaL Te 621 |Compensating piston | 1 | 662 | Spring + | 887 en 1 622 | Piston case 4 708 | O-ring ; 18 G75 4 B97 | Pin; OSK19L_ 1 625 | Compensating rod + | 722 [o-ring 18 Pe 3 | 298 [in sort ext 1 624 | Spring seat (©) +_| 724 |o-rng 186 8_|[52a]|socketscrew:maxzo | 1 625 | Outer spring 1] 725 o-ring 18 P10 | 1 | 081 |Sub.check vaivo 2 626 | inner spring + | 728 Jorrng 18 P18 + | 079 | sale separesl aicngone| 1 [527] Adjusting stem (C) 1. | 730 [o-ring :18 P22 La | (7 The codes in a rectangle represent adjust screws Do not tamper with the adjust screws as much as possible, 24-1124. COMPONENTS SYSTEM 2411.32 OPERATION (1) Control function Control function ...... Electric flow control Positive flow control “Total horsepower control Emergency mode control. *Hydraulic positive contrat Hydraulic total horsepower control (2) Summary The regulator KR3G-YTOK for the in-line type axial piston pump K3V series is composed of the control ‘mechanism as mentioned below: 1) Electric flow control and positive flow control The titing angle of the pump (delivery rate) is controlled by controlling the current command value of the solenoid proportional reducing vaive attached to the regulator. The regulator makes positive flow control (positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional reducing valve rises. Since this function permits the output power of the pump to be varied, itis possible to attain optimum power according to the operating condition. Also, since the pump delivers only the necessary oil flow, the machine does not consume excessive power. 2} Constant power control at emergency mode ‘When the electromagnetic proportional pressure-reducing valve cannot output the secondary pressure due to the trouble, the spool for emergency mode is switched automatically, and the control is switched from electric control to hydraulic control (emergency mode). In emergency mode, the power shift command pressure PF shifts the power set value. The power shift pressure (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power control section of regulator on each pump through pump inside passage and shifts respective control to the same power set value, In the power shifted condition, as self pump delivery pressure Patt rises, the pump tit angle (delivery rate) is automatically reduced; consequently the input torque is controlled to the constant value or less. (When the speed is constant, the input power is aiso constant.) This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is controlled, the regulator of each pump is controlled to the different tit angle (delivery rate). Consequently in the condition where the power is controlled, the overloading of engine is automatically prevented regardless of the loading of pump 2, And in normal candition, because the power shift pressure is OMPa, the power control is not worked With this mechanism, itis possible to obtain proper power for the working condition, This regulator is made up of the above two kinds of control system, but when both controls are actuated together, the low tit angle (low delivery rate) command precede on mechanical operation described later. (3) Explanation of operation 1) Flow rate electrical control The pump delivery rate is controlled according to the command current value corresponding to the movement of control devices. This relation is shown in right figure. Delivery flow rate Q Command current | Fig. 24-10 24-422, Flow rate increase (See Fig. 24-11) As the command current value | rises, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve rises, and by pressing pilot piston (643) in (A) direction it stops at the position the secondary pressure 2 balances the pilot spring force (646). The ‘movement of plot piston is transferred to lever 2 (613) through pin (875), and rotates at (B) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) androtates at (C)fulerum in the same arrow direction as (8). Consequently the spool (652) connected to feedback lever moves towards (D). When the spool moves towards (D), the port CL cannected to tank port is open and the pressure in servo piston large bore diameter chamber is released, consequently the servo piston (532) moves towards (E) according to delivery pressure Pdt in small bore diameter piston chamber, resulting in the rise of flow rate. Since the feed back lever is connected to the servo piston and spool, the feed back lever rotates at (F) fulorums with the movement of the servo piston towards (E), consequently the spoo! is returned to the original position. With thls movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely. 24-13 24, COMPONENTS SYSTEM pot Gos it argo fines marr of Hydrulis circuit diagram Fig, 24-1124. COMPONENTS SYSTEM , Flow rate decrease (See Fig. 24-12) AAs the command current value | is reduced, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve is reduced, and by pressing pilot piston (643) in (G) direction it stops at the position the pilot spring force (646) balances the secondary pressure P2. The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (H) fulerum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (I) fulcrum inthe same arrow direction as (H). Consequently the spool (652) connected to the feedback lever moves towards (J). When the spool moves towards (J), the delivery pressure Pat is led in servo piston large bore diameter chamber through spool and port GL. The servo piston ‘small bore diameter chamber constantly receives delivery the pressure Pd, consequently the servo piston moves towards (K) according to the difference of area resulting in the reduction of tilt angle, and finally the flow rate is reduced. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (L} fulcrum with the ‘movement of servo piston towards (K), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely, Fig. 24-12 2) Power control (in emergency mode) A ‘When the load pressure rises, the pump tiltangle is reduced preventing the overloading of engine as shown in Fig. 24-13, ‘The operation of powar control is the same as the flow rate contol, and is explained below Delivery flow rate Ll Delivery output (Pd1) Fig. 24-13 24-14a. Overload prevention operation (See Fig, 24-14) Because the dalivery pressure Pd1 acts on the ‘compensating rod stepped section with the rise of self pump delivery pressure Pd the ‘compensating rod (623) is pushed towards (M), and moves to the position the delivery pressure Padi balances the spring force of outer spring (628) and inner spring (626). The movernent of ‘compensating rod is transferred to lever 4 (612) through pin (875), and rotates at (N) fulcrum in arrow direction. Furthermore the lever 1 (612) movement is transferred to feecback lever (611) through pin (897) and rotates at (O) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected with feedback lever moves towards (P). When the spool moves towards (P), the delivery pressure Pd1 is led in servo piston large bore diameter chamber through spool and CL port. Since the delivery pressure Pt is constantly led to servo piston large bore diameter chamber, the servo piston moves towards (Q) according to the difference of area, resulting in the reduction of tit angle, consequently the flow rate is also reduced. Since the feed back lever is connected with servo piston and spool, the feed back lever rotates at (R) fulcrum with the movement of the servo piston towards (), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely. 24-15 24. COMPONENTS SYSTEM Eee wah ‘Gameter chamber of Hydraulic circuit daigram Fig. 24-1424, COMPONENTS SYSTEM b. Flow rate recovery operation (See Fig. 24-15) Because the compensating rod (623) is pushed towards (S) with the force of outer spring (625) Seat wan gs and inner spring (626) with reduction of self cepegerner pump delivery pressure Pd, and moves to the position the spring force of outer spring (625) and inner spring (626) balances the delivery pressure Pd1. The movement of compensating rod is transferred to lever 4 (612) through pin (875), and rotates at (T) fulcrum in arrow direction Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (T) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected to feedback lever moves towards (V). As the spool moves towards (V), CL port is open and connected to tank port, the pressure of servo piston large bore diameter chamber is released and the servo piston (532) moves towards (W) with delivery pressure Pdt in small bore diameter chamber, and consequently the flow rate Is raised. Since the feed back lever is Hycreulic circuit éaigram connected to servo piston and spool, the feed back lever rotates at (X) fulcrum with the movement of the servo piston towards (W), consequently the spool is retumed to the original position, With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely 3) Priority mechanism of low tlt angle (low fiow rate) command As the said expianation, the titing commands of flow rate control and power contro! are transferred to feedback lever (611) and spool (652) through the large bore section of lever 1 (612) and lever 2 (613), but because the pin (dia 5) is extruded in large bore (dia 9), pin (897) on the side where making tit angle smalier contacts with it, consequently the bore (dia 9) of lever on the side where larger tit angle command is given is free without contact with pin (897). In this mechanical selecting manner, the commend on the side of low tit angle of the flow rate control and power control has a priority. Fig. 24-15 24-1624. COMPONENTS SYSTEM 4) Power shift control ‘As shown in Fig, 24-16, the pump set power is controlled according to the movement of control by power shift pressure Pf. As power pressure Pf rises, the compensating rod (623) moves rightward through pin (898) and compensating piston (621). Consequently ike the overloading prevention operation of power ‘control, the pump tilt angle becomes smaller and the power setting value is reduced. Conversely, if the power shift pressure Pf is reduced, the Delivery pressure (Pat) power set value is raised, Fig. 24-16 The power shift pressure Pf of this pump is ordinary set to OMPa, but in emergency mode, the power shift pressure Pfs raised to 4.9MPe. Delivery flow rate Q 24.14.33 ADJUSTING THE REGULATOR The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at emergency mode control) control characteristics, flow control characteristics using the adjust screw, (1) Adjusting the maximum flow (See Fig. 24-3) Adjust the maximum flow by loosening nut (808) and by tightening set sorew (954) (or loosening it). Tightening set screw (954) decreases the delivery rate, as indicated in Fig. 24-17, Only the maximum fiow varies, but other control characteristics remain unchanged, Delivery flow rate Q ‘Adjust screw no. 954 No. of tums for tightening 4 bs Input current | (Pit pressure Pi) Fig, 24-17 Adjusting the max. delivery flow Pilot pressure Pi (Input current |) | No change Min. increase in delivery flow Limin 58 (2) Adjusting the minimum flow (See Fig, 24-3) ‘Adjust the minimurn flow by loosening nut (806) and by tightening socket screw (953) (or loosening @) Tightening socket screw increases the delivery rate, as indicated in Fig, 24-18. Other control characteristics remain unchanged in the same way as maximum flow adjustment, care should be used of the fact that overtightening may increase a required power at the maximum delivery pressure (at relieving action). —$§_ — Input current (Plot pressure Fi) Adjust screw no. BEES eso Fig. 24-18 Adjusting the No. of turns for tightening 14 Dalivery flow rate Q delivery flow Pitot pressure Pi (input current !) | No change Min. increase in delivery flow L/min 46 24-4724. COMPONENTS SYSTEM (3) Adjusting the input horsepower (At emergency mode) Since the regulator is of totel horsepower control type, turn the adjust screws of both the front (No.1) and rear (No.2) pumps when changing horsepower set values. Agjust the horsepower settings of both pumps to a same level. The pressure change values by adjustment are based on two pumps pressurized at the same time, and the values willby halved when only one pump is loaded 1) Adjusting the Outer Spring (See Fig, 24-8) (At emergency mode) Adjust it by Ioosening lock nut (680) and by tightening eojust screw (628) (or loosening it). Tightening the adjust screw shifts the control chart to the right and increases the input horsepower, as indicated in Fig, 24-19, Since turning the adjust screw C (628) by N turns changes the setting of the inner spring (626), return the adjust screw C (627) by NX1.48 turns at first Delivery pressure (Pat) Fig. 24-19 Adjusting the input horsepower (1) Delivery flow rate Q Adjust sorew no. 628 No. of turns for tightening i 4 Increase delivery pressure MPa_| 2.06 Increase in input torque Nom 50 2) Adjusting the Inner Spring (See Fig. 24-9) {At emergency mode) Adjust it by loosening nut (802) and by adjust ° screw (C) (627) (or loosening it). Tightening the g adjust screw increases the flow and then the 7 =H input horsepower, as indicated in Fig. 24-20. And a ene the input torque raises. s Adjust screw no. 627 5 No. of turns for tightening 4 Fae Increase inflow Limin 12 Delivery prossre (Pd) Incroaee pad eee Nh es Fig. 24-20 Adjusting the input horsepower (2) (4) Adjusting the flow control characteristics (See Fig, 24.9) ‘Adjust them by loosening nut (801) and socket bolt ° (824) (oF loosening it). Socket bolt causes the 2 control chart to move to the right as shown in Fig. = 24-24 2 Adjust screw no, 924 3 No. of turns for tightening 14 i Increase Pilot pressure MPa 0.18 Decresss in delvery dow Laan | 18.5 Input current (Pilot pressure Pi - Fig. 24-21 Adjusting the flow control characteristics 24-1824, COMPONENTS SYSTEM 24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR ‘When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter YN33-I!" (1) When the engine is overloaded, Load every unit of pump, and check on pumps on the right and left sides for possible damages. When pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the one side is failed, start checking from para. 3), 1) Check that the power shift command current | is normal 2) The power shift pressure is low. + Check the dither of amp, + Replace solenoid proportional reducing valve. 3) Stick of compensating piston (621) and compensating rod (623) + Disassemble and clean it. 4) Stick of pin (898) + Disassemble and clean it. (2) The max. flow rate is not delivered, 1) Check that pilot ciferential pressure Pi is normal 2) Stick of pliot piston (643) + Disassemble and clean it. 3) Stick of spool! (652) + Disassemble and clean it 4) Stick of pin (898) + Disassemble and clean it Note ; When the damage of part is severe, replace the part with new one. 24-1924, COMPONENTS SYSTEM 24.1.1.4 CONTROL CURVE OF PUMP bead Be TI) 98hW Fi made al avdleg.r optional doring | (2) H mode a open alacant epi revaion 2000 i __|2ocomin':_ | 131 76K 1 mode at ering atachmen — ptpaton Sth a (H modey Inga orque 544 om eoomin'._ hs i | iad (S modey |S Rarace vale WT) “Two pumps are loaded atthe sametime é E150 Sg 2 & & 100 2 50 | ° 3 70 75 20 35 308 ao Delivery pressure Po (MPa) ie | | aysikw a L718ma 000m 2200 | 00m} 200 era + Reference value in (| Pf:Powver shift pressure (Reference value) - aa — un | aaa 981 Delivery flow rate @ { Limin | 3 8 | La icurve 7 BMPa at Ona —~ = jitorque Nem 10 15 40 Delivery pressure Pd [MPa] o 1 z 3 % [MPa] Plotpressure Pi 24-2024. COMPONENTS SYSTEM 244.2 CONTROL VALVE 241.21 SPECIFICATIONS 244.244 OUTSIDE VIEW Prunus m Eee. “a ah tam She fea Fig. 24-22 Outside view 24-2124. COMPONENTS SYSTEM 244.24.2 PORTS “Port size Tightening torque Ports Description PFSI4 150~180 Nem (111~133 IbFett) MU : 7 (13)__Piuges i Ee PPI2 98~120 Nem (72~89 Ib) (3) Pluged (P4) Pluged PFSIB (69-78 Nem (51-56 bh) Paat [arm + (in) pilot port PBat_—_|Arm 4 (out) plot port PAD Boom (up) pilot port PBb Boom (down) pilot port Pac Bucket (digging) pilot port PBc Bucket (dump) pilot port PAL Travel loft (forward) pilot port PBL —_ Travel left (reverse) pilot port Par [Travel right (foward) pilot port PBr | Travel right (reverse) plot port PAs [Swing (right) pilot port PBs |Swing (left) pilot port PAa2 [Arm 2 (in) plot port PBa2 ——_[Arm2 (out! pilot port PAo |Option pilot port PB [Option pilot port Z | a OR Drain port PRIA 34=39 Nem (25-29 Ibfft) Pss [Swing pilot high pressure select port PLe2 Lock valve select pilot port Papt Bypass cut valve (Pt side) pilot port PBp2 —_ [Bypass cut valve (P2 side) pilot port PL JAttachment boost port PBt [Boom (up) confiux pilot port PT ‘Travel straight pilot port Poa Unload valve (P2 side) pilot port Pcb Unload valve (P1 side} pliat port al PCE [Bucket (digging) stroke limiter pilot port Miz 83-110Nem (61-81 lbFft) Pt Pump port (P1 side) P2 Pump port (P2 side) 1 [Tank port 4 12 [Tank port 2 M0 49-65 Nem (36-46 lbFtt) A IRight travel motor port (forward) Br IRight travel motor port (reverse) AL Left travel motor port (forward) BL Left travel motor port (reverse) As ‘Swing motor port (right) Bs [Swing motor port (let) Ab Boom cylinder head side port (up) Bb Boom cylinder rod side port (down) Aa [Arm cylinder head side port (in) Ba |Arm cylinder rod side port (out) Ac ‘Bucket cylinder head side port (digging) Bo Bucket cylinder rod side port (dump) 24-2224. COMPONENTS SYSTEM Port size Tightening torque Paris Description ‘Ao [Optional pilot port Bo, Optional pilot port 244.24.3 SPECIFICATIONS tem if Specifications ‘Model _|kMx150/844001 7 ‘Maximum flow rate (Limin (galimin)] 220 (582 Maximum set pressure [MPa (psi) Main relief vaive set pressure [MPa (psi) When power boost pressure ‘Overioad relief valve set pressure (Boom head, Bucket head, Arm rod) IMPa (psi) Overload relief valve set pressure 7 (Boom rod, Bucket rod, Arm head) (MPa (psi) [37.8 (5480) (Pump port) 39.7 (5760) (Actuator port) ‘Std 34.3 (4970) [at 70x2L/min (18. 5x2galimin)] 97.8 (5480) [at 60x2L/min (15.9x2gallmin)| 39.7 (6760) fat 30L/min (Bgal/min)] 37.8 (5480) [at 30L/min (galimin)] 24-2324, COMPONENTS SYSTEM 241.22 | CONSTRUCTION AND OPERATION 24.42.24 CONSTRUCTION (1) Control vaive Pee, hea} 163 162163 169 155 162 SECTION At 154 464 Pre ea) 162 162 169 155763 162 SECTIONB.B 24-28 Section (1/6) 24-2424, COMPONENTS SYSTEM ¥ H 273x10 | =e 4 Prunes Teal F (revel stent i é ; é o77 1h & fi com sonx 7 tower aioe o 978x2 oY 5 Beam | y [1 swing t 4 T NAB t e I 0 : } 4 i i : fm i t t é 2TBxt 273x10 273x10 Fig. 24-24 Section (2/6) 24-2524. COMPONENTS SYSTEM 201 333 331 336 324 323 331 261 308 ies 162 sit 521 161 183 511 824 551 164 163 161 284 208 551 164 162 163 SeTIONC-C Travel stral Lf Travel straight Boom conflux Pes Travel right 202 333, 331 339 326 326 331 2B: ant bat 551 164 305 551 164 310 SECTION D-D 2 unload Fig. 24-25 Section (3/6) 24-2624, COMPONENTS SYSTEM swing 208 Boom zs is 333 pt | 6 yao i {| 221 301 264 288 int 602, : Pm Feat 204 208: aR 166 Pe ee ‘ SECTIONEE TOSS suet ee ; rr roo ft as my a of i vst 33 4 eee 336 ah 3 321 02 a i eos 3s 31 an 460 54 a 556 or ro 521 eat ie C 551— _ 164- 164 162 161 204 Ls 502 603 C a 205 F d a a SECTION FF ~ 808 Fig, 24-26 Section (4/6) 24-2724, COMPONENTS SYSTEM 201 333, 331 340 328 32t 331 281 208 162 162 162 sit 521 851 164 515 521 651 164 162 161 264 208 Bit 52 551 164 SECTION 6-6 201 333 331 336 324 323 B04 331 261 au ott 521 551 164 604 264 208 16 168 163 162 si 521 i 881 [—~ 164 SECTION Fig. 24-27 Section (5/6) 24-2824. COMPONENTS SYSTEM 606 163 SECTIONS SECTION KA Fig. 24-28 Section (6/6) 24-2924, COMPONENTS SYSTEM eee No. Parts aty eee No. Parts ary 101 [Casing A 1 324 [Spring 5 102 |Casing 8 1 322 |Spring 4 220-250 162-184) | 154 |Plug PESIA 3 323 |Spring 3 110-190,01-06) | 185 [Plug PFA/2 2 324 |Soring 3 20-24 (15-18) _| 159 [Plug PTA MEC (Pre-cost bot) | 1 325 |Spring 1 78-0.868-72) | 160 |rugPTino mec Precom oon) | 5 326 [Spring 1 161 |O-ring 7 327 |Spring 3 162 [O-ring 15 328 |Spring 1 163 |O-ting 1" 329 [Spring 3 164 [O-ring 19 331 |Spring seat 24 169 [o-ring Fence. | 333 [Spacer bot 12 201 |cover 5 336 |Stopper 10 202 |Cover 4 339 |Stopper 1 208 |Cover 1 340 [Stopper 1 204 |Sub cover 1 511 [Poppet " 205 |Cover 7 512 [Poppet 2 206 |Cover 1 514 |Poppet 2 207 |Back pressure check awe cover | 1 515 |Poppet 1 209 |Cover 1 517 |Poppet 1 9.9-14 (72-103) | 214 [Lock valve selector sub 2 518 |Poppet 1 242 |Piate 1 524 [Spring " 213 [Plate 1 522 |Spring 2 216 [Piston 1 523 |Spring 1 261 |O-1ing 2 524 |Spring 2 264 {O-ring 40 527 |Spring 1 266 [O-ring 4 528 |Spring 1 25-24 (18-25) | 273 |Sockst bolt 40 || 250-250 170-192) | 554 [Plug 13 98-120(72-€8) | 274 |Socket bolt 4 || 130-150 (86-110) | $52 [Plug 2 se~120(72-€8) | 275 |Socket bolt 4 || 230-260 (170-192) | 686 [Plug 3 25-04 (18-25) _| 278 [Socket bolt 5 562 [O-ring 2 301 [Boom spoo! sub 1 |] es-7ecsi-s6) | 601 |Main relief valve 1 302 /Arm 1 spool 1 || es-7acsi-se) | 602 |Port relief vaive 2 303 |Swing spool 1 |] c0-78(61-50) | 603 |Port relief valve a 304 [Bucket spool 1 |} 69-76151-58) | 604 |Relisf vane plug assy | 2 305 |Boom confiux spool 1_||__69-76181-58) | 605 JOverload reliet valve | 1 306 | Travel spool 2 || 98-120 72-89) | 606 [Bypass cut valve 2 307 |Travet straight epoo! 1. || 140-180 103-138) 973 |Socket bolt e 308 Arm 2 spool sub 1. | | 140-180(108-138)| 974 |Socket bolt 2 309 |P1 unload spool 1 977 |Name plate 1 310 |P2 unload spool 1 978 |Rivet 2 311 [Option spot 1 24-3024. COMPONENTS SYSTEM (2) Main relief valve (Two step relief) (601) 523 a5 \ ey set Lhe 121108 4 104 f 664 a1 Fig. 24-29 Main roliof valve (Two stop relief) anarteried No. Parts ay Maen No. Parts aty 69-78 (51-58) | 103 |Plug; M27 1 62 [Back up ring 1 104 |Adjust screw 1 611 [Poppet 1 121 |C-ing 1 613 [Stopper 1 122 |Spacer 1 614 |Piston 1 128 |C-ring 1 621 [Spring 4 424 [Filter stopper 7 652 [Adjust screw 1 125 [Fitter 1 664 [O-ring 1 183 |O-ring 1 663 [O-ring 1 512 [Plunger 1 64 [o-ring 1 521 |Spring +] 28-91 (21~23)_ | 674 |Lock mut; M14 1 "| 841 [Seat a + || 46-62 (94-38) | 673 [Lock nut: Maa 1 561 [O-ring 1 1 24-3124, COMPONENTS SYSTEM (3) Over load relief valve (602,603,605) rer '7 541 soy yee 102 88t 67t Fig. 24-30 Over load relief valve Tightening Tightening torque No. Parts Qty torque | No. Parts ty Nem (loft) Nem (lott) 69-78 (51~58) | 101 |Body ; M27 1 ‘B41 Seat 1 69-78 (51~58) | 102 |Plug : M27 1 561 |Oxring 1 161 O-ring 1 582 | Backup ring 1 162 |O-ring 1 563 |O-ring 1 128 |C-ting 1 564 [Backup ring 4 124 [Fitter stopper 1 ‘611 [Poppet 1 125 {Filter 1 612 |Spring seat 1 301 Piston 1 621 | Spring i 511 [Plunger 1 651 |Adjust screw if 521 |Soring 1 661 |O-ting 1 522 [Spring 1 [| 28-34 (21-23) | 671 [Lock nut ; mia 1 24-3224. COMPONENTS SYSTEM (4) Arm 2 spool (308) 308 317 340 364 371 350 351 371.961940 319 Fig. 24-31 Arm 2 spool Thien Torque | No rans aty||— Tateningtoase dg | pans fay Nem (Iipfeft) 308 |Spoot 1 ||16~18 (33-38) Loctite #638 | 350 |Piug 1 217 [Pings 1 | pe-t8 2-35) oct 828 | 35 |g i 319 |Plunger 1 361 O-ring 2 240 | Sing 2 37 Buckupring | 2 (6) Boom spool (301) Spe 301 317 340 361 371 350 Fig. 24-32 Boom spoot Tight eee rn Tightening torque * torque | No. Parts ay NOR No. Parts ay Nem (bff) uated 301 [Spoot 1 [/16-16 (12-13) Lootte #638 | 350 [Plug 7 317 [Plunger 1 364 fo-ring 1 340 {Spring 1 374 |Buckup ring 1 24-3324. COMPONENTS SYSTEM (6) Lock valve selector (211) 101 164 201 324 166 541 167 511 161 Fig. 24-33 Lock valve selector ory Thon torque | No Parts oy Tohening oe Pars Nem (ibfett) | 7 10% [Sasa 7 tenia actos] 7H [Socks ba 161 [O-ring 4 || 49-69 (86-44) | 201 Plug 164 |O-ring 1 321 |Spring 166 |O-ring ti 511 |Spool 167 [owing || 541 [Stove 24-3424, COMPONENTS SYSTEM (7) Bypass cut valve (606) 402 491 PR ma freee IP Pi ee tr ON zs 201 202 102 101 Fig, 24-34 Bypass cut valve Tightening torque Tightening torque. T “nem tort) | NO Parts Oy em cnn) | S| Parts aty 98~120 (72~89) | 101 [Piug 1 201 |Plunger 1 102 |O-ring 1 302 |Spring 1 201 |Poppet 1 || 69-78 (61~58) | 401 Plug 1 202 [Spring 1 402 [O-ring 1 24-3524. COMPONENTS SYSTEM (8) Swing shuttle valve cover (204) Fig. 24-35 Swing shuttle vaive cover paren Tightening torque torque | No. Parts Oty nem cota) | NO Parts any Nem (ibfft) 166 |O-ing 1 542 |Seat 1 202 [Cover 1 || 25-29 (18-21) | 554 |Piug 1 541 |Stee! ball 1_|[7.9-9.8 (6.9-7.2)| 555 [Plug 1 24-3624, COMPONENTS SYSTEM (9) Boost check valve (547) te 7a T{ J) “it _—— 107 | 102 Uk ~101 Fig. 24-36 Boost check valve Tightening ] ] wore | ne.| rans feay]}— Pamenngtorve |x bars | ay Nem (ft)| | (ior) 101 [Poppet 1 | [20-29 (15~21) Loctite #262 | 104 [Plug 1 ___| 102 |Poppet 4 107 [Spring 1 24-3724. COMPONENTS SYSTEM 241.222 HYDRAULIC CIRCUIT DIAGRAM ras Travel straight _! Travel left Boom confiux: P2 unload Fig. 24-37 Hydraulic circuit diagram 24-3824, COMPONENTS SYSTEM 244.223 OPERATION (1) In neutral position The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading valve P1 (309), low pressure circuit (D) and boost check vaive (517), and retums to the hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to fallure of electric control system, because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the hy¢raulic ol through hydraulic pump P1 port passes through travel straight spoo! (306), anc! then flows though the center by-pass passage (52} which passes through travel right, boom, bucket and arm 2 and the by-pass cut valve (608) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1 The hydraulic ail delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic oil from hydraulle pump P1. And when the operation of unloading valve is impossible, because the by-pass cut valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic ol through hydraulic pump P2 port passes through main passage, end then flows though the center by-pass passage (56) which asses through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into low pressure circuit (D) and boost check vaive (517), and then returns to the hydraulic tank through tank port 74 pressure eveut of Pa side oxsng Fig, 24-38 In neutral position 24-3924, COMPONENTS SYSTEM (2) Actuation in travel operation 1) In travel independent operation On starting travel operation (forward) started, the hydraulic oll delivered by hydraulic pump P1 is fed into travel right motor, and the hydraulic oll delivered by hydraulic pump P2 is fed into travel left motor. The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of springs (323)(324) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports PCb and PCa and switches unioading spools (309) (310). The hydraulic ol delivered by hydraulic pump Pt passes through travel straight spool (307) and flows inlo main circuit, and flows through between the perimeter of right travel spoo! (206) and casing and is fed into ‘A side of right travel motor through port Ar. The hydrautic oil delivered by hydraulic pump P2 flows through between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through port Ar similarly to the stream of hydraulic oil delivered by hydraulic pump 1 But in the meantime, the retum oil from the B sides of left and right travel operations passes through between the perimeter of right and left travel spools (308) and casing through ports Br and BL and flows into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1.. On traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the actuation is similar to that in forward travel operation. Left travel motor A B AL “MT \ | \ | \ Dele Fig. 24-39 in left reverse travel (at PBL is pressurized) 24-4024. COMPONENTS SYSTEM 2)_ In travel straight operation When actuator other than travel operation and the travel operation are operated simultaneously in the said item 1) "in travel independent operation” the pilot signal from the outside acts on port PTb and the travel straight spool (307) moves upward. With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used for each actuator, and the hydraulic oll delivered by hydraulic pump P2 mainly flows from P2 to B and into main passage, and is used for right and loft travel operations as hydraulic oil realizing the actuator and travel simultaneous operation. (Travel straight function) At circuit (I) position, a part of hydraulic oll delivered by hydraulic oll Pt passes through circular notch on travef straight spool (307) and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch on travel straight spoot (307) closes and the pump line on the travel sides is independent from pump line on actuator. PATA |= ‘1 For 8] LB roescn attr To travel right To travel right - creuit t) iru Fig. 24-40 Movement of travel straight spool 24-4424, COMPONENTS SYSTEM (3) Actuation in bucket operation 1) In bucket digging operation ‘On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load ‘heck valve LCc (511), and flows through between the perimeter of bucket spoo! (304) and casing through U-shaped passage, and supplied to buckel cylinder head side (H) through port (Ac). lin the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of bucket spool (304) and casing, flows through low pressure circull (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1 ‘And when the flow rate of hydraulic oll delivered by hydraulic pump P1 with engine running in low idling is low, the pilot signal from the outside enters port PCe and piston (216) moves rightward. With this actuation, the maximum leftward stroke of bucket spool (304) is limited, consequently the area of passage belween the perimeter of bucket spool (204) and casing minimizes. Consequently the flow rate of return oll from bucket cylinder rod side (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may bbe ocourred on bucket cylinder head side (H). (Stroke limiter ON) 216 l ® wn Fig. 24-41 In bucket digging operation (Stroke limiter ON) 24-4224, COMPONENTS SYSTEM 2) In Bucket dumping operation On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves rightward the force of springs (321)(322). and simultaneously the secondaty pressure of solenoid proportional valve [Xi] acts on port PCb and switches unloading spool (308). The hydraulic oll delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (671), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder rod side (R) through port (Bc). Inthe meantime, the return cil from bucket oylinder head side (H) passes through between the perimeter of bucket spool (304) and casing and flows through law pressure circuit (D), and retums to the hydraulic tank through tank port 74, The return oil does not pass through boost check valve (517). Downstream of boost check valve AR) “ Fig, 24-42 In bucket dumping operation 24-4324, COMPONENTS SYSTEM (4) Boom 4) in boom up operation On starting boom up operation, the pilot pressure enters port PAb and boom spoo! (301) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCa and switches unloading spoo! (309). And the pilot pressure enters port PB1 and boom conflux spool (308) is switched against the force of springs (825) (326) and the secondary pressure of solenoid proportional valve [X2} acts on port PCa and switches unloading spools (310). ‘The hydraulic oll delivered by hydraulic pump P1 flows into paralle! passage (53), pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spoo! (301) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab) In the meantime, the return cil from boom cylinder rod side (R) passes through between the perimeter of ‘boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port Tt Fig, 24-43 In boom up operation (Boom spool) 24-4424. COMPONENTS SYSTEM 2) In boom up conflux operation The hydraulic ol delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage (66), and pushes and opens load check valve CP2, and flows through between the perimeter of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic oil from the hydraulic pump P1 side. 326 925 sit See Conflux passage To Ab port of P1 casing Fig. 24-44 In boom up conflux operation (Boom conflux spool) 24-4524. COMPONENTS SYSTEM 3) In boom down operation (On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward against the force of springs (321) (322) and the secondary pressure of solenoid proportional valve [X‘] acts ‘on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is switched, and the poppet (514) is released because the spring chamber of lock vaive poppet CRb (514) is connected to the drain circuit The hydraulic oil delivered by hydraulic pump 1 flows into paralis! passage (53), and pushes and opens load check vaive LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb). In the meantime, the return oil from boom oylinder head side (H) enters the control valve through port (Ab). Because the retention of lock vaive poppet CRb (514) which is located on this side of boom spool (301) is released, the lock valve poppet (514) pushes and opens. And then the retum oll enters BH chamber and passes through between the perimeter of boom spool (304) and casing, and flows through low pressure circuit (D) and boost check valve (517), and the retums to the hydraulic tank through tank port T1. And a part of the retum cil flows into the inside of boom spoo! (301) through circular notch of boom spool (301). Since the return oilcontains sufficient pressure with the self weight of boom, arm, etc. the return oll passes through inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function) fs) ®) = : di (oy Fig. 24-45 In boom down operation 24-4624. COMPONENTS SYSTEM (5) Arm operation 1) In arm out operation (On siarling erm out operation, the pilot pressure enters ports PBat and PBa2, and arm 1 spool (302) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unioading spool (310). And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (321) (628) and the secondary pressure of solenoié proportional valve [Xt] acts on port PCb and switches unloading spools (208). The hydraulic oil delivered by hydraulic pump P2 flows into perallel passage (56). pushes and opens load check valve Ca (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. Inthe meantime, the hydraulic oll delivered by hydraulic pump P1 flows through center by-pass passage (52) ‘and pushes and opens load check valve LCAT2 (611) and enters U-shaped passage, and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the hydraulic oil lows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber through casing inside passage (RR) and confiuences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic olf opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R_) In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm 1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage (HH) and then flows into low pressure circuit (D’} through between the perimeter of arm 2 spoo! (308) and casing The retum oil in low pressure circuit (O') returns to hydraulic tank through tank port T1 without passing through boost check valve (517). i aR ® a 302 sense chamber gf VV ag Vt \\ \ LOAT2, Loape Ba BPea2 se oF p— Tear 1 spool a (HEAD) ea (Rob) To pilot cu vaive 308511 LcaT2LCAP2 Fig. 24-46 In arm out operation 24-4724. COMPONENTS SYSTEM 2) In-arm in operation (At light load: arm recirculation function) On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves leftward against the force of springs (221) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310), At the same time, since the ‘poo! of lock vaive selector (241) is switched, the spring chamber of lock valve poppet CRar (514) is connected to the drain circuit and the retention of poppet (514) is released ‘And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves leftward against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (308). But in light load operation, because the solenoid proportional valve [XR] actuates and arm 2 spoo! (308) stays in the position of circuit (I) The hydraulic oll delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LGa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. in the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load chack vaive LCAT2 (511) and enters U- shaped passage, and also the oll from parallel passage (53) pushes and opens load check valve LCAP2 (618) provided with orifice and flows into U-shaped passage. And then the hydraulic oil lows through ‘between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic ol from hydraulic pump P2 side. ‘The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa). In the meantime, the return oil from arm oylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the retum oil pushes and opens lack valve poppet CRar (514) and enters AR chamber. The retum ollin AR chamber is led to arm 2 spool (308) through arm 1 spoo! (302) and casing inside passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D} at circuit (I), the entire flow rate flows Into arm 1 spool (302). The return oil from chamber AR passes through the perimeter of arm 1 spool (802) and casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spoo! (308) through circular natch (a) of arm 2 spool (308). In ight load operation, since the return oil contains higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spoo! (308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head side (H) again. (Arm recirculation function) ‘And a part of the return cil which was led to arm 2 spool (308) passes thraugh cheok valve (31), and flows. through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank through tank port 71 aR 322 321 chamber 5 (0° 1B) pecare ores tse Fealce aig Tne HEAD) “To itt ct vade si) 321 308gr9(0)5f1 LeaT2 UcAPZ Fig. 24-47 In arm in operation (At light load: arm recirculation function) 24-4824, COMPONENTS SYSTEM 3) In arm in operation (In heavy load operation) The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in heavy load operation (work required large power); the function causes the power loss. This control vaive selects the presence of recirculation function in light and heavy load operation with solenoid proportional valve [XR]. (Variable recirculation function) The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinders the same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional valve [XR] actuates and arm 2 spool (308) Is positioned to eircult (I), The return oil rom arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) Which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens look valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through ‘arm 1 sp00! (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure passage (0) at circuit (AU), almost all the return oil passes through between the perimeter of arm 2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and retums to the hydraulic tank through tank port T1 The retur oil from AR chamber passes through between the perimeter of atm 1 spool (302) and casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular ‘notch (a) of arm 2 spool (308). In heavy toad operation, since the pressure on arm cylinder head side (H) is higher than the rod side, the hydraulic ol in arm 2 spool (308) does not flow into casing inside passage (HH), but flows through cheok valve (319) and passes through boost check valve (517) through low pressure (D) and retums to the hydraulic tank through port T1 ADL eH) 392 AR 322.321 chamber 514) t / LCAT2 , LCAP2 bs Penk chica ty : L To ain 4 spoal Epa Head} (ROD) To pilot cut valve Circuit () Fig, 24-48 In arm in operation (In heavy load operation) 24-4924. COMPONENTS SYSTEM (8) Swing operation On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or rightward against the force of springs (321) (922), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Ps. The hydraulic oil deivered by hydraulic pump P2 tlows into parallel passage (56), pushes and opens load check valve LCs (611) and flows through between the perimeter of swing spool (303) and casing through U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs). In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing ‘spool (303) and casing through port (Bs) or (As) and flows through tow pressure circuit (D) and boost check valve (517), and then retums to the hydraulic tank through tank port Tt Swing motor Fig, 24-49 Swing operation 24-5025. AIR-CONDITIONER SYSTEM TABLE OF CONTENTS 25.1. BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER), 25-3 25.4.1 AIRCYCLE . aa 7 25-3 25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE Se ce 254 25.2 COMPONENT AND CONSTRUCTION 2565 25.2.1 COMPONENT 2565 25.2.2 CONSTRUCTION 7 alate 25-6 25.3 PIPING. ose senate 25-9 25.3.1 AIR CONDITIONER. paaaatiaa eer 2D 25.3.2 AIR DRYER ASSY...0. : ecaneeeeecoe! 25-411 254 FUNCTION 25-12 25.4.1 MECHANISM OF COOLING CIRCUIT, i Se 2512 28.4.2 COOLING CIRCUIT 25-14 28.4.3 COMPONENT PARTS die 25-15 28.5 DISASSEMBLY AND ASSEMBLY. 7 en 2-19 25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .. 26-19 25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT, svn 25-20 28.6 CHARGING REFRIGERANT 26-26 28.8.1 PRECAUTIONS TO BE EXERCISED IN OPERATION 25-24 28.6.2 OPERATING PROCEDURE, es 25-25 25.6.3 CHARGING PROCEDURE 7 penne 25-26 25.7 ELECTRIC CIRCUIT. a seein 25°82, 25.7.1 WIRING DIAGRAM AND CONNECTORS 7 25-32 25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS BND THE INSPECTION... 26-34 26.8 TROUBLESHOOTING. a 7 i 25-37 25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL rennnetnecerne BM 28.9.1 POSITION OF INDICATION FOR FAILURE. 2... 25-44 25.9.2 EXPLANATION OF INDICATION FOR FAILURE. ....... : 25-44 25.9.3 EXPLANATION OF MONITOR MODE: 7 25-48 Book Code No, S5YN2518E01 25-125, AIR-CONDITIONER SYSTEM Issue Date of Issue Applicable Machines First edition August, 2006 SK200-8 : YN11-45001~ SK210LC-8 : YQ11-08001- ‘SSYN2518E01 (ASIA, OCE) 25-225. AIR-CONDITIONER SYSTEM 25.1. BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) ‘Ai-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside / ouiside air switching unit. And this unit changes het air to cool air. 25.1.1 AIRCYCLE + Heater Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with hat air (heating) at the heater core of air-con unit, and then the heated air blows off fram grille through duct. + Cooler Inside airor outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with cold air (dehumidifying and cooling) at the evaporator of ai-con unit, and then the cooled air blows off from grille through duct, + Heater system The heater recycles (circulates) the cooling water in the engine, and the het water delivered by the engine flows In the heater core of air-con unit and then heat exchange is performed. The intake air is heated and the heated air blows off from the grille provided on the inside of cab. The blow off air temperature is controlled by the temperature control switch on the control panel, and the operation is controlled by air mixing damper on the air-con unit. 25-325. AIR-CONDITIONER SYSTEM 25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE AIR CONDITIONER CONTROL PANEL §}| 280%_]] oS 2 | SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOUR ‘COMPRESSOR @Q——+ AIR OUTLET SWITCHING SIGNAL] CONTROLLER AIR MIXED DAMPER SIGNAL AIR-CON BLOWER REVOLUTION SIGNAL REFRIGERANT PRESSURE SWITCH Gs ven ee ~ —--] INNER AIR, INoroR 7 I ACTUATOR) I woot | feta 25-425. AIR-CONDITIONER SYSTEM 25.2 COMPONENT AND CONSTRUCTION 25.21 COMPONENT Fig. 25-1 Air-conditioner group AIC ASSY YN20M00104F1 No. Parts Q'ty | |_No. Parts Qty No. Parts Qty 27 |Air-conditioner assy 4 32 |Compressar 1 35-6 |D hose 1 27-1 | Air-conditioner unit 4 33 | Pulley 4 35-7 |L hose 1 27-2| Hose fa 34 |Condenser 4 35-8 |L hose: @ 15.5 1 2T-3|clamp 2 || 35 |Airdryer assy 1 |] 35-9 /S tube 0 16 1 21-5|Filter 1__| [35-1 Receiver dryer 1 | [38-10|Ltube : @ 8.5 1 27-6) Tube assy 1 35-2 | Bracket 1 39 | Filter 4 30 |Panel assy 1 35-5}S hose : @ 24.5 1 40 |Solar radiation sensor] 1 25-525. AIR-CONDITIONER SYSTEM 25.2.2 CONSTRUCTION (1) Air conditioner unit Fig. 25-2 Air conditioner unit (1/2) 25-625, AIR-CONDITIONER SYSTEM Fig, 25-3 Air conditioner unit (2/2) 25-725. AIR-CONDITIONER SYSTEM No, Parts aty|] No. Parts ay] No Parts ay 7 |Sorew NB o a UPORATOR ASS which is used to secure the heater core and then we we "eS @Blower motor remove the heater core from the lower unit Ben WS { 1 OSX \ & asin 1 EN \ & 7 LAA, Gr Se 3) Install it by the reverse procedure of removal. aN ee : (7) Replacing blower motor 1) Disconnect connector which is connected to the : : blower motor and remove the blower motor from Wigs - AE the lower unit casing f * Do not remove the fan from the blower moter. LOWER UNIT CASING > 2) Install it by the reverse procedure of removal Fig. 25-19 (8) Replacing evaporator and expansion valve 1) Take the evaporator with expansion valve off from the lower casing 2) Remove evaporator sensor with sensor holder from the removed evaporator. 3) Insert the sensor holder into the new evaporator at the position shown in Fig. 25-20 and install the evaporator sensor again. EVAPORATOR 11TH ROWS OF FIN 4 EVAPORATION SENSOR Fig, 25-20 25-2125. AIR-CONDITIONER SYSTEM 4) Remove 2 socket bolts MSx40 with Allen wrench (4mm) and remove the expansion valve from the evaporator, 5) Fil O-ring (NF O-ring 5/8 and 1/2 one each) to new evaporator. * When assembiing again, fit O-ring paying attention so as not to be caught with others. (Socket bolt M5x40 (2 pes.) Tightening torque 6.9Nem (5.1Ibfeft) * Donot apply undue force to pipe of evaporator outlet, This undue stress causes the leak of refrigerant from "A" part of evaporator, ‘Moreover, when tube assembly (27-6) (see Fig. 28-1) connected with expansion valve is disconnected from expansion valve, similar careful work is necessary. (8) Replacing motor actuator 1) Replacing mode actuator 2) Remove connector connected to the motor actuator. b) Remove FACE rod and VENT rod which is used to connect MA mode lever and mode cam from the holder. ©) Remove 3 plus screws and remove the motor actuator with lever MA mode from the unit d) Remove the lever MA mode from the removed motor actuator, and install iton new motor actuator by the reverse procedure of removal. 2) Replacing air mixing actuator a) Remove connector connested to the motor actuator, b) Remove rod air MIX which is used to connect the motor actuator and the lever MA air MIX. ©) Remove 3 plus screws and remove the motor actuator with MA lever air MIX from the unit d) Remove the MA lever air MIX from the removed motor actuator, and install iton new motor actuator by the reverse procedure of removal, 25-22 EVAPORATOR i EXPANSION VALVE SOCKET BOLT MBx40(2 PCS. —lf Fig. 25-21 Sue VENT ROD Og FACE ROD MA MODE, | LEVER 3 pus scREW.¢ | pos MODE Fig, 25-22 AIR MIXROD \ MA AIR MIX LEVER CONNECTOR pide Gone ‘AIR MIX ACTUATOR Fig. 25-2325. AIR-CONDITIONER SYSTEM 3) Replacing inner and outer air switching actuator MA INTAKE LEVER a) Disconnect connector conn led to the * ea motor actuator. Jalr-tightness }9as leak refrigerant Lower than’ -750mmHg [Gauge indicates [abnormality [Charge refrigerant gas to a gauge [Check and correct joints }<—— pressure of 0.1MPa (14 psi) (9) Tools No.| Paris | Q'y| Service ||No.| Parts [Q'ty] Sketch Service | 4 Jouickiont | + | on sfRSD¥ER [tow Presse 4 [Gauge : | side manifold : abe i For service can i valve Pere Res Hee — high pressure side r ue Service can 2 [Crarsing | 5 | ¢ I 6 poomeocan | 5 For service can hose tow prossure side valve Yetow f vacuum pump sido H é Vacuum High pressure For side pump ladapter 25-2525. AIR-CONDITIONER SYSTEM 25.6.3 CHARGING PROCEDURE 25.6.3.1 VACUUM MAKING OPERATION (1) Connecting gauge manifold (See Fig. 25-25) 1) Close the high pressure vaive (Hi) and the tow pressure valve (LO) of the gauge manifold. 2) Connect the charging hoses (red and blue) with the service valves of the compressor. Red hos High pressure side (HI) of the gauge manifoid—shigh pressure side (DIS) of compressor Blue hose Low pressure side (LO) of gauge manifold-siow pressure side (SUC) of compressor AcAuTION + Do not mistake the high pressure hose for the low pressure hose in any circumstances when connecting them. Put the hose in firmly tila clicking sound is heard 3) Connect the center valve of the gauge manifold with the charging hose of the vacuum pump, |AxCAUTION Some kinds of gauge manifolds are not equipped with an openiclose valve in the center. 25-26 {oLosepLow HIGH PRESSURE RESSURE VALVE VALVE(CLOSED) RED BLUE: YELLOW ‘COMPRESSOR vacuum PUMP(STOP) Fig. 25-25 CHARGING HOSE (GAS VALVE) Fig, 25-26 Connecting gauge manifold25. AIR-CONDITIONER SYSTEM (2) Vacuum making (See Fig. 25-27) 1) Open the high pressure valve (HI) and the low pressure valve (LO) of the gauge manifold. 2) Turn on the switch of the vacuuurn pump and make vacuum for more than 30 minutes. 3)When vacuum making for a specified duration is over (degree of vacuum : less than - 750 mmHg), close the high pressure valve and the low pressure valve of the gauge manifold. 4) Then turn off the vacuum pump. Airtightness Check Close the high pressure valve and the low pressure valve of the gauge manifold, leave itas itis for more than five minutes and make sure that the gauge indication does not return toward 0. 6 |ACAUTION If the gauge indication swings toward 0, there is somewhere that is leaking. Retighten pipe joints, make vacuum again and make sure of no leakage. 25-27 (CLOSE) r cose HIGH PRESSURE VALVE(OPEN). GAUGE MANIFOLD Fig, 25-27 Vacuum making operation25. AIR-CONDITIONER SYSTEM 28.6.3.2 GAS CHARGING OPERATION (1) Charging from high pressure side (See Fig. 25-28.) 1) After making vacuum repeatedly, change the charging hose (yellow) of the gauge manifold from the vacuum pump to the service can. 2) Air purge Open the service can vaive. (However, close the high and fow pressure valves of the gauge manifold.) Then push the gas vaive of the side service port on the low pressure side of the ‘gauge manifold, using a screw driver, in order to let out the air in the charging hose by the pressure of the reftigerant, (See Fig. 25-28.) (The operation ends when a hissing sound is heard.) 3) Open the high pressure valve of the geuge ‘manifold and charge in refrigerant. [Charge in gaseous refrigerant to a gauge pressure of O.AMPa (14psi).} After charging, close the high pressure valve of the gauge manifold and the service and valve. (See Fig, 25-29.) LAAWARNING| Do not run the compressor during this work, (Otherwise the refrigerant flow in reverse direction which causes the service can and the hoses to rupture. This is very dangerous.) (2) Checking for gas leak Check for gas leak in the cycle, using @ gas leak detector (electric type). Retighten and correct, leaking points, [ACAUTION) Always use the leak tester for R134a. (Do not use ‘one for flon gas service as it provides poor sensitivity.) 25-28 — ‘CLOSE open senvice Krewow, Sava LOW PRESSURE: VALVE(CLOSE} HIGH PRESSURE VALVE, (OPEN) —» (CLOSE) RED FILL IN 1~1.5 CANS OF REFRIGERANT (OPEN) —> (CLOSE) CHARGE, S Fig, 25-29 Gas charging operation (High pressure side)(3) Charging from low pressure side (See Fig. 25-30) 41) Make sure that the high-pressure and low- pressure valves of the gauge manifold and the service can valve are closed. 2) Start the engine and run the revolution to 1500:100pm and fully close the cab door and the windows. 3) Turn on the air-conditioner switch, set the fan snitch to Max and the temperature control switch to cool Max. 4) When charging gas, set the discharge pressure of the compressor to 1.41.6 MPa (200~230psi) 5) Open the low pressure valve of the gauge manifold and the service can valve and fill in refrigerant ti air bubbles of the sight glass of the receiver go away. (See Fig. 25-30) {Total amount of gas to be charged 900g2509 (2,020.11 Ibs)] 6) When refrigerant charge is over, close the low pressure valve of the gauge manifold and the service can valve. |A\WARNING| + Do not open the high pressure vaive of the gauge manifold in any circumstances. + Never place the service can upside down. (The compressor valve may be scored because the refrigerant is sucked in a liquid state.) 25-29 25. AIR-CONDITIONER SYSTEM LOW PRESSURE, HIGH PRESSURE VALVE VaLVE(CLOSE) OPEN ——> close Rep (CLOSE SECURELY) BUBBLES I THe SGuTciass BIsABPea yeLLow os BLUE SERVICE CAN g VALVE(OPEN) COMPRESSOR VICE CAN OPERATION SSRN (00 NOT TURN iT OVER) Fig, 25-30 Gas charging operation (Low pressure side) SIGHT GLASS N, ‘RECEIVER DRYER Fig. 25-31 Receiver dryer25. AIR-CONDITIONER SYSTEM (4) Criterion for checking the amount of refrigerant filed in © JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER After AIC is turned on, only a fitle PROPER LEVEL bubbles are seen and thereatfer light milky white is seen. After A/C is turned on, OVERCHARGE no air bubbles are seen. Aller AIG is turned 0, continuous UNDERCHARGE air bubbles are sen. [AAWARNING] + Ifthe air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor, + If the refrigerant is charged too much (overcharged), the cooling performance is deteriorated. Moreover, the circuit pressure gets abnormally high : Always keep a proper level, (5) Removing Gauge Manifold When the refrigerant level has been checked, disconnect the charging hoses from the ‘compressor in the following manner 1. Press the "L" shape metal fitting of the charging hose (blue) on the low pressure side against the service valve of the compressor so the refrigerant does not leak out and joosen the nut ‘As soon as the nut has been removes, disconnect the charging hose from the service valve. 2. Leave the high pressure side as Its tll the high pressure gauge reading falls. [below 1MPa (140psi)) 3. Disconnect the charge hose (red) on the high pressure side the same way as on the low pressure side 25-3025. AIR-CONDITIONER SYSTEM This page is blank for editing convenience. 25-3125, AIR-CONDITIONER SYSTEM. 25.7. ELECTRIC CIRCUIT 25. WIRING DIAGRAM AND CONNECTORS D Hone zo sic & Mang: nagsuesicr TORRANCE © Fang eeuess ) MAKER -YAZAK! CORD. DENNER EES. NeRON AME Ke onset 700085 PRESSURE SWMTCH (RECEIVER DRYER) MaKe : SUMITOMO, HOUSING Nov 6'85 a004 aver vazaKtcORP 3) RamaesS Sear iabae Heoaoig FERMI, TBOGOTIC ots HEE N SES aa0 FUSE208 LIGHT SWITCH nn cm com hier Rvezancone | 1 oan roe | TERMINAL 71 FERUNAL feet : MARKEY SW 2. JON) Snore FUSE T58 Maken: vazaut cone, MUSING Nous y-28 a0 TERMINAL SH MAKGR -vazant comp BUS Ne ER ze © TeeMa et ‘compressor IPPON AME Kx 174086-2 AToRMNAD 7802-1 RNIN REE ‘TERMINALS ASSSE 5000 | >) TERME RES. sono wae azar cone. y RESSRG NST 8 5e0 TERNAL 74st NOTE) 1-THe douse cain ne inca me wing Shine excavator ade 2 The connact: car cate the cord color seen from he connesing pa [MAGHINE SIDE WARING (PARTS) <—43 PIWTET RY POC Fig. 25-32 Electric diagram (1/2) 25-3225. AIR-CONDITIONER SYSTEM (CCU (OPERATION PANEL + CONTROLLER) ‘eoror acruaTER (ReCeRESH INTHE CAB i CONTIONER SE ‘Hn PARTS) Fig, 25-33 Electric diagram (2/2) 25-3325. AIR-CONDITIONER SYSTEM 28.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION (1) Control panel and control unit The control unitis integrated into control panel, and processes the signal input by each sensor, ete. and the signal input by each switch through control panel with the function of the builtin micro computer, and comprehensively controls each actuator (Inner and outer air flow select, air mix), fan motor and compressor on the output side, ‘And the self-diagnosis performance is provided to facilitate the trouble shooting. Q) Blower controller (TKS-B215A1) The power transistor shifts the fan motor into variable speed with base current from the control unit \ Tesi conrmuy + = [CONTINUED (4.7k 95%) lg ITester| ~ | + | [NOT CONTINUED. ~ | eonmvenoiooe PARTE | EE JAND FORWARD DIRECTION FLOW} In normal operation 1. Disconnect the connector of blower amplifier. 2. Check continuity between terminals on the blower amplifier cide * The instaling position is provided on the left side of air-con unit 25-3425. AIR-CONDITIONER SYSTEM (8) Relay @ Four-electrode relay is used for the blower OFF relay and compressor relay. 41) Blower OFF relay The blower OFF relay tums on after receiving the signal from the contro| amplifier. When the blower OFF relay turns on, the source voltage is supplied to the blower motor and the blower motor starts running, 2) Compressor relay The relay ON—OFF is tripped by the contro! amplifier and electronic thermostat control 3) Relay inspecting items 1. Relay (24-4PE) 2. Coll resistance: 320 2 3. Specified voltage: DC20V~30V 4, Be careful about the coil side of relay because this relay has polarity. 5, Inspection: Inspect the continuity between 3 and 4 according to the conditions mentioned below. 20~30V applied between terminals 1-2: Continued 20-30V not applied between terminals 1-2: Not continued Air mix actuator Air mix actuator is instalted at the canter of air-con unit, and opens and closes air mix damper through the fink, The air mix actuator contains potentiometer which is switched by being coupled to the shaft of actuator. When the target air mix door position Is determined through the temperature control switch, the control unitreads the level of potentiometer of the actuator, and determines the rotating direction of motor in either normal rotation or reverse rotation, Then as the motor rotates, the contact point is moved, and when the contact point is detached or the output signal of control unit turns OFF, the motor stops rotating 25-35 Fig, 25-3625. AIR-CONDITIONER SYSTEM (5) The actuator for inner and outer ‘The actuator for inner and outer air flow select is installed on the blower intake unit, and opens and closes inner and outer air damper through the fink The actuator for inner and outer air flow select Contains position detection switch which is switched with the movement of shaft of the actuator. news ‘When the inner and outer damper position is set by the inner and outer switch on the control panel, the \ : ‘contro! unit reads the signal of the position a 4 detection switch in the actuator and determines the csaen: rotation direction of motor in elther normal rotation heats or reverse rotation. Then as the motor rotates, the | ceo position detection switch also rotates and makes it stop at the set position of the inner and outer air Fig. 25:38 damper. (6) Evaporator sensor This sensor is used to contro! the evaporator outlet temperature with the compressor ON-OFF to protect the evaporator from freezing, and this evaporator sensor functions as a sensor of this control + Evaporator sensor inspecting items (Specification) Terminal resistance Fig, 25-99 at 0 degree C :7.2k0 at 25 degree C» 2.2k9 (7) Dual pressure switch Tis dua pressure swte ie atached on hose F ands used to tum OFF the compressor, and employs dual type (for high and low pressure a control) to protect the cooler cycle from possible failure at the time when abnormal pressure was jenerated on the high pressure side. 8 ae Fig. 25-40 ‘SPECIFICATION OF DUAL PRESSURE SWITCH O.02MPa(2.9psi) _0.S9MPa(s6psi) ee HE ea oF 0.20MPa(29psi) 3.14MPa(455psi) (LOW PRESSURE SIDE) (HIGH PRESSURE SIDE} (8) Solar radiation sensor This solar radiation sensor, which is used to correct the solar radiation to the auto air conditioner detects the strength and solar orientation of sunbeam after transforming them into current by means of photo diode, Inspection : Check for the continuity between terminals. 25-3625. AIR-CONDITIONER SYSTEM 25.8 TROUBLESHOOTING Air temperature does not fall. Note : M/A is motor actuator * is any of the SESE eee numbers 0 ~ & If AUTO switch or A/C switch is pushed, |HL.E" is indicated on the set temp. display of the panel : __NO Yes “HL. is shown on the set temp. + Connector for air mix MA is display of the panel disconnected or in poor contact. eee + Air mix MA is failed ___No_| ves ‘Main harness shows poor continuity. ‘A snow mark (2) on ‘A snow mark (#2) the panel is flashing. on panel is flashing. | _ inspect an correct or replace parts. No] YES + Inner air sensor or hamess is disconnected or shorted, Inner air sensor connectors d'sconnected arin poor: + Both inner air sensor and ‘contact evaporation sensor are See section monitor mode. ————————— disconnected or shorted. + Controller failed. Inspect and correct or replace parts. 820 section monitor mode. A NO. yes > Blowout temp. falls if tem at 18.0°C (64.4°F) (COOLI blowout mode is changed p. is set MAX) and the to vent mode. Evaporation sensor connector is disconnected or in poor contact, Evaporation sersor is disconnacted or shorted. NO. YES Inspect and correct or replace parts Air mix damper is in COOL! Cool aii flowing MAX. into inner air sensor inspect and correct or replace parts. NO. YES NO. yes and measure If MIA is at stop halfway, eliminate cause, correct force, (less than 14,7N : OK), Turn compressor clutch | on and off. inspect and correct electric circuits, operating Controller is faulty or inner air sensor is faulty. Inspect duct or } cool air intrusion. Refer to Troubleshooting for refrigeration cycle. Inspect and replace. MA + Inspect, correct or replace + After cleaning lever link, apply grease. MWA is ou lever tink, 25-37 failed or controller it of order. Replace! eliminate cause for25. AIR-CONDITIONER SYSTEM Air temperature does not ris: Note: * is eny of the numbers 0~ 9, HL.E is shown on the set temp. display of the panel NO. YES "HL." is shown on the set temp, display of the panel, NO. YES: + Connector for air mix MIA is disconnected or in poor contact. + Air mix MIA is failed. + Main harness shows poor continu + Inner air sensor or hamess is disconnected or shorted + inner air sensor connector is disconnected or in poor contact [pect and cored or eplace pais See section manitor mode. NO YES Inspect and corect or replace part, NO YES Blowout temp. rises at blowout mode if temp. is set at HOT MAX 32.0°C (64.4°F) NO YES. ‘Airmocdamperis| [Warmers flowing into in HOT MAX. inner air sensor. NO YES aoe no] _yes IEMIA action is at stop, | [Inspect warm water piping I elaine ce Controleror |] [inspect ductor grt measure operaing J inner ai sensor | | ebminate causes Ht Lis out of order. for warm air entry. NO_|_YES 4 inspect and replace “spect, correct or WIA fale or contro] replace MIA iver lk is out of order, Clean leverink and apply grease | [Replece. 25-3825. AIR-CONDITIONER SYSTEM Nate 2) Note 1) Biower motor does not run. ‘At air flow Hl, battery voltage acts across both terminals (+) and (-) of biower motor. NO, Yes Battery voltage acts across red (+) and body of blower motor. Blower m 9tor fails, NO Yes. Replace, rotates if white / red wire and red wire of | | and grounding of blower blower motor relay are direct connected. No | Yes [ Wire harness is faulty. Inspect and correct or replace. Ingpect blower motor relay. Blower motor] [Approx. TOV acts across light greon wire amplifier. NO Yes. [Controtier is out of order_| [Remove blower amplifier and check fo |Replace lcontinuity across light green wire lend black wires ; you get continuity, NO YES Battery voltage acis across white / red wire and body of blower motor relay.| | Eliminate cause and repiace NO. YES. blower ampli. Inspect and repair harness or replace, Blower turns if orange is connected with ground. of blower motor relay NO__|_YES { Inspect and | repair hamess., Replace relay. Inspect and correct harness| Jor replace controller. Note 1) Measure with connector set. Note 2) Always turn off air-conditioner, starter key switch and light switch before work. 25-3925. AIR-CONDITIONER SYSTEM Blower motor speed does not change | CASE (1) "HL." is shown on the set temp. display of the panel Note} # is any of the numbers 0~ 9. NO. YES Replace blower amplifier controller. + Inner air sensor or harness is disconnected or shorted. + Inner air sensor connector is disconnected or in poor contact. See section monitor mode. CASE (2) Inspect and correct or replace parts. is other face mode? [Does not blower motor speed [change because the setting mode| NO. YES | Is door or front window open?| yes_|_No See CASE (1). | The limiting or control operation] is actuated by door switch or front window switch. [Seo caSE CH 25-4025. AIR-CONDITIONER SYSTEM Magnet clutch does not engage. ‘Snow mark (3) lights fC switch is pressed. No Yes ‘Snow mark (23) flickers and E is Voltage acts upon clutch shown on panel display. Na Yes ‘On page 25-37 | Voltage is applied to Clutch faulty pressure switch hamess. No Yes Pressure switch is faulty or refrigerant gas is under charged or overcharged Voltage acts across white / green wire and | | Groune (Black) connector connected to excavator. | No, Yes es Refer to troubleshooting | forretiguaton oye Inspect clutch Inspect air-conditioner fuses harness. No fault No Yes, Replace hamess, Replace controller. Inner air and outer air do not change over. Inner / outer air mode display on operation panel is flickering No Yes [WIA lever includes foreign matter [Connector of inner/outer air | oris broken. MIA is disconnected or in poor No Yes [contact cee ]Or MIA failed or main harass failed, MIA failed Remove foreign matter Land replace parts. | Inspect or replace. Replace 25-4125. AIR-CONDITIONER SYSTEM. Modes do not change. ‘Mode display (Mark of person) on operating panel is flickering No Yes MIA rod does not disengage. | Mode M/A connector is ] 7 a disconnected or in poor contact or M/A faied or main harness is faulty, Repair] Each damper lever does not disengage | No___| Yes Inspect or replace Repair When rod is removed and cam is operated by hand, itis heavy. (more than 19.6N.) No__[_ Yes MIA or controller is out of order. + Cam or damper shaft includes foreign matter or is broken foneous motion occurs due tol Replace, dirty grease, femove foreign matier or replace parts. Clean cam and apply new grease. 25-4225, AIR-CONDITIONER SYSTEM Trouble with refrigeration oycle. Bot high end ow pressures are lower. ee] Fi weg i ‘Air bubbles are seen in [ ‘High pressure NO Yes, ‘Cooling does not work ‘il comes out from | irun at nigh speed. piping ane parts, ‘Compressor oyider| Compressor oyinder | = = cos nt got et ets very Ht NO. ves. NO. YES E 8 | Expansion vate | [Expansion vane] [Naural Gas eas | fs cogged | |istrozen oc | eactrem | | frompipe L moist revues by water| | hose jamsand | [Expansion vanes [Compressor does Traladusted at dacharge Wo {too much open) Tajustorvepace) [Ater mating Sshanson valve,| | vactury ft Fagen end lreingerent | [charge coe] | Revahten Sno episce ne ister Renace [Repace conor] expansion vale. me ‘Ai-bubbiesare seen insight glass. | wo] rs apse ee Gentes ome ee, amps vs| |r logged up. | go out even tf water Remove Clean’ L gree, | [Beene | pies 25-4325. AIR-CONDITIONER SYSTEM 25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL. The failure of motor actuator and each sensor can be identified on the display of panel. 25.9.1 POSITION OF INDICATION FOR FAILURE. ‘The error is indicated on 2 digits segment. 25.9.2 EXPLANATION OF INDICATION FOR FAILURE. (1) Failure of Motor Actuator 1) HL. is indicated on 3 digits segment, Check harness or connector to motor actuator for the air mix damper for disconnection. 2) MoDE J is flickering, Check hamess or connector to motor actuator for the air outlet damper for disconnection 3) RIF ae is flickering, Qo Fe, ABP py TS] 8 cic inion increas norte z “A G ames and comector were ghssnnected under the canton @ *, ol) BC the panel ON/OFF svetchis ON eter wos soca pore! ONOFF snes timet Otten 2 25-4425. AIR-CONDITIONER SYSTEM (2) Fallures of sensors 1) HL-*is indicated on 3 digits segment. AUTO BF, Gide! te bebaraniordt Gabteed ey alaenseas eis and shen cro an ao connectr or cencton \¢ is any of the numbers 0 10 9.) 2) “*E and % mark are fickering ("is displayed leaving the present set temperature value) Check evaporator sensor or the hamess for disconnection and short circuit, and also connectors for disconnection. Note) The above displays in items 1) and 2) are indicated by 3 digits segmont when error occurred undor the condition the panel ON/OFF switch is ON. And, after cortection of failure ifthe panel ON/OFF switch is switched from OFF to ON, the error indication is released. (3) Communication error of control amplifier and panel 1) Eis indicated on the only use segment of display. Check the hamess of control amplifier and panel for disconnection, a and connectors for poor connecion, 25-4525. AIR-CONDITIONER SYSTEM 25.9.3 EXPLANATION OF MONITOR MODE When error of 26.9.2 (2) sensors is displayed, the monitor mode is available to identify the sensor condition (disconnection, short circuit). (1) Position of monitor mode indication Peeve SEGMENT FOR ONLY MONITOR INDICATION 3 DIGITS SEGMENT (2) Operation of monitor mode 5 ~ : [= | | Oy) 2 | O%| ot 1) Press inner and outer air flow select switch and ON/OFF switch simultanecusly for 1 second. 2) Press AUTO switch. (After all segments are lit on for 1 second, the mode is switched into moniter made.) 3) Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd digit of segment in three digits. The 1st digit is indicated by "H" 4) Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing UP or DOWN of blower switch, and the required sensor is selected from the list below. 25: 5F HS {Excluding above mentioned indications, for example “from 3 to 9 and from B to F" are not used at service work.) SEGMENT ASSIGNMENT LIST. INNER AIR SENSOR, 1_|EVAPORATOR SENSOR 2 |SoLAR RADIATION SENSOR 5) The monitor display is terminated by pressing the inner and outer air flow select switch (RIF) and ON/OFF switch for 1 second again, or turning off the main switch of excavator. Notes) 4. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for operation and setting until the monitor mode is cancelled. 2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized Therefore turn on ON/OFF switch again, and the error display is disappeared, 25-4625, AIR-CONDITIONER SYSTEM (3) Contents of monitor mode display Refer to the list of segment display exclusively used for monitor and the ist of segments in three digits. 1) Example 1 ‘When the segment exclusively usc for monitor indicates O spp (2009 he era senor en, Since the segmiert indicates 3F, the sensor is in normal operating condition acnordng othe lt of 2 segments. > The inner air sensor fn normal operating condition 2) Example 2 ‘When the segment exclusively used for monitorindicates 1 a 4 (displays the evaporator sensor condition, since the segment indisates 00, the sensor is 2 & in disconnection condition according tothe lst of § segments The evaporator sersor is in disconnection condition 3) Example 3 When the segment exclusively used for monitor indicates 2 {displays the sotar radiation sensor condition), since the ‘sogmont indicates FF. the sensor isin short-crculting condition accotling to the is of 3 segments. ~The solar radiation sensor is in short-circuiting condition, 4) List of 3 segments. NS SECOND SEGMENT \ eT Te Ts ase Pe Ps PATE Tee Lee TINEA ATR SENSOR DRCOWEGION 6 EVAPORATOR SENGOR BISCORMESTION SOUR EADETON SHORTCRCUTNE | \S ld Gace e Et] BEAM EWES) cacuscncorisnorn aia ats Biz ele an Fla n 5 | - = 2 SOLAR SENSOR SY SIDE SHORT-CIRCUITING Sees Ci Hes : THER AR SENSOR SORT SROUTNG EVAPORATOR SENSOR SHORT CRCUTNS 25-4725. AIR-CONDITIONER SYSTEM [MEMO] 25-4831. DISASSEMBLING AND ASSEMBLING ‘TABLE OF CONTENTS, 31.1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSENBLY... 31-3 31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ...ccsstnenens 34-3) 31.1.2 INDICATION OF TIGHTENING TORQUE eee 7 B13 Book Code No. S5YN3118E01 31-131, DISASSEMBLING AND ASSEMBLING ISK210LC-8 : YQ11-06001~ tose Bate oma “Apcbie Neches Ee Romenenea SK330-6 :LC10-07001~ SSYN3118E01 First eat eee July. 2006 | s4350L0-8 : YC10-03501~ (ASIA, OCE) | : august, 2008 |SK200-8: YNTT-45001~ " A 31-231. DISASSEMBLING AND ASSEMBLING 31.1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY 31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY This chapter is consist of 3-Section as follows. (1) ATTACHMENTS ..setsssnna inns Chapter 32 4) Removing and Installing 2) Disassembiing and Assembling a. Cylinder (2) UPPER STRUCTURE 41) Removing and installing 2) Disassembling and Assembling a. Hydraulic pump Control Valve Pilot Valve (ATT) Pilot Valve (Travel) Slewing Motor £ Swivel Joint (3) TRAVEL SYSTEM s-Chapter 34 1) Removing and Installing 2) Disassembling and Assembling a. Travel Motor Chapter 33 34.1.2 INDICATION OF TIGHTENING TORQUE Tightaning torque is indicated as follows, for example Tolerance is +10% unless otherwise specified + Refer to "Chapter 11 TOOLS" for standard tightening torque. 31-331. DISASSEMBLING AND ASSEMBLING [MEMO] 31-432. ATTACHMENT ‘TABLE OF CONTENTS 32.1 REMOVING AND INSTALLING... 7 7 cee B23 32.1.1 ATTACHMENT ASSY. 7 . . os on B23 824.2 BUCKET nase 7 . 7 7 32:3 32.1.3 ARM. Paisiit 326 32.14 BOOM i . sees 829 32.2, DISASSEMBLING AND ASSEMBLING... . ee B23 32.2.1 CYLINDER... oe ud a 32-13 Book Code No. S5YN3218E01 324132. ATTACHMENT Tesue [Date of nawe | appcabia wach font [SK200-6 : YN11-45007~ SSYNZTBEO! First eit Y I rstedition | August 2006 || sx240L0-8 : Yat1-06001~ (ASIA, OCE) ‘ PREFACE (1) This Manual describes all the procedures from removing to attaching, arranging them by item, (2) This Manual consists of 2 sections. “Removing and Installing”, and "Disassembling and Assembling" (3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted. (4) The removing and installing procedure does not completely cover alll possible situations because of differences of field condition and defective section. (5) Please be aware that the procedure to be followed must be determined according to the above conditions. When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then starts working, 32-232. ATTACHMENT 32.1 REMOVING AND INSTALLING 32.1.1 ATTACHMENT ASSY {D) ARM CYLINDER HEAD PIN, () BOOM CYLINDER ROD PIN —_(A)BOOM FOOT PIN, (©) 800M TOP FIN \ He Z \ ARM crLNDER \ one \ ag (G) BUCKET CYLINDER HEAD PIN > BUCKET CYLINDER 3, aria i, (IDLER LINK PIN, // \ TOLER Link BUCKET LINK Na Boon cyinBeH (H) BUCKET CYLINDER ROD PIN (9 BUCKET ATTACHING PIN HEAD PIN Fig. 32-4 Front attachment and position 32.1.2 BUCKET 321.21 REMOVING BUCKET (1) Put the machine in position to remove bucket. Fig. 32-2 Position to remove bucket (2) Removing pin (2) Expand slit of ring (1) with screwdriver, and remove it. Push out the pin (2) with flal-blade screwdriver BOSS SECTION Fig. 32-3 Removing pin (2) 32-332. ATTACHMENT (3) Removing buoket attaching pin (K) Lift up bucket, position it so that bucket attaching pin (K) is not loaded, adjust bucket link, and pull out bucket attaching pin (K). (4) Removing bucket drive pin (J) Put bucket on the ground, position it so that the bucket drive pin (J) is not loaded, agjust bucket link, and pull out pin (J). Store the removed pin (J) in original position again ATTACHING BUCKET (1) Attaching bucket drive pin (J) Attach bucket drive pin (J) first, then continue in the reverse procedure of removing aura] When aligning the pin holes, do not put your finger in the pin holes, but align them visually. Check the seals for damaged and replace as necessary. ‘When inserting the pin, coat the shaft with grease. 32.1.2.2 Cs y Fig. 32-6 Attaching bucket 32-432, ATTACHMENT 32.1.2.3 Adjustment of clearance between bucket and arm ¢ ¢ 11) Shift O-ring (3) towerd the bucket boss, using @ spatula. (2b) 2) When adjusting clearance (B), bring the non- adjusting side of the bucket in contect with the arm. (8) Measure clearance (B) and check that it is within ¢ ¢ ( c ( 4.0mm (0.04in) (4) Adjust clearance (B) where it is more than 1.0mm (0.04in), (5) An average of 5 shims (9) of 1mm (0,04in) thickness are set in the plate (8) fixed by the three ‘capsorews (11). The clearance can be decreased by ‘mm (0.04in) if one shim is removed. Draco, Tightening torque : 273N-m (206 lbfeft) (6) After adjustment, tighten the capsorews evenly, + The gap exceeding the specified dimension causes early wear, 7) Operate the bucket and confirm that the total sum of both clearance is within 4.0mm (0.04in). (8) Replace O-ring (3) on its original position, ACAUTION) ‘When shifting O-ring (3) by means of a spatula, use care 80 as not to damage O-ring (3). Remove shims (9), push out bushing (7) rightwards by means of three capscrows (11) and adjust clearance (B) so it settles within the standard value evenly all round. 32-5 PROCEDURE FOR ADJUSTING CLEARANCE, op rest preventive oh 3263864 238) \ New bucket 2: WASHER, $:0-RING 11: CAPSCRE! NN 7: BUSHING ~ 8: PLATE || Instat pin (40) unt the top ose 10°PIN of pins even surtaoe swith bushing Fig, 32-7 Adjusting clearance between bucket and arm32. ATTACHMENT 324.3 ARM 32.4.3... REMOVING ARM {1) Put the machine in position to remove arm, Extend the arm cylinder, retract the bucket cylinder and bring the arm down on the ground. (2) Disconnecting piping of bucket cylinder Release pressure of hydraulic tank, place oll pan to prepare for oll leaking, and disconnect pipes. (note Plug both end of disconnected pipes. Plug : Tools section 11.5.2-(4) ‘Tools section 11.5.2) ‘When the removal of bucket cylinder is not required, skip to procedure (6). (3) Removing bucket cylinder rod pin (H) Loosen nut (9), remove capscrew M16x140 (8), and push out pin (H). 2am (4) Removing oylinder head pin (6) Loosen nut (2), remove capsorew M16x150 (2), and push out pin (6), ae: pam Fig. 32-9 Disconnecting piping of bucket cylinder tar stent of i, th al gp Sey Ho SEOTION D-D Install plastic shims ‘0 bucket link side, PLASTIC SHIM” “STEEL SHIM Fig, 32-10 Detail of bucket cylinder rod pin (H) Install plastic shims to bucket link side. z SHIM ; 2 \ Alter agjustment of shim, the total gap, shoud be win : \ BSS oen (2-0 05 a SHIM < Aoply grease i of bushing SECTION AA Fig, 32-11 Detail of bucket cylinder head pin (6) 32-632, ATTACHMENT (5) Removing bucket oylinder ‘ Sling tubs of bucket oylinder with nylon sling, and remove it. Buoket cylinder weight : 140 kg (310 lbs) Fig. 32-42 Slinging bucket cylinder (6) Removing arm cylinder rod pin (E) Put a wooden block between the arm cylinder and the boom. Install plastic shims Loosen nut (3), remove capscrew M16x150 (4), fo bucket link side and push out arm cylinder rod pin (E). See Apply grease to nner wall ofbiching 2am Sosy ITAL Retract arm cylinder rod, and return pin (E) to the VY 3 original position (hole). Alter. adjustment a Shim, the total gap Should Be wrnin 66-2 0mm (0.02°0 06in, SECTION BB Fig. 32-13 Detail of arm cylinder rod pin (E) (7) Removing boom top pin (F) Tightening torque 144N-m (106 WF) Loosen capscrew M14x30 (2), and pull out boom, Papi ook ad to bon Bae hg top pin (F}. om 22mm SHIM Install plastic shims fo arm Insert pin (F) into the original hole. side. * Apply grease bs toner wall ‘Atoraglustment of of bushing shim, he tel gap shouia be wine 4.5mm (0.021), SECTION Avs 32-14 Detail of boom top pin (F) 32-732. ATTACHMENT (8) Singing arm assy Sling arm with nylon sling and remove it. ‘Arm weight : 660 kg (1,455 lbs) Fig. 32-15 Slinging arm assy 324.3.2 ATTACHING ARM instal the arm in the reverse order of removing, paying attention to the following 1) When aligning the pin holes, do not put your finger in the pin holes, but align them visually. 2)Check the seals for damage and replace as necessary. 3) When inserting the pin, coat the shaft with grease. 4) Pin lock nut handling procedure aS t CLEARANCE a 24mm 5) When installing the arm and the cylinder, inspect the clearance in the thrust direction of the pins and decide the thickness of shims by referring to the Maintenance Standard, 6) Tightening torque Tightening torque 7 ion | Size }— Giessfcation | Size -— a Mia 144 108 Metric threads : mie [| 147 108 PPT threads| 1/8" | 167 123 32-832. ATTACHMENT 32.1.4 BOOM 32.144 PREPARATION FOR REMOVING AND ATTACHING BOOM When removing and attaching boom in the position shown in Fig. 32-16, to remove and attach boom foot pin (A), removing and attaching of cab and guard are required 32.1.4.2 REMOVING BOOM (1) Put the machine in position to remove boom. cee Place top end of boom down on block, etc. giving attention for arm cylinder rod not to be extended. “pL00k Fig. 32-16 Position to remove boom {2) Lifting up boom eylinder temporarily Remove the right and left boom cylinders one side by one side according to the following procedure: Lift up boom cylinder temporarily to prevent it from dropping, Fig. 32-17 Lifting up boom cylinder temporarily (3) Press the boom cylinder rod pin (C) Install plastic shim to cylinder side A the one side of pin (C), loosen nut (5), remove SHIM ccapscrew (3) (M16X150), and remove boss (4). ‘ater adustvet of shi, ~ ‘And push pin (C) to the ene of boom boss. Recah ial SHIM. oN a 24mm (4) Preparing for disconnecting cylinder pipes Retract the above mentioned cylinder rod, and piace one side of cylinder on stand. (See Fig. 32- 17) SECTION AA Fig. 32-18 Detail of boom cylinder rod pin (C) 32-932. ATTACHMENT (6) Disconnecting the arm oylinder and bucket cylinder pipings Release pressure from arm and bucket circuit and bleed air in hydraulic tank, and then disconnect pipe at (A1), (A2), (A3), (Ad) and hose (B1), (B2), (83), (B10). 36,44 mm After disconnection of pipe, plug every pipe. ORS Plug : See Tools 11.5.2-(4). onne! NS aro Be ‘BUCKET (R) eto \ ARM (H) ARI (R) Fig. 32-19 Boom piping disconnection (6) Lifting up boom assy temporarily Lift up boom eyiinder with nylon sling so that boom foat pin (A) is not loaded. Weight of single boom : 1,310 kg (2,890 Ibs) a Boom assy temporary lift up procedure aah (7) Removing boom foot pin (A) Aor susan tatu 1) Loosen nut (3) and remove capscrew (2) wan Oem (oom: SM M20x175, a 30mm = 3 ~. Aboly molybdenum adel igtease fo inner wall of bushing ~SHIM Install plastic shim to boom side. 2) Draw out pin (A). 2 SECTION Fig. 32-20 Details of boom foot pin (A) section 32-1032, ATTACHMENT (8) Hoisting boom assy Hoist and remove boom assy. Weight of single boom : 1,310 kg (2,890 Ibs) Boom assy hoisting procedure (2) Completion of removal of front attachments a When the removing and attaching of cylinder are SS not required, the work is finished. (10)Removing and installing arm cylinder 1) Lift up arm cylinder (2) with nylon sling so that the head of cylinder is not loaded. 2} Disconnect hose (F1) and (F2) at position A. shcesapecnsntae Aer discomecton of hose, plug both ends of Simrecsse hose. a'5etomm (002-0 04, Install plastic shim to ? ett Plug : TOOLS cylinder side. SHIM é / 11.6.2-(4) Plugs for ORS fitting stn Y Be ae 11.5.2:{5) Plugs for half clamp Vea E=Apply reese \ toinner wal a 36mm : of bushing 42 mm c 4 = - sectionp-p © 3) Removing arm cylinder head pin (D) Loosen nut (3), remove capsorew M16%150 (2) and pull out pin (0). Fig. 32-21 Removing arm cylinder 24mm 4) Removing arm cylinder (2) Weight of arm cylinder : 258 kg (560 Ibs) 32-1132. ATTACHMENT (11)Removing and installing boom cylinder 1) Release pressure from boom circult and bleed air in hydraulic tank, 2) Sling boom cylinder (2) using nylon sting temporally not to act the weight of cylinder upon the cylinder head. 3) Disconnect each two hoses (C2] and (C3). And plug their both ends. Plug : TOOLS 11.5.2(4) Plugs for ORS fiting a -07,32,38.41mm 2) Remaving boom cylinder foot pin (8) (See Fig. 32-23,Fig, 32-24) Loosen nut (5), remove capscrews M16%150 (3) and pull out pin (8). ae 24mm 3) Remove boom cylinder (2) Weight of boom cylinder : 170 kg (875 Ibs} 4) Remove another boom cylinder the same way. 32.1.4.3 ATTACHING BOOM (1) Attaching boom foot pin (A) First of all, insert boom foot pin (A) and install the boom assy. Attach it in the reverse procedure of removing, paying attention to the following points. 1) When aligning the pin holes, do not put your finger in the pin holes, but align them visually 2) Check that the dust seals is not damaged and replace as necessary. 3) When inserting the pin, coat the shat with grease, 4) Refer to paragraph 32.1.3.2 (page 32-8) about installing of jam nut 5) When installing boom and cylinder, check the clearance of mounting section in thrust direction, and decide the thickness of shim according to the maintenance standard. Install plastic shim first, and insert iron shim into remaining gap. Regarding the position of shim, refer to Fig. 32- 20 ® ca 32-22 Removing and installing boom cylinder te aunt thi ‘he ota gep shoud be wahn 5"7onwm (0.02~0.0a pk salt SH of bushing Apply grease to inete? wal of bushing f— shin Install plastic shim SECTIONB-8 cylinder side Fig. 32-23 Removing and installing boom cylinder head pin (B) Fig, 32-24 Boom foot pin (A) 32-1232. ATTACHMENT 32.2 DISASSEMBLING AND ASSEMBLING 32.2.1 CYLINDER 32.211 PREPARATION BEFORE DISASSEMBLY Before assembly, secure a dusttree workshop and necessary equipment and facilities. 32.24.41 WORK AREA The following working area is required for disassembly: (1) Ample space For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this reason, the first condition is that the working area is long enough for the work. In terms of width, itis also necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the work can be performed. (2) Suitable working environment ‘The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding operation should not be performed in the neighborhood of the working area to keep it clean. 3224.1.2 APPARATUS The following equioment are required for disessembly (1) Hoist or crane The hoist or crane must be capable of carrying the cylinder in an assembled condition. it must also be capable of making level and liner movement under load for retracting and extending the piston rod and the tube. (2) Work bench The work bench must have strength and rigi-dity capable of accommodating the total lenath of the cylinder in its most retracted condition and of withstanding the repulsive force of the tightoning torques of the cylinder head and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large. 8 Support stand If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent damage of seals, (4 Hydraulic source A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oll leak tests after completion of assembly, ) Jet air source lis used for drying after oil draining and cleaning of the eylinder. (6) Cleaning bath, cleaning oil and detergent {7) Oll pan and oil reservoir ‘An oll pan is necessary to contain oil drained from the cylinder and oil spitt during work. An oll reservoir is required to collect oll spilt on the floor and waste oil (8) Others Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary. 32-13,32, ATTACHMENT 3224.13 NECESSARY TOOLS Tools and jigs vary with types of cylinder, but itis necessary to prepare the tools in Table32~1 as a guideline. Table32-1 List of Tools and Jigs Tool / Jig Remarks Tool / Jig Remarks Hammer |1. Steel hammer Spatula [Metallic one with smooth comers. 2. Wooden or plastic mallet ‘Sorewdriver/A few types of large and small sizes ~ Gimlet [A sharp-point tool may be used in piace of a aimiet Special ig |1. For removing and press-fting bushing, (A), (D). (C) 2, For press-fiting wiper ring. (O) Chisel |Fiat chisel 3. For inserting and reforming seal ring (E)(F)(G).(H} See para 32.2.1.9 for detail) Vise [One having an operation wide enough to| ust hold cylinder head O.D. and tube remover mounting pins (clevis) Wrench |. Eye wrench Measuring [1. Slide caliper 2. Alien wrench instruments|2. Micrometer 2, Extension pipe for wrenches 3. Cylinder gauge (Fig. 32-25) 4. Veblock | + For the details of special tools and jigs, refer to the back pages of this manual, 32.21.14 EXTERNAL CLEANING The cylinder taken off the excavator has dust and foreign matter, and grease is usually adhered to the levis part. Far this reason, remove external soil and contamination from the cylinder with water and steam before bringing it into the workshop. + The following describes the construction of boom, cylinder. When disassembling and servicing the cylinder, confirm the construction of cylinder referring to Parts Manual 32-25 Cylinder gauge 32.24.15 DISCHARGING OIL Place a wooden-block on the work bench and place the _-~\\_ WOODEN BLOCK oylinder on it to prevent it from rotating. Charge air into ports A and B alternately to actuate the piston rod til the PORT hydraulic oil in the cylinder is drained out. At this time, connect a suitable hose to each port so that the hydraulic oil may not gush out. BLOCK \. OIL PAN Fig, 32-26 Preparation 32-1432, ATTACHMENT 32. 212 25 24 12 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER) 2428 fra beans ONEHOLE 7 Dew Paton va penn Woe 9 4 HE eae 30 11:10 2 1 13:14 «15 17 16 18 19 72021 22 23 Li i] [ [ | os sana sat A | (owed — ar ‘ | Fig. 32-27 Construction of general cylinder No Parisname[aty|| No] Parsname [aiy|[No | Parts name [ay 41 |Cylinder tube 1 10 |O-ring 1 19 |Slide ring 2 2 [Piston oo 1 |] 11 [Back-up ting + |] 20 {stim " 3. [Rod cover 1 |} 12 [socket bot 12 || 21 [Piston nut 4 4 [Bushing 4 |] 13. [cushion bearing 1 || 22 |Setscrew : m2 4 5 |Snap ring 1 14 {Cushion seal 1 23 |Steel ball 1 6 [Buer rng +] 28 [Piston 1 [| 24 [Pin bushing 2 7 luring + || 16 [seating 4 |] 25 |wiperring 4 8 [Back-up ting 11147 [Back-up sing 2 [Wiper ring + |[ 1 2 Note : In case of piston with piston nut type, the parts with * are not used. 32-1532, ATTACHMENT. 32.24.3 DISASSEMBLY + When disassembling and servicing the cylinder, check the construction and the availability of service parts as well as necessary tools and jigs, on separate Parts Manual. + The figures in parentheses after part names correspond to those in Fig. 32-27. + The following explanation and quantities are for general use cylinder which has separated piston and piston nut, In case that piston and piston nut are combined, the construction differs from separated type, refer to the sentence in parenthesis. 32.2.1.31 REMOVING ROD COVER AND PISTON ROD (1) Hold the clevis section of the tube in a vise. AXCAUTION] Use mouth pieces so as not to damage the machined surface of the cylinder tube, Do not make use of the outside piping as a locking means. (2) Pull out piston rod (2) about 200mm (Bin). Because the piston rod is heavy, finish extending it with air pressure after the above-mentioned oll draining operation. (3) Loosen and remove socket bolts (12) of the rod cover in sequence. CAUTION Cover the extended piston rod (2) with cloths to prevent it from being accidentally damaged during operation. (4) Strike the comer of the rod cover flange by means of a plastic mallet til rad cover (3) comes off. 32-16 Fig, 32-28 ALLENWRENCH 12 2 Cover here with clits Fig, 32-2992, ATTACHMENT + Atthis time, the weight of piston rod (2) is loaded ‘on rod cover (3}. Therefore, lit the top end of the piston rod with @ hoist to the extent that only the rod weight may be held, {5) Draw out the piston rod assy from cylinder tube (1). ACAUTION| Since the piston rod assy is heavy in this case, lif the tip of the piston rod (2) with a hoist and draw it out, However, when piston rod (2) has been drawing out to approximately two thirds of its length, lft it in its center to draw it completely. However, since the plated surface ‘of piston rod (2) is lifted, do not use a wire rope which may score the surface, but use a strong cloth belt or a rope. (6) Place the removed piston rod on a horaizontal wooden V-block, + Cover a V-block with cloths, (7) Remove slide ring (18) and (19) from piston (18) 32-17 KNOCK This EDGE. WITH APLASTIC MALLET, Fig, 32-30 Drawing out piston rod assy (2). LIFT HERE. g PULL STRAIGHT [) SIDEWAYS HORIZONTALLY Fig. 32-31 Method of drawing out the piston rod assy LA : PISTON ROD ASSY WOODEN V-BLOCK {PLACE CLOTHS) Fig. 32-32 Method of placing the piston rod i 18, Remove slide ring by widening the slit toward the arrow 19 18 Fig. 32-33 Remove slide ring (18) and (19)32. ATTACHMENT 932.2.1.3.2. REMOVING PISTON ASSY (1) Fix piston rod (2) by holding its clevis section in @ vise. Fix the piston rod (2) securely as piston nut (21) is tightened to @ high torque. AQXCAUTION + Note that the tightening torque differs with the type, the working pressure and the mounting method of the piston (15), though the rod diameter remains the same + It’s also necessary to place a suitable supporting block near the piston (15). In case a V-block is Used, put cloths or something over the rod to prevent it from damage. (2) Scrape off the caulked part of seiscrew (22) of piston nut (21) by means of a hand drill and loosen setscrew (22) and remove ball (23) (8) Loosen and remove piston nut (21) oF [piston (15)}. rN + Since piston nut (21) is tightened to @ high torque, use @ eye wrench suitable for the outside diameter of piston nut (21) + Incase that piston and piston nut are combined, apply the eye wrench to hexagonal part of piston and loosen the piston directly. ON] (4) Remove piston (15) by tapping with plastic maliet, supporting weight of piston (15) with hoist. AcauTion| In case that piston and piston nut are combined, the shim (20) is not used 32-18 7 WOODEN BLOCK WOODEN V-BLOCK (PLAGE CLOTHS) Fig, 32-34 How to loosen piston nut (21) TURN COUNTER clockwise, // EYE WRENCH oe Fig. 32-36 How to loosen piston nut (21) Fig, 32-37 Removing piston (15)32, ATTACHMENT (5) Alter removing cushion bearing (18) and cushion seal (14), separate rod cover (3) from piston rod (2). Hits too hard to slide it, knook the flanged part of rod cover (3) with a plastic mallet. But when drawing it out, lift rod cover (3) by hoist an¢ pull it straight horizontally. AXCAUTION| Take care so rod bushing (4) and the lip of packings (6,7,8,9) may not be damaged by thread of the piston 10d (2). 32.2.1.3.3 DISASSEMBLING PISTON ASSY (1) Remove seal ring (16) and back-up ring (17). CAUTION Cut the seat ring (16) by tapping itwith a screwdriver or a chisel. Take care not to strike it too hard, otherwise the groove may be damaged. UPT WaTH A HOIST. Q STRIKE WITH A PLASTIC MALLET. PULL STRAG nna Nove: boner 1 Daan \._ fistonroo | nae HTT \ \ 3 4 6 87 9 2 Fig. 32-38 Removing rod cover (3) an ww = BACKUP RING ) SEAL ane 16 ~ Le 8 vezgnenor” ~ Shwe meats Fig, 32-39 Removing seal ring (16) and back-up ring (17) 32-1932. ATTACHMENT 32.2.1.3.4 DISASSEMBLING ROD COVER ASSY (1) Remove O-ring (10) and back-up ring (11). Remove back-up ring (11) and O-ring (10) in that order. Remove back-up ring (11) and O-ring (10) by pulling and stretching them with an spatula like earpick. (2) Remove buffer ring (6), Usring (7) and back-up ring (8). Each seal is fixed in the groove on the bore and removing in flawless is impossible. Stab each seal with a gimlet and pull it out of the groove, ACAUTION! ‘Take care in this operation not to damage the grooves. (3) Remove wiper ring (9). When taking out wiper ring (9), fix rod cover (3) in a vise. (4) Remove snap ring (5) and bushing (4). Remove snap ring (5) first, and remove bushing (4). But the bushing (4) is press fitted in rod cover (3), 80 push it out by press with jig as shown in the figure. See para $2.2.1.9.3 (1) for removing, 32-20 Cla Fig, 32-40 Removing the outer circumferential seal of rod cover (3) y 8 = 4s fi {5 6 4 J AULT 2 Fig. 32-41 Removing the inner circumferential seal of rod cover (3) HAMMER SCREW. 3 ORIVER Ty ie 9 WOOD PIECE Vise aan an Fig. 32-42 Removing wiper ring (9) WOOD PIECE cHuckassyTooLa _ {PRESS HERE Fig. 32-43 Removing rod bushing (4)32. ATTACHMENT 32.2.1.3.5 REMOVING PIN BUSHING (1) Apply driver to wiper ring (25) of cylinder tube (1) and piston rod (2), and strike it by hammer lightly. (2) Push out pin bushing (24) press fitted in cylinder tube (1) and piston rod (2) with press. 32.2.4.4 CLEANING (1) After disassembly the cylinder, wash all parts with commercial detergent ACAUTION Never use benzene(gasoline, thinner, etc.) because it may be damage the rubber, etc. (2) Do not use the used oil seal, O-ring, back-up ring, etc. even if they are not damaged after inspection (3) After cleaning, dry all parts by compressed air, and put them on the working bench taking care not to damage them. 32.2.1.5 ASSEMBLING PIN BUSHING Start assembling the following sub assy + Cylinder tube assy + Piston assy + Rod cover assy 32.21.51 ASSEMBLING PIN BUSHING (1) Press fit pin bushing (24) in cylinder tubo (1) and piston rod (2) respectively with press. (2) Press fit wiper ring (25) in the upper and lower sides of cylinder tube (1) and piston rod (2) respectively with press. AcAuTION + Before press fitting, apply grease on wiper ring and, boss hole. + Before press fitting the pin bushing, align the position of ail hole. 32-21 PUSH WITHA PRESS, wr 24 BASE Fig. 32-44 Drawing out pin bushing (24) PUSH WITH A PRESS, 24, g OIL HOLE LOCATION Fig. 32-45 Press fitting of pin bushing (24)32. ATTACHMENT. 92.2.1.5.2 ASSEMBLING OF PISTON ASSY (1) The fitting of seal ring (16) requires special tool as shown in Fig. 32-46. Seal ring (16) is pushed in by press, etc. with pushing in tool as shown in the figure. (The O-ring of seal ring (16) and back-up ring (17) on one side should be installed beforehand.) [AcauTioN| Heat them, and they may be soften, But never heat them over 100°C (212.0) or more. (2) it back-up ring (17) on the other side. After fitting, correct it immediataly to prevent from expansion of seal ring (16) with correcting jig (H) as shown in Fig, 32-47. ASCAUTION| For piston, stop it once tentatively (for 3 to § seconds), and then push it in fully After fitting, wind tape around seal ring (16) 2 or 3 times, and remove itimmediately before piston (18) Is inserted in cylinder tube (1). Fit slide rings (18) (19) at the same time when piston (15) is inserted in cylinder tube (1). 92.2.1.5.3 ASSEMBLING ROD COVER ASSY (1) Press fit Bushing (4) in rod cover (3) with bushing press-fitting jig (A). Then, fit snap ring (5) in the groove. Apply hydraulic oil on internal surface of rod cover (3). CAUTION. ‘The snap ring (5) can not be fitted when the bushing (4) is not press-fitted fully to the stop end. (2) Apply grease to wiper ring (9), and fit wiper ring (9), directing the lip side toward the groove af retainer tool (D). And set retainer too! (D) on rod cover (3) and press fit wiper ring (9) with press. 32-22 PRESS HERE weTAL (6) PRESS JIG (E) sulk NI J, SLIDE JIG (F) 32-46 How to fit seal ring (16) PRESS HERE Wi CORRECTIONAL 4 |i JiG(Hy NN Fig. 32-47 Installing seal ring (16) PRESS HERE. (STRAIGHT DOWN) ~ b ~ PRESS FITTING JIG (A) \ ily GROOVE FOR |_| oar rein snaP eine 6) Ep Press bushing ill bushing E==7 "comes in contact with F= 2 | __ this face. Fig. 32-48 Press fitting of bushing (4)92, ATTACHMENT (3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in their grooves in that arder. Before setting packings, coat them with hydraulic oll (or vaseline if not available). If you forget the coating, the packings maybe scored. When attaching seals, deform them in a heart shape as illustrated. |AACAUTION| + Usting (7) is harder than other packing and it would be dificult to deform them ina heart shape. In such ‘case, put a U-ring in the groove obliquely by hand as deep as possible and push in the last part with a Push bar til itis set with a click, + Buffer ring (6) should be fitted taking care of the fitting direction. The reverse fiting may cause deformation, damage, etc. of the piston due to high pressure generated between the buffer ring and U- ring. + If U-ting (7) is set upside down, the lip may be damaged. Check that itis positioned correctly. + Attach back-up ring (11) on the open air side of O- ring (10). (See Fig. 32-80). 32.215.4 inserting rod cover (3) to piston rod assy by the following procedure. (1) Fix piston rod assy on working bench. (2) Install rod cover (3) on piston rod (2) with inserting uide jig (1) as shown in Fig. 32-51 paying attention for the lip section of U-ring not to be caught on the stepped section, ACAUTION| + For the rod the outer diameter of piston installing section is small, insert spacer on the faucet section of rod first, and attach inserting guide jig, + Apply hydraulic oll on the inserting guide jig and outer surface of pistan rod lightly to make the insertion smooth, 32-23 INSERT U-RING INTO GROOVE FROM THIS SIDE Fig, 32-49 Inserting a seal into the inner circumference of rod cover. PUSH BAR (WOOD OR PLASTIC) A0 ae & i Lo? eee Fig, 32-50 How to fit U-ring (7) INSERTING ROD COVER ASSY TO PISTON ROD INSERT GUIDE JIG (I) 3 <> PUSH mot Fig. 32-54 inserting rod cover (3)32, ATTACHMENT 32.21.55 (3) Install cushion on the extraction side, cushion bearing (13) and cushion seal (14) by the following procedure. 1) Put cushion seal (14) on it, directing the sii machined side toward the piston side. 2) Fit cushion bearing (13) on it directing the fiattening side as shown in Fig. 32-52 (2) When cushion is installed on the retraction side, fit cushion bearing (13) and cushion seal (14) by the following procedure, 41) Fit cushion bearing before fitting piston nut. The nut attached obstructs the fiting of cushion bearing 2) Putoushion seal onit, directing he slit machined side toward the piston side 3) Fit cushion bearing on it directing the flattening side as shown in Fig. 32-83, 4) Put stopperin the groove. Push cushion bearing to stopper fully, and drive snap ring. Use plastic mallet in order not to damage the rod, cushion bearing, AACAUTION Cushion seal and cushion bearing should be fitted taking care of the fiting direction. If they are fitted in reverse directions, the cushion does not effective. ‘After installing cushion, be sure that the cushion bearing moves up and down, and right and left ASSEMBLING PISTON ASSY ONTO PISTON ROD PISTON “FLAT SECTION Direct sit toward piston side Fig. 32-52 Cushion mechanism on extension side Direct slit toward thread side ans THREADED PART oer Pee YO — 0 N ‘SNAP Ri AP RING CUSHION SEAL CUSHION STOPPER (Sit trace) BEARING BEARING (Dice ino 2 portions) Fig, 32-53 Cushion mechanism on retraction side 32-2432, ATTACHMENT (2) Insert shim (20), and tighten piston nut (21) or [piston (15) tit gots tight Always tighten the piston nut (21) or [piston (18)] of ‘each piston to specified torque (Refer to 32.2.1.7.3) | ARCAUTION| + Incase thatpiston and piston nut are combined, the shim (20) is not used. Apply the eye wrench to hexagonal part of piston and loosen the piston directly, + Always correct the threads in piston nut (21) or {piston (15)] before fixing piston nut, using a tapping + Insufficient tightening torque causes an inner leak and a damage of thread. And over tightening torque causes @ bulge of cushion bearing and a deformation of piston contacted surface. + Clean and decrease (with solvent) the parts of piston assembly, and dry it, then tighten this piston assembly. (4) Put steel ball (23) into hole and tighten setscrew (22) mm Atter tightening the setsorew to @ specified torque, caulk the two places of the thread of the piston nut side to secure the setscrew. See para 92.2.1.7.3 for torque. (5) Altach two slide rings (18) and (19). Take off vinyl tape wound around the perimeter of piston (15), apply high-quality grease (or vaseline) to slide ring (18), (19) and attach the slide rings in a manner that they may be coiled around the groove. Set the slide rings about 180 degrees apart with each other so that the slits may not point to the same direction, 32-25 Fig. 32-54 Tightening piston nut (21) ANTLLOOSENING 22 CAULKING 20 23 24 a 2 |_—- vipLock Fig, 32-55 Attaching setscrew (22) [> vetock Fig. 32-56 Attaching slide ring (18), (19)32, ATTACHMENT 32.2.1.5.6 OVERALL ASSEMBLY (1) Place a V-block on a work bench (A wooden V- block is preferable.). Place the cylinder tube assy (1) on it and fix the assy by passing @ wooden bar through the clevis pin hole to lock the assy. Insert the piston rod assy into the cylinder tube assy, while lifting and moving the piston rod assy with 2 hoist. In this operation, apply hydraulic oil (or vaseline) to the inner surface of the tube mouth and the circumference of the piston. Align the center of the piston rod assy with the center of the cylinder tube assy and put it in straight forward. When inserting, make sure that slide rings (18), (19) on the perimeter of the piston is not out of the groove. (2) @ Tighten socket bolt (12). Match the bolt holes of the rod cover flange to the threaded holes in the cylinder assy, and screw in socket bolts (12) one by one. Tighten the bolts to 2 specified torque, taking care so the bolts may not be tightened unevenly See para. 32.2.1.7.3 for torque. 14mm Take care so as not to damage the rod surface by accidentally stip a wrench. Covering the rod surface with cloth is recommended to prevent damage to it ur STRAIGHT PREVENT TURNING Z WITH WOODEN BAR, Fig, 32-57 Inserting piston rod assy 12 PLACE CLOTH is a ‘ALLEN WRENCH “ f TURN CLOCKWISE Fig. 32-58 Tightening socket bolts (12) 32-2632.2.1.6 INSPECTION AFTER ASSEMBLY (1) No-load functional test Place the cylinder level at no load, operate the piston rod 5 to 6 strokes by the directional valve and make sure that it operates without failure, | AMCAUTION| + Do not raise the hydraulis pressure above the maximum pressure of 37.8MPa (5480psi) for the cylinder of the machine. + Grease coated on the O-rings and the seals of the rod cover may come out. Wipe it off and retest the cylinder in such a case. (2) Leak test 1) Apply a test pressure to the retracting and extending sides of the cylinder for three minutes: independently, and check thal the rod section and the welds have external leaks and permanent deformation. For an internal leak test, connect the cylinder with a test unit as shown in Fig. 32-60. 2) After completing the test, apply a plug to each port and store the cylinder. (Fig. 92-61) + For storage, place the cylinder on wooden V- biocks and bring the cylinder to the most retracted condition 32-27 32, ATTACHMENT DIRECTIONAL VALVE HYDRAULIC CYLINDER Fig. 32-59 External leak test MEASURE THE INTERNAL LEAK, “Sa, FROM DIRECTIONAL VALVE Fig, 32-60 internal loak test CYLINDER ASSY Fig. 32-61 How to store the cylinder32, ATTACHMENT 32.2.1.7 MAINTENANCE STANDARDS 322.1.7.4 INSPECTION AFTER DISASSEMBLY Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental to use are not present. (1) Inspection item Table32-2 Part Name Inspecting Section Inspection Item Remedy 1. Neck of rod pin Presence of crack Replace. 2. Weld on rod hub Presence of crack Replace. S Sepped oot Wet Ioesenecfrak epic. 4, Threads Presence of seizure Recondition or replace Measure degree of bend (See 5. Bend Fig 32.59) Refer to (Table32-3) Piston rod [6, Plated eurface (Check that 1) Plating Is not worn off to |1) Replace or replate base metal 12) Rust is not present on piating.|2) Replace or replate I) Scratches are not present, |°) Recondition, replete or replace. 7 Roe |Wear of O. ©. Recondition, replate or replace. 8 Bushing at mounting part_|Wear of |. Replace. 1. Weld on bottom Presence of crack Replace. [2. Weld on head Presence of crack Replace. Cylindertube |. Weld on hub Presence of crack Replace. 4. Tube interior Presence of damage Replace if oll leak is seen. '5. Bushing at mounting pert_|Wear on inner surlece Replace. +. Bushing 1) Wear on inner surface 1) See para. 32.2.1.7.2 Rod cover Bee ee eee 2) Replace if score is deeper than coating. (2) Repair method Check all seais and parts to see that they do not show excessive damage and wear, For correction af scores on the piston rod, observe the following procedure: 1) Correct very fine Iongitudinal soratches with an oilstone. Replace the piston rod if the soratch is so deep as may be caught by your nail 2) Incase of a smooth indention, recondition by removing the sharp area around the indention with an citstone. If the score o the indention is oxcessive, replace or replate the damaged part. + Aways regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in). + Incase plating is removed to the base metal during reconditioning with an oilstone, do not fail torepiate the surface. 32-2832. ATTACHMENT 92.2.1.7.2 LIMIT OF SERVICEABILITY Serviceabilty limits represent the limits of wear on the sliding surfaces of the cylinder tube and the rod that have no such damage as may degrade the sealing effect (1) Clearance between piston rod and rod bushing Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25mm, (0.01in). (2) Bend of piston rod The allowable bend of the rod is maximum trmm f ‘1m (0.04"/9'3"), For measurement, support both ends of the parallel section of the piston rod with V- blocks, set adial indicator in the center between the two Veblock tur the piston rod, and read the difference between the maximum and minimum deflection on the dial indicator. Table32-3 shows an example of measurement Fig. 32-62 Measuring Method ‘Table32-3 Example of Measurement Distance between | Dehection ofthe dial indicator Veblocks | Inmemiddecttherea. | Remedy nm Or | 4 1(00e) [Replace AXCAUTION! Even if the bend is within the above limit, the cylinder may not operate smoothly because of localized bend Beware of it during function test after assembly. Replace the rod if the cylinder makes a squeaking noise or dose not operate smoothly. 32.2.1.7.3 TIGHTENING TORQUE Unit :N-m (IbF ft) A B c cyl sneer TTS et | Socket bolt} Setscrew Boom | 5460 (4030) | 267 (200) | 56.9 (42) ‘Arm | 7890 (6820) | 967 (270) | 56.9 (42) Bucket | 6200 (4870) | 267 (200) | 56.9 (42) 32.21.74 VOLUME OF OIL LEAK The oll leak rates as mentioned in 1.6 (2) of inspection after Assembly are as shown in INSPECTION AFTER ASSEMBLY32.2.1.6 (2). Cyinder | Volume of nernal OF Leak Boom —[{;0co,0.06 cixn) or below / arin Arm 1.066 (0.06 cusin) or below / 3min "Bucket ]1.008 (006 eurin) or botow amin 32-2932. ATTACHMENT 32.2.1.8 TROUBLESHOOTING Table32-4 Trouble Failed Parts, ‘Cause Remedy 1. Oil leak through sliding (1, Back-up ring |. Foreign matters trapped inthe 1, Remove foreign matter. surface of piston rod. Oil bore of back-up ring fing is formed on piston 2. Lips on outer and inner diameter [2. Replace back-up ring, tod, and the ring grows up surfaces of back-up ring are to oil drops, and they drip, scored. 8. Other back-up ring are failed. __|3, Replace back-up ring 2. Usting 7. Foreign matter is trapped in the __|1.Remove foreign matter. OIL LEAKS FROM HERE bore of ring, 2 Score is prosent on the bore ofring.|2. Replace U-ring 13. Other rings are failed. 3. Replace U-ting [S. Buffer ring 1. Foreign matters trapped inthe |1. Remove foreign matter. bore of ring, '2, Score is present on the bore of ring |2. Replace buffer ring, [3. Other rings are faite. '3. Replace buffer ring |4. Wiper ting [1. Foreign matter is tappedin the |7,Remove foreign matter. bore of wiper ring 2. Lip on the bore of wiper ring is |2, Replace wiper ring, scored. 3. Another wiper ring is failed, 2. Replace wiper ring 5. Piston rod |1. Score is present on the sliding _|1.Smooth out he sliding surface with surface of piston rod anoilsione. ifleakage occurs even ifthe sliding surface is finished below 1.65, rod packings may be ‘scored. Disassemble andinspectit andl replace rod packings as required. IF teak will not stop by that treatment, replace piston rod, 2, Hard chromium plating has peeled |2. Replate. off 2, Oil leaks from the 4. O-ring 1. O-ting is damaged 1 Replace O-ring. Gitcumference of rod cover./2, Backup ring _|[1. Back-up ring is damaged. 1, Replace back-up ring, HO [* Cvindertuoe |. Sweting of ender tubo 1. Replace cylinder tube. OIL, LEAKS FROM HERE 3. Oil leaks from welds. 1. Cylinder tube |7. Welds of cylinder are broken. |. Replace cylinder tube. I I weLDs 4. Cylinder fais by itseft. |. Piston seal |1. Foreign matler'is tappedin the __[1. Remove foreign matter [When the rod is loaded with sliding surface of seal ring. a static load equal to the 2. Scores present onthe siding |. enlace seal rng maximum working pressure| surface of seal ring multiplied by the area of the 1 Stiding surface of slide rings i 2. Slide ri 1, Replace slide ring. cylinder bore, he maximum | 0° "9 scored. i 7 movement of the pistons [3, Piston rod __|1. Elongation.Piston rod and piston | 1. Replace pision rod more than 0.5mm (0.02") in are elongated, (Loose nut) fen minutes.) 32-3032, ATTACHMENT 32.249 JIGS LIST 92.21.91 SPECIAL JIG LIS’ sT (POSSIBLE TO SUPPLY) When assembling, the following jigs are required. Table32-5 Described Appltion i Shape paint A D For removing and press 32.2.1.3.4, fitting bushing EDsE OF c 32.2.1.5.2 cHuck | => Sad ? Fe ‘or press fiting wiper ee ring For correcting seat ring | 32.2.1.52 CORRECTING sic For inserting rod cover 32.21.54 For above jigs, contact our dealer. (The Jig No. List provides by eylin der maker is shown in the following page.) 32-3132, ATTACHMENT Special Jig No. List (1) For jigs for rod cover, select jig corresponding to respective rod diameter (2) For jigs for piston, select jig corresponding to the cylinder bore. Table32-6 Application rod diameter (mm) KitNo. of maker 6 3006-56001 70. 3007J-06001 75 30074-56001 80 '3008J-06001 eer 85 3008-56001 removing & instal =o uaa 95. 3008-56001 100) 3010-06001 105 '3010J-56001 110 3041-06001 115 3011-86001 120 3012-06001 Application cylinder bore (mm) KitNo, of maker 95 3009J-5100% 400) 3010-01001 105) 30104-51001 110 30110-01004 115 30110-51001 Jig for seal ring 120 3012-01001 inserting & 128, 3012J-51001 correcting 130) 3013J-01004 135, 3013J-5100% 140 3014J-0700% 145 3014J-51001 150) 30154-01001 160) '3016J-01001 170) 30170-01001 32-3232, ATTACHMENT 32.21.82 OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP) (1) Bushing removing jig (Symbol J) a QD (97) materia : Mia steet 501515 Unit : mm (inch) 38 GyinderUsed cz | Re [Fo 7 Bucket ! ee 10°) BS ‘Arm : al wet oJ Boom ae q é ee a i 1 Fig. 32-63 Bushing removing jig (2) Wrench for piston nut or {piston] Unit: mm (inch) 140 Arm 98 Boom Pe 95. Bucket Fig. 32-64 Wrench for piston nut or [piston] 32.3332, ATTACHMENT 32.2.1.9.3 SPECIAL JIG HANDLING PROCEDURE (1) How to remove bushing from rod cover. 1) Attaching chuck assy tool Insert too! in rod cover slowly until the edge top end of chuck assy teaches to the end of bushing (4). + Special attention must be paid so that the inner surface of rod cover is not damaged by the edge of tool * Attach top on the position Smm (0.2 in) from the bushing end face so that the edge does ot protrude from the end face. so.9r and Sine “| JicHucK 2) Tightening chuck assy tool temporarily a. Fitallen wrench to the head of adjuster bolt on the top end of tool, and insert lever in the round hole an the rear end of tool b. Fixit with allan wrench and lever to the position where the tool does not drop even if the rod cover is raised, inclining it forward and rearward. + Move rod cover onto the working bench holding tool attached, + Be careful not fo drop it on foots, ete. ALLEN WRENCH 32-343) Attaching tools for retainer Put retainer on the press bench directing the wiper ring fitting section of rod cover upward, then put retziner tool (D} on the rod cover. + Fitretainer too! as shown in the right figure directing large diameter section (flange section) upward + Clean the surface of press bench, and take cate for the tool bottom face not to be damaged by foreign matter like dust, chip, etc 4) Cutting into of the edge of chuck Press the upper section of retainer tool gradually 80 that the edge of chuok tool (A) cuts into the bushing surface. Set the pressing force to 2~8 tons (4410~6615 ibs). After completion of pressing, tighten adjuster bolt again by hand. + Press it with retainer tool (D). 32-35 32. ATTACHMENT FLANGE CHUCKING JIG A ad32. ATTACHMENT 5) Setting of tools for block Prepare block (C), and put rod cover (2) on it aligning them, Select corresponding block (C) in shape, dimensions, etc. from the table shown below. ia (wontalvze)) o b a5 207) | BEAD | SAL | WEL] 60230) (67 eee) | 86S 7; [BD 8) 265230" 722m) | 9605 7180.15 S70 (276) [-7Fe03)-| 100 (84) [60.1 975 (2.95) | 82 (3.23) | 110 (4.33) | 80 (3.15) 980 (8.18) | 87 (843) | 112 (4.41) | 803-19 5 (825) [02 62) | Tae 8) | 90 S00 (G54) | Br (ena) | tases | sols sh pos (7a) [ won eoey [as 7H) [a0 oa) tools) torte) |-1e6 BT wea TYRE Ce EE [atio asa) T4ir 61) 165 (0) [eo (658 ito (a3) | 427(ea0) | 470(6.09) | 90 (054) 16130 (6 1 | 4137639) 1 190,748) [00.1888 6) Removing of bushing a, Move block (C) and rod cover (3) with tool under the press, b, Press the upper part of retainer tool (D) slowly Until bushing (4) is take out from rod cover (3) (until there is a sound that the chuck tool (A) drops on the work bench) + The force of 3 tons (6615 Ibs or less) is necessary to press it out. The stroke of press ram is about 32-52mm, (7.26in~2,04in), (But it varies according to the difference of dimension of cylinder head.) + Press il with retainer tool (O}, When the block and rod cover assy are not aligned, interrupt the work and align the block and rod cover assy. 32-3632, ATTACHMENT 7) Removing of rod cover a, Remove block (C) with rad caver (3) near side, remove retainer tool (D) from rod cover (3), and then move rod cover (3) to other place. bi. Take out the chuck toot (A) with bushing from blook (C) (AA WARNING} Do not work under the press because it is very dangerous. 8) Removing of bushing a, Place chuck tool (A) with bushing (4) sideways, and loosen adjuster bolt with allen wrench and lever, b, Place the chuck tool (A) vertically and turn the adjuster by hand until the wedge is raised about Smm (0.2 in), c, Remove the wedge from the edge of chuck. *+ Clean the surface of work bench, and be careful for the tool not to be damaged by foreign matters like dust, chips, etc. 32-3732, ATTACHMENT 9) Tightening of adjuster bolt Tighten the chuck tool (A) the bushing (4) is removed to the extent that there is no gap between the chuck and the wedge upper face, turning the adjuster bolt by hand + This special tool differs according to the corresponding piston rod diameter. + The chuck edge is an important portion. Take care of handling and storage. 32-3832, ATTACHMENT (2) Red cover bushing press-fitting procedure 1) Temporary setting of head bushing Put rod cover (3) on the press-working bench directing the tube connection upward, Set bushing (4) on the inner surface of rod cover (3) temporarily + Make sure that the inner and outer surfaces of bushing (4) are free from foreign matter. 2) Setting chuck assy tool (A) Insert the chuck assy tool (A) in ternporary-set bushing (4) directing the flange downward, and set it on rod cover (3). + Be sure that the adjuster bolt is tightened to the extent that there is no gap between adjuster of chuck assy (A) and wedge. _ ADJUSTER BOLT Hk weoee 32-3932, ATTACHMENT 8) Attaching retainer tool Put retainer tool (D) on the wedge stepped section of chuck assy tool (A) slowly directing the flange upward. + Align chuck assy (A) and the wedge. 4) Preparation for press-fitting Move the rod cover on which chuck tool (A) and retainer tools are attached under the press. + Adjust itso that the press ram is centered to the tool. 32-40 PRESS RAM, RETAINER(D) CHUCK (A) BUSHING(S) BUSHING PRESS- FITTING PART32. ATTACHMENT 5) Press-ftting of bushing Push the head of retainer (D) with press, and press fit bushing (4) to the specified position of od cover (3) slowly, + The pressing force should be held 6 tons (11025 ibs) or less, keeping the required force for the press-fiting, + Raise the pressure gradually adjusting the force by means of pressure adjusting valve of press unit + Be sure that the end face of bushing is located ‘on the interior of the groave for snap ring When itis located on near plece, press fit and adjust the location again. UFTING THREAD / _ RETAINER JIG (0) BLOCK TOOL (c} Bushing removing and press fitting jig (For reference only} 32-4132. ATTACHMENT [MEMO] 32-4233. UPPER STRUCTURE ‘TABLE OF CONTENTS 33.1 OPERATOR SEAT a - Ett ne 33 33.4.1 OPERATOR SEAT. i bet eee 33.3 33.12 CAB i Seta : sn 33.1.3 BATTERY : : esenen B6 33.4.4 GUARD : : 33-7 33.1.5 UNDER COVER... im : a soe BAB 33.1.8 FUEL TANK al pee 33-44 33.1.7 HYDRAULIC TANK : 33-46 93.1.8 HYDRAULIC PUMP. ee 33-20 33.4.9 AIR CLEANER es - sn B25 831410 MUFFLER. ene aa eer 33.26 334.11 COUNTERWEIGHT. eons BRB 3.1.12 RADIATOR & OIL COOLER cnn nnsrnnnn 33.29 93.1.13 ENGINE es Sana prennrenter sean 3S 33.114 CONSOLE COVER . _ 83-38 33.1.15 MULTI CONTROL VALVE (Only for Oceania) 33-99 33.1.16 CONTROL VALVE : 5 33-40 33.1.17 PILOT VALVE (FOR ATT) se cnnsunone soe BBAB 33.118 PILOT VALVE (FOR TRAVEL) : a svn AM 33.119 SWING MOTOR UNIT. 33-48 38.1.20 SWIVEL JOINT. f : 33-48 33..21 UPPER FRAME. SE pees se 83-51 38.2 DISASSEMBLING AND ASSEMBLING. a severe B54 33.2.1 HYDRAULIC PUMP « REGULATOR. : ae e584 33.22 CONTROL VALVE 33-80 33.23 PILOT VALVE (ATT), ce 33411 33.2.4 PILOT VALVE (FOR TRAVEL) a - i 33-121 33.25 SWING MOTOR UNIT 7 cH 33-130 33.26 SWIVEL JOINT... oe 33-187 Book Code No. S5YN3318E01 33-133. UPPER STRUCTURE Issue Date of issue Applicable Machines Remarks SK200-8 : YN11-45007~ SSYNGO16E01 | First edit A fedora aust, 2098 | so10L6-8 - YOtt-06001~ ASIA, OCE) \ PREFACE (1) This Manual describes all the procedures from removing to installing, arranging them by item, (2) This Manual consists (Removing and installing), and [Disassembling and assembling} (3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of ‘actual repairing or time saving some process can be omitted, (4) The removing and installing procedure does not completely cover all possible situations because of differences of field condition and defective section. (5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize the work procedure, before starting work. (8) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component and wiring are performed. {7) The explanatory note and figure of this manual may differ from the actual machine by the difference in specification 33-233, UPPER STRUCTURE 33.1. OPERATOR SEAT 93.1.1 OPERATOR SEAT 33.1.1.1 REMOVAL (1) Preparation for removal 1) Remove the head rest (A1-1) of the operator's, seat (A1) to ease handling, 2) Move the whole control stand to its foremost position, 3) Mave the operator's seat to its forward end, 4) Incline the reclining seat as forward as possible. (2) Remove operator's seat. (Include upper rail.) 41) With the above-mentioned condition, remove two cap screws (B2) MBx20 from the upper rail Then move the control stand to its rearmost end and remove two capscrews (82) MBx20. ©: 6mm 2) Remove the operator's seal. [about 20kg (44 tbs) Carty out the following operations as required 3) Remove seat belt (C1) 4) Remove armrest (A3)(A4). 5) Remove bracket assy (1), rail (8). 33.1.1.2 INSTALLATION Install tin reverse procedure of removing according to the tightening torque table, Alen |Tightening torque Tightening position | wrench Towening oa ‘Capscrew (B2) 6 23 (17) ‘Sems bolt (62) 7 46.1 (34) ‘Sems bolt (A5,A6) [13 9.6 (7.1) Reference : Movement on rail Upper rail ...... Fixed on lower surface of seat [Forward 80mm (0.26in), backward 80mm (0.26in)] Lower rail ...... Fixed on seat stand. [Forward 60mm (0.19in), backward 60mm (0.19in)] Amount of adjustment of seat height [Up; 23mm (0.07in), down; 37mm (0.16in)] 33-3 Fig. 33-2 Disassembling and Assembling armrest33. UPPER STRUCTURE 33.4.2 CAB 33.1.2. REMOVAL (1) Remove floor mat (2) Remove cover (A7) Lift cover (A7) upwards and remove it. (Fixed with 2 clips) (3) Remove cover assy (At) 1) Loosen 4 sems bolts (A22) M6x16 and lft cover assy (At) up, 2) Disconnect each connector for both speakers. Then remove cover assy (A1). (4) Remove the harness connector (See Chapter 23) 1) Disconnect connectors of cab hamess (CN- 515), (CN-518), (CN-71} (CN-72) and (CN-500) at rear right of cab. 2) Disconnect antenna cable coming from backside of tuner at rear left of cab, (5) Remove the plastic tube for the window washer from the rear left of cab. (6) Remove the right panel of cab 1) Remove 2 caps (A29} loosen 2 sems bolts (A40) M6x2S and 1 sems bolt (A39) M616, And right panels (A4) and (A4-2) are freed, AED | TORK driver T30 2) Lift cover (A3) upwards and remove it. (Fixed with 3 clows and 2 clips) 3) Unfix 3 harness clips (A4-8) of inside on right panel (A4-2). And free the hamesses connected to key switch, 4) With hamesses are connected condition, install key switch cover (A3) to bracket (A1) of rear cab temporally. (See Fig, 33-5) 5) Disconnect hamess connectors of work light switch on right panel (A4), air conditioner pane! and cigarette lighter, and remove right panel (Ad) and (A4-2). (See Chapter 23) 6) Loosen sems bolts (A22) M6x16 and (A23) Méx<40 one each, and remove front panel (A5-2) with air conditioner duct 8 : Plus driver Fig, 33-3 Disassembly and assembly of cover (A7) and cover assy (At) Fig. 33-4 Disassembly and assembly of right panels (A4-2), (A3) and (A5-2) 33-433. UPPER STRUCTURE (7) Remove cab attaching bott 1) 5 capscrews (At) M12x65 and 1 capscrew (A3) M1230, (Mark A) 2) 2 nuts (B4) M16 (Mark ©) (8) Slinging cab 1) Remove two plastic plugs at the front of the ceiling of the cab. Then place a wire sling with eye rings and a hook around the cab, as shown in Fig. 33-7. 2) Then lft up stowly avoiding interference with Surroundings. Fig. 33-6 Removing and installing cab mounting Wire with hook ; bolts. Length 1.5m (4ft 41in)xDia, 8mm (0.318in)x3pes. Weight of cab ; Approx. 250kg (880 Ibs) 33.1.2.2 INSTALLATION install itn reverse order of removing according to the Tightening Torque Tabie. Tightening postion | wmeren | Tang rcee iio oe Nut M16 (B4) 24 [194 (140) Capscrew (A1)(A3) 49 79.4 (60 ems pot me (as9xaao)| FSOY" 8.56.9) Sems bolt M6 (A22\(A23) | Plus driver | 5.0 (3.7) Fig. 33-7 Slinging cab 33-539, UPPER STRUCTURE 33.1.3 BATTERY 331.34 REMOVING (1) Open left panel assy (21). 41) Open it with starter key, 2) Open left panel assy (21), 3) Fix it with stay. (2) Remove battery cover (1) and (2) Loosen nut (7) 10 and remove battery cover (1) and (2). But only Asia specification equips cover (1). re 7mm (3) Remove battery cable 1) Remove cable (/A4) [between the earth and battery (-)). (Always remove (-) terminal first and install it at last.) 2) Cable (A3) [between battery (+) and (-)) 3) Cable (A2) [between battery (+) and battery relay] atm AXCAUTION Follow the battery removal order. Start removing battery from grounding side, and finish attaching to grounding side. If this order is missed, short-circults may occur. (4) Remove battery (81) 4) Loosen 2 capscrews (4) M10x236. D7 0m 2) Remove plate (3). 3) Remove battery (81), 33.1.3.2 INSTALL (1) Install the battery in the reverse order of removing, Hold down plate (3) against battery (81), and tighten capscrew (4). D7 nm, Tightening torque : 10.8Nem (8.0 Ibftt (2) Installing grounding cable Install grounding cable (A4) last. Especially care must be taken that the grounding face is free from painting, rust, ete a tamm 33-6 TNS, Fig. 33-9 Removing and installing battery33, UPPER STRUCTURE 33.1.4 GUARD 331.41 PREPARATION FOR REMOVAL (1) Remove guard in the following procedure. Remove the guards in the order of (19}96)96) (7) 92) 921) 9123) 98)-9(4)-> (22) and (1) (2) All the locked cover, open them using starter key. 33.1.4.2 REMOVE GUARD (1) Remove bonnet assy (11) 1) Unlock catches (2) and unlatch catches (2), (3), and open bonnet (1). 2) Remove four nuts (7) M12, 3) Remove bonnet (11). BD som Weight : 37kg (82 Ibs) (2) Remove guard (5) 1) Remove 4 sems bolts (41a) M1225 on upper side. 2) Remove 3 sems bolts (41b) M1225 on the side. 3) Remove guard (6) BD somm ‘Weight :10kg (22 Ibs) 33-7 Fig. 33-12 Removing guard (5)33. UPPER STRUCTURE (3) Remove guard (6) and guard assy (3) 1) Remove 4 sems bolts (35) M1226, 2) Remove a sems bolt (418) M12x25. 3) Remove guard (6) 4) Remove a sems bott(41b) M1226. 5) Remove guard assy (3) D> som (4) Remove stay (7) 1) Remove 2 sems bolts (41) M1226. 2) Remove 2 sems bolts (43) M12x40, 3) Remove stay (7), D> somm (5) Remove guard (2) 1) Remove 2 sems bolts (41) M1228. 2) Remove connector for right side deck light, 3) Remove guard (2). Dom (6) Remove panel assy (21) 41) Unlock panel assy (21) 2) Remove 4 nuts (4) M10. 3) Remove panel assy (21), Dir mm Weight : 15kg (33 Ibs) 33-8 Fig. 33-14 Removeing stay (7) A 2 | 7 pea Hee Ze | —_ ee Fig, 33-15 Removing guard (2) Fig. 33-16 Removing panel assy (21)33, UPPER STRUCTURE (7) Remove panel assy (23) 1) Remove 4 nuts (4) M10, 2) Remove panel assy (23). Drm Weight : 10kg (22 tbs) (8) Remove panel assy (22) 41) Unlock and open panel assembly (22). 2) Remove 4 nuts (4) M10. 3) Remove panel assy (221 Drm ‘Weight : 18kg (33 Ibs) (9) Remove guard assy (16) and guard (14), (15). (17) 1) Remove 9 sems bolts (41) M1225 and a sems bolt (6A) M12x30 and guard assy (17), (15), (16). (14) in order. Oo Fig. 33-19 Removing guard assy (16) and guard (14), (45), (17). (10)Remove pillar (11) 4) Remove 4 sems boits (42) M12x30 and remove pillar. Ds 01 Fig. 33-20 Removing pillar (11) 33-939, UPPER STRUCTURE (11)Remove beam (4) 1) Loosen 6 sems bolts (41) M1226. 2) Remove beam (4) D somm Weight : 8kg (18 Ibs) (42)Remove pillar (10), (12) Remove battery relay box in advance and remove pillar (10). (See Chapter 23) 1} Loosen 2 sams bolts (42) M12x30, 2) Loosen 2 sems bolts (43) M12x40, 3) Loosen a sems bolt (51) M12x35. BD 19 mm 4) Remove pillar (10), (42). Weight : Pillar (10) : 12kg (26 Ibs) (13)Remove guard assy (18) and (13) 1) Loosen 4 capscrews (33) M1220, and remove guard assy (18). 2) Loosen 2 sems bolts (42) M1220, and remove guard assy (13). BD t9mm Weight : 12kg (26 ibs) (14)Remove guard (19) Loosen 6 sems bolts (41) M12x25, and remove guard (19). Fig. 33-23 Removing and installing of guard assy and guard 33-1033, UPPER STRUCTURE (15)Remove cover (2) 1) While air cleaner is removed, loosen hose clamp of engine intake and disconnect the hose. 2) Loosen 6 sems bolts (6) M1225, and remove cover (2) D som (16)Remove guard assy (1) Loosen 4 sems bolts (6) M12x25, and remove guard assy (1). BD s0 mm Weight : 20kg (44 Ibs) (17)Remove guard assy (3) Loosen 4 sems bolls (8) M12x25, and remove guard assy (3). SO Weight : 15kg (18)Remove piate (20) Loosen 3 sems bolts (41) M12x25, and remove plate (20), D9 ne Weight : 18kg (33 Ibs) 33-11 Fig. 33-24 Removing and installing of cover and guard assy Fig. 33-25 Removing and installing of plate (20)93, UPPER STRUCTURE (18)Remove cover assy (1) 1) Unlock the lacks and open cover (1-2). 2} Remove 4 soms bolts (41) M12x25 3) Remove cover assy (1) D 5m Weight : 30kg (20)Remove other brackets, as required 33.4.3 INSTALLATION (1) Installing is done in the reverse order of removing, (2) Tightening torque Unit Nem (loft) Size | Capscrew ‘Sems bolt Ma = 235 (17.3) M10 46.1 (34.0) Miz 124 (90) 79.4 (58.8) 1. 33-26 Remove cover assy (1) 33-4233, UPPER STRUCTURE 33.1.5 UNDER COVER 33.1.5.1. REMOVAL, (1) Remove under cover (1,2,3.4,5, 8) 4) Remove attaching sems bolts (9) M12x30 and (10) M12%26. 2) Remove covers. D 19mm Fig, 33-27 Under cover assy 3315.2 INSTALLATION (1) Install under cover (1,2,3,4,5,8,7,8) D 90m Tightening torque : 79.4 Nem (60 Ibft) 33-1333. UPPER STRUCTURE 33.1.6 FUEL TANK 33.1.6.1. PREPARATION FOR REMOVAL (1) Draining fuel. (See Fig. 33-29) 11) Unlock cap (82) with a starter key and open it 2) Loosen valve (A8) under the tank. 3) Draining fuel Capacity of tank : 367L (97gal) (2) Remove stay (7) and guard (2). (See 33.1.4 GUARD) (3) Remove the connector for level sensor (A4), (See Fig, 33-29) (4) Remove fue! hose 1) Loosen clip (16),(23) and draw aut hoses (24) and (7), 2) Put in plugs that match the hose bore. 33.1.6.2 REMOVAL (1) Remove 4 capscrews (A1) M16x40. D240 (2) Hook the wire tothe lifting eye on the fuel tank assy (C1) and remove the fuel tank. Weight : 102kg (228 tbs) (3) Remove shim (43). ce) Record the shim locations. 33-14 Fig, 33-28 Removing fuel hose (7), (24) Fig. 33-29 Removing fuel tank33, UPPER STRUCTURE, 33.1.6.3 INSTALLATION (1) Installing is done in the reverse order of removing, ‘Tank attaching bolt (A1) M1640 BD 24 ro, appiy Losite #262 Tightoning torque : 191 Nem (140 thf) ACAUTION If the gap (looseness) between tank mount and frame exceeds 1mm (0.04inch), adjust the gap with shim (A3) and tighten capscrew (A1) to install the tank (2) Tightening torque i Name [ary [Fenenng ore AM [Capscrew [a | 194 (140) 6 [Machine screw 5 1.96 (1.4) ‘AB [Cock 1 34 (25) 33-1533. UPPER STRUCTURE 33.1.7 HYDRAULIC TANK 33.1.7... PREPARATION FOR REMOVAL (1) Remove panel assy (2), guard (6) and other guards necessary to remove the hydraulic oil tank. (See 33.1.4 GUARD.) (2) Release internal pressure of tank Remove cap on air breather and push valve (head of bolt) by your finger. _-Air breather Element No. ‘YN57v000048002 AXCAUTION| Keep pressing until the hissing stops. (2) Remove cover (C2). 1) Remove 6 sems bolts (C5) M1025. Dir com 2) Remove cover (C2). 3) Remove suction strainer (B2). (4) Remove cover (C3). 1) Remove 6 capscrews (C5) M102, Drm 2) Remove cover (C3). 3) Remove filter element (B6). (5) Turn the handle of element assy (B), and disassemble the removed filter element (86). Disassemble parts : (8), (C), (D2, (E), (F) (6) Draining hydraulic oil Place pump in tank and draw up hydraulic oil Capacity of tank : 146 L (39gal) Fig, 33-32 Remove cover (C2), (C3) 33-1633. UPPER STRUCTURE 33.1.7.2 REMOVAL (1) Draw cut the suction hose (A3) Remove 2 clips (419) of the tank side and pull out hose (A3}, 89 2 : Fiat-biade screwdriver (2) Disconnesting the main pipe return hose Remove sems bolt (15) M&x35 and remove return hose (3), a tz mm (3) Remove drain hose (6) of pump a 36mm (4) Remove drain hose (9) of swing motor a ormm (6) Disconnecting pilot return hose 1} Remove pilot hose (A1). ae 22mm 2} Remove pilot hose (A10}. a 22mm 3) Remove pilot hose (A13} ae 22mm (6) Remove drain hose (2} of pilot pump a 22mm Atinstaling suction hose, a3: apply PERMATEX to the inner ond of both hoses. A12 Fig, 33-33 Removing and installing the suction hose He & Fig, 33-34 Removing main piping return hose Fi Fig, 33-36 Removing pump drain hose 33-1733. UPPER STRUCTURE (7) Remove hydraulic tank attaching bolt Remove 4 capscrews (A1) M16x40, a (8) Slinging hydraulic oil tank Place a wire sling, using the lifting plate on top of the tank. Tank weight : Approx : 140kg (310 Ibs) (9) Remove shim (A3). (CNote) Record the shim locations, 33.1.7.3 INSTALLATION (1) Cleaning hydraulic oil tank (2) Cleaning suction hose (3) Cleaning mount of tank, Installing is done in the reverse order of removing (4) Install 4 mounting capscrews (A1) M16x40 with Loctite #262. (See Fig. 33-37.) (DD 24 mm, Apply Loctite # 262 Tightening torque : 191 Nem (40 Ib) |AACAUTION Ifthe gap (looseness) between tank mount and frame ‘exceeds 1mm (0.04inch), adjust the gap with shim (A) and tighten capscrew (/A1) to install the tank 33-18 Fig, 33-37 Removing hydraulic tank33, UPPER STRUCTURE (5) Connection of suction hose (A3)(See Fig. 33-33) 1) Apply PERMATEX on pipe side of hose connection and insert It. 2) Put the hose with clip (A19) Tightening torque : 5.39 Nem (4.0 Ibfft) (6) Assembling return element Assemble filter element by the use of element kit (8-100). (See Fig. 93-32,Fig. 33-38) Note 4. Two elements (D) are used as one set 2, Replace O-ring (C) and packing (F) with new ones respectively. (7) Install return element. (See Fig, 33-32) (8) Installing suction strainer (B2) (2) Tighten sems bolts (C5) M1028 that attach tank covers (C2), (C3) M10 Tightening torque : 46.1 Nem (34 tbfett) |AXCAUTION| Replace O-ring fitted on the back side of tank cover with new one, B2 SUCTION STRAINER, ‘Ywsovo0004F7 _| Fig. 93-38 33-19 O-RING ELEMENT KIT (@-100) YNS2V01008R100 ( | | i |__@ S&S Element & suction strainer93. UPPER STRUCTURE 334.8 HYDRAULIC PUMP 3.1.8.1 PREPARATION FOR REMOVAL (1) Release pressure in hydraulic oll tank (See 83.1.7HYDRAULIC TANK) (2) Remove six capscrews (C5) M10x26. (3) Remove cover (C2) D7 mm (4) Take out suction strainer. (6) Install suction stopper. For suction stopper, see chapter 11. Tools, (6) Remove guards 11) Remove bonnet assy (1) 2) Remove guard (5), (14), (18), (17) and guard assy (16) 3) Remove those parts that are required to remove the hydraulic pump such as the fuel filter assy. 4) Remove drain hose at the bottom of the muffler. 33-20 = ce? a if co Fig. 33-40 Removing guards33. UPPER STRUCTURE 33.1.8.2 REMOVAL (1) Loosen sems bolts (13) M12x40 and remove half ‘lamp (A10). And disconnect 2 hoses (A1), (A2) from the delivery side. arm (2) Remove pilot pump suetion hose (1) (See Fig, 33-42) ae. 36 mm (3) Remove suction hose (AS) and drain hose (6) 41) Remove 4 capscrews (B2) M12x30 © 10mm 2) Remove elbow (B1) of suction hose (3) from pump. 3) Remove drain hose (8) (Dr). X36 mm (4) Removing other hoses 1) Disconnect hoses of the following ports. Port | HPS? -pant-Too! Remarks ps | 2 | 22 Drain ). (15)Bleed air in pump Bleed air by loosening the drain port (Dr). (16)Check nycraulic ot fevel (17)Start engine and check it for oil leak and noise. (18)Attach drain down pipe under engine mufter. (19)Install guards (See Fig. $3-40,Fig. 33-19) Tightening position |e Tool |Tishtening torque mm | Nem (orf) Fig. 33-46 Bleed air port (Dr) in pump Sams bolt Mi2 19 79.4 (59) 33-2499. UPPER STRUCTURE 33.1.9 AIR CLEANER 33.9.1 PREPARATION FOR REMOVAL {1) Opening bonnet assy (24) and (23) (See 33.1.4 GUARD) (2) Open bonnet assy (11). (See 83.1.4 GUARD) (3) Remove Panel assy (3). (See 33.1.4 GUARD) (4) Unplug terminals on indicator (1-8) wiring, (Soe Fig, 33-48) 33.1.9.2 REMOVAL (1) Pulling out hose (3). 41) Loosen clias (5), (6) on both sides of hose (3). 2) Pulling out hose (3) © : Flatbiade screw driver {2) Remove air cleaner assy (1) 1) Remove 4 sems bolts (8) M1025 D7 mm 2) Remove air cleaner assy (1) from plate (4). 93.1.9.3 INSTALLATION (1) Instaling is the reverse order of removing with attention paid to the following items: 1) Put in air hoses (2), (3) to the end as shown in Fig. 33-48. 2) Tightening torque No. | Name | Tightening torque Nem (ibf-ft) 1-8 | Indicator 3.929) “8 [Sems bot _ [39.2 (29) (Apply Loctite #262) 5,6,7 | Clip 5.9 (44) Inge with of hse 33-25 Engine se hose Fig, 33-48 Removing air cleaner at & = O RING (1-6) (YN11P000298006) FILTER ELEMENT (1-3) (YN11P000298003) FILTER ELEMENT (1-2) (YN11P000298002)93, UPPER STRUCTURE 331.10 MUFFLER 33.1101 PREPARATION FOR REMOVAL, (2) ve bonnet assy (11) and guard (5). 7 (2) Remove panel assy (22). (3) Remove guard (14), (15), (17) and guard assy (16). (See Fig. 33-19) Fig, 33-49 Preparation for removal 33.1.10.2 REMOVAL (4) Remove U bolt (4). 1) Remove 4 nuts (10) M& D som 2) Remove 2 U bolts (4) (2) Remove clamp assy (5) 1) Remove 2 capscrews (9) M10x35 D7 m 2) Separate clamp assy (5) from muffler (1). (3) Removing other parts Remove brackets (2) as necessary. BD om ‘Teron tne be soem Si-7206% “igen ra (13 hero gape Pare Bemen sea! owe “2119 {\ 10mm (0.4 in) frome | \\ _,melip trmiest 5 i ) AM ie { Procedure of a fasienng Ubot —_Instaling lamp side (6) Fig, 33-50 Removing and installing the muffler 33-2633. UPPER STRUCTURE 33.1.10.3 INSTALLATION Installing is the reverse order of removing with attention paid to the following items: (1) Procedure of fastening U bolt (4) (See Fig. 33-50) 41) Tighten 4 nuts (A) till there is no space and make sure that the dimension C is even all around. 2) Tighten nuts (A) to specified torque and confirm the C dimensions on the right and left once again 3) Tighten nuts (B) to specified torque and make sure that U bolts are not inclined 4) Tightening torque Nut A : 8.8 Nem (6.5 Ibft) Nut B 10.8 Nem (8.0 Ibi) (2) installing clamp assy (5) 1) Place the end of clamp (5) 10mm (0.40in) away from the tip of the muffler slit so the joint of clamp does not extend over the sii in the muffler. (See Fig. 33-50) 2) Install the clamp assy (5) in the illustrated direction (3) Tightening torque No. | Name | Tightening torque N-m (ibtft) 8 [Sems boit | 108 (80) (Apply Loctite #262) (4) Replacing parts Name Part No. Muffler (1) ‘YN12P00041P1 i 33-2733, UPPER STRUCTURE 33.411 COUNTERWEIGHT 331.111 PREPARATION FOR REMOVAL Remove plug (AS) on the counterweight and attach 2 M36 eye bolts (See chapter 11) to the counterweight. ae 55mm 33.4.11.2 REMOVAL (1) Lifting up counterweight temporarily Hook wire rope to slinging jig, and lif it and stretch wire rope to the degree where itis providing no slack temporarily. Weight of counterweight ; Approx. 4,020kg (8,860 lb) Wire more than 316 (0.63 inch) ; 4.5m (Sit}x2 pos. (2) Removing counterweight 1) Remove 4 capscrews (A1) M27x355, D 44mm 2) Remove shin (Ad), (AS), (AB). (Select) 3) Remove counterweight (C1) Fig, 33-82 Removing counterweight 93.4.11.3 INSTALLATION (1) Install counterweight in the reverse order of removing. (2) install shim (A4), (A5), (AB) as it was. (select) (3) Slinging counterweight ‘Check that the attaching bolts can be screwed in by hand. (4) Apply Loctite #262 on capscrews (A1), and tighten them with washers (A2) D4 con Tightening torque : 1270 Nem (940 lett) (5) Remove slinging tools, and attach plugs (A3). At a2” Fig. 33-53 Fastening the counterweight attaching capscrew 33-2833, UPPER STRUCTURE 331.12 RADIATOR & Ol COOLER 33.1121 PREPARATION FOR REMOVAL (1) Bleed air from the hydraulic tank and install the suction stopper.(See 33.1.7 and 23.1.8) (2) Remove bonnet assy (11) (See 83.1.4 GUARD) (3) Remove battery (See 33.1.3 BATTERY) (4) Remove beam (4). (See 33.1.4 GUARD) (5) Open panel assy (21). (See 33.1.4 GUARD) (6) Removing under cover installed on lower side of a radiator. tb 1) Remove 2 sems bolts (10) M12x25. Fig, 39-54 Removing under cover (4) 2) Remove cover (4), Ds 0mm (7) Drain down of radiator Put container 481 (4.8gal) under drain valve hose for draining water. [Water capacity of radiator : 5.5L (1.5gal)) (8) Remove hose from radiator sub tank (1) Remove clip of radiator cap side and disconnect hose (8). AACAUTION Do not loosen the joints of the hoses related to the ai conditioner. Otherwise the refrigerant leaks. (9) Move air-conditioner condenser and receiver tank 1) Loosen 2 sems bolts (23) M8»25 and 2 sems bolts (6) M10x26. BD t5mm 17 mm 2) Move @ set of air-conditioner condenser and receiver tank. (10)Disconnect connector of coolant level switch (B5). Fig, 28-57) Pies (See Fig, 33-57) Veneta die al! } agen aL | Fig, 33-56 Moving condensers and receiver tank 33-2933. UPPER STRUCTURE 33.1122 REMOVAL (1) Remove radiator stay (A1) 1} Remove a sems bolt (A2) M12x35 and 3 sems, bolts (A3) M1230. aH 19mm 2) Remove 2 stays (A) (2) Remove water hose (2),(3) 1) Loosen the hose bands (30) for water hose (2. AED Fiat blade screwdriver 2) Remove hose (2) 3) Loosen hose band (30) on water hose (3) and remove capscrew (22) M10x26. ED: Flat-blade screwdriver a atm 4) Remove hose (3). (8) Remove hoses (4)(5) for inter-cooler 1) Remove two fixing U-bolts (17) from tube (11). a 43mm 2) Loosen sems bolt (21) M1020. a 7mm 3) Loosen hose bands (30}, (31) and remove hose (4), HD Flat blade screwdriver 4) Loosen hose bands (30) and remove hose (6). ED Fat biade screwdriver 5) Loosen hose bands (31) and remove hose (5). ——*89) - Flat-blade screwdriver (4) Remove guard (12), (13) (See Fig. 33-55) 41) Remove 4 sems bolts M8x20, 2) Remove guard (12), (13). ae iam Fig. 33-88 Removing hose for radiator/inter-cooler 33-3033. UPPER STRUCTURE (5) Disconnecting hysraulic oll hose (1), (2) 1) Loosen 2 capscrews (16) M12x58 for attaching clamp (13). 2) Place an oll pan under the hose joint. Loosen 4 ssems bolts (15) M12x35, and remove hoses (1) and (2). (6) Remove radiator assy. (See Fig. 33-57) 1) Remove 4 sems bolts M12%25, Ce 19mm, BD so0m 2) When lifting the engine fan, shift the radiator so It does not interfere with the engine fan. 3) Plug up pipe ends with clean cloth, ete. 4) Removing radiator Place a wire sling in the lifting eyes of the radiator assy and remove the assy by crane. Weight : 92kg (203 Ibs) 33-31 Fig, 33-59 Removing hydraulic oil hose (1), (2)33. UPPER STRUCTURE 33.1.12.3 INSTALLATION (1) Installing is done in the reverse order of removing, ‘And removed clips of hose should be clamped at criginat position (2) instal radiator assy Place a wire sling in the fifting eyes of the radiator ‘and move it to original position temporally. And install hydraulic hose, radiator hose end hose of inter-cooler. Regarding Inserting widtn of hose. (See Fig. 33-60) (3) Radiator attaching bott Apply Loctite #262 on 4 semsbolts (A2) M12x35, D tem Tightening torque: 121 Nem (89 Ibfft) (4) Adjust the clearance between the fan and the radiator shroud all around the circumference, as below Circumferential direction: 2085mm (0.8in40.2in) 3986mm (1.5in#0.2in) (5) Clean the plastering area of the insulation thoroughly before plastering it. (6) Making up hydraulic oll and LLC (Long Lite Coolant) After completion of other installation, make up hydrautic oll and water. Coolant volume of engine body : 9 L (2.4gal) Coolant capacity of radiator : 5.5 L (1.5gal) Hydraulic cil capacity of oil cooler : 2.4 L (0.63gal) 33-32 lesa mith othe “cup. ‘eravo SON % si) cup SBR cae Fig. 33-60 Inserting width of hose ‘Agus the engine tan — folie roar ond sick fut 36mm (18. fom the edt shroud, Fig, 33-61 Back-and-forth adjusting position of radiator33. UPPER STRUCTURE 33.1.12.4 (1) Preparation for disassembly and assembly 1) Remove one under cover at the bottom of the radiator. 2) Wait till the engine coolant cools down so you do not get burned. Then remove the cap of the radiator, discharge the coolant by opening the drain valve located at the back bottom and receive it in a container. * In case of removing inter cooler only, the above mentioned work is not necessary. (2) Disassembly 1) Loosen each 2 bolts (30), (37) at head and bottom of shroud, remove upper plate (27) and lower plate (28), 2) Disconnect wiring connector of radiator coolant level switch. 3) Loosen 4 sems bolts (8) M820 attaching plate assy (10), remove plate assy (10). 4) Loosen 2 capsorews (15) M10x20 attaching radiator core. 5) After confirming that the coolant has been drained out completely, loosen and remove only the radiator side of hose bands (30) at the top and bottom of the radiator. (See Fig. 33-58) 6) Lift and remove radiator core using liting eyos and hoist on the radiator core. Weight : 10kg (22Ibs) Confirm the missing of rubber bushing (14) Under the radiator core. 7) Loosen 2 capscrews (15) M10x30 attaching the top of the inter-cooler core. 8) Loosen and remove only the inter-cooler side of hose bands (31) at the top and bottom of the inter-cooler. (See Fig. 33-58) 9) Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler. Confirm the missing of rubber bushing (14) Under the inter-cooler. 33-33 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE 1 «18 16 16 Ls ‘ Lif va i Tightening torque a7 Baan INTERCOOLER 10 (17a) L [ j Detail of radiator care mounting part vIEwA Fig. 33-62 Removing radiator and inter-cooler