KOBELCO Dame SK200-6 * SK230-6 - SK320-6 TRAINING TEXT Model Code Serial number $K200-6 YN YNO7-30001 ~ $K230-6 La | La0s-o4801 ~ | sKazo8 | “LO ~T Lc06-05801 ~ 1999.09 KE © Book code No. S6YOOO114ZE02 1088.07 KE ©CONTENTS 1, SPECIFICATIONS 1-1 Specifications + 1-2 Engine 2. DRIVING UNITS 1 Layout of driving unit 2 Explanation of driving units 3 Switch panel and New functions 4° Others stesso 216 224 3. INSPECTION AND ADJUSTMENT Priority of warning display and self diagnosis display 34 Multidisplay self diagnosis 1 2 3 Trouble history diagnosis *+-+-+++++-+ 4 Service diagnosis «vr-vsrssrsseeseseen -5 Checking oil level of hydraulic tank and making up oil 6 Releasing internal pressure of hydraulic tank and system 7 Adjusting tension of belt -++++++ 8 Adjusting tension of air-con belt 9 Performance test -10 Performance inspection standard 11 Adjustment and Inspection of electrical equipment 12 Mechatro controller “A” adjustment -- 4, COMPONENTS AND CIRCUIT DIAGRAM Layout of Hydraulic Components -- Hydraulic diagram of Main control valve Hydraulic diagram +++ 1 42 4-3 4-4 Layout of Blectric components «sss 4-5 Mechatro controller -» 4-11 4-6 Gauge cluster 4-15 4-7 Wire colors and types of wiring harness +--+» ve dG 4-8 Electric equipment +--+ see - 4-17 4-9 Electric circuit diagram -+++ sessseemssnennneenseeenes Ae 5. MECHATRO SYSTEM Outline of Mechatro system Operation Units List when controlling every operation Outline of pumping control Outline of Boom raise conflux «+++ Arm in & Sequence conflux control Arm in anti-cavitation control « Outline of Arm out conflux (SK200-6+*SK230-6) Outline of Arm out conflux (SK320-6) ~ Outline of Bucket digging system (SK200-6+SK230-6)5-10 Outline of Bucket conflux system (SK820-6) vrs 517 5-11 Arm in Swing priority control +--+ 5-19 5-21 5-12. Travel straight system control 6. HYDRAULIC CIRCUIT DIAGRM IN OPTION 6-1 Breaker - 6-2 Nibbler & Breaker 7. HYDRAULIC COMPONENTS Hydraulic pump Main control valve 1 2 3 Explanation of control valve operation « 4 Swing motor +++ '-5 Travel motor 6 7 8 9 Cushioning Mechanism of Cylinder Pilot valve (For ATT) srvsessssesesseeeseeseeeee Pilot valve (For travel) Swivel joint 7-10 Solenoid/Proportional valve block 8. ELECTRIC EQUIPMENTS Engine speed sensor 8-1 8-2 Governor motor 8-3 Construction of proportional valve 8-4 Construction of solenoid valve 8-5 Pressure sensor 8-6 Potentiometer (For accel dial) 8-7 Engine coolant temperature sensor APPENDIX Conversion Tables ~1, SPECIFICATIONS 1-1 Specifications @ Performances Item $K200-6 $K230-6 $K320-6 ‘Standard bucket capacity Stender bucket coed m] 080/059 | 1.0/0.78 14/10 ‘Swing speed min” {rpm} 11 {11} —_— 9.1 {9.1} “Travel seed (ist 72nd) km/h | _40760 — 34/58 Gradeabilty % (cegree)| 70 (35) 135/146 166/172 a Digging force (Bucket) KN (k&t1 | 13,8007 16,2001 | (16.900 / 17.500) |{22.500/24.700} a 97.1/107 113/125 162/179 Digzing force (Arm) FN (8 9,900 / 10,9001 | (11.500 12,700} | {16.500 18,2001 Minimum swing radius (ATT) mn] 3560 3.880 4.200 © Dimensions Overall length mn [9410 10.080 11200" Overall width mm 2,800 2,990 | 3.200 Overall eight mm | 2.980 3.060 3.360 Ground clearance mn 450 500 @ Weights Complete machine re] 10400 73.600 32,000, @ Engine Model MITSUBISHI MITSUBISHI MITSUBISHI 6D34-TE1 6D34-TLE1 6D16-TLE1 4-oycle, water cooled ‘Type 6-cylinders, Direct injection __ type Diesel engine _|(With inter-cooler)|_<———— Number of oyl. — Bore x Stroke man | 6-104 x 115 6-118 x 118 Total displacement co 5,861 7,545 =i 107/2.000 | 12572100 | 17772200 Rated output/Speed RN min" 1PS/romiT 145/72,0001_|_1170/2.1001_|_1240/2:2001 Te 5197 Acprox.,600 | 590/Approx.1,00 | 824/ Acorox.1,800 Max torque//Speed _N-m/min™ {kef-m/rEm) | 3 approx .600 | (60/Aprox..6001 | (84/ Approx. 800} @ Hydraulic components Pump (Main) Varieble displacement axial piston wat tort Diasing creat 343/87. (360/385) pressure of system = * MPa Tket/om) | Travel circuit [343 (350) | ‘Swing circu | 2791265) | 2.41300) | 275 12801 Swing motor Axial piston type Travel motor 2 speed variable axial piston type @ Capacity Hydraulic tark7System C1667 246 | 1667260 | 2067351 Fuel tank u 340 — 6601-2. Engine TEM MODEL[ _SK200-6 2306 SKE MITSUBISHT | MITSUBISHI | MITSUBISHI Engine model e034-Te] | 6034-TLET | SDi6-TLEI Diesel engine | Diesel engine | Diesel engine ‘oe. war cooled, direct Type injection type with turbo charger (With inter-cooler))_-——— Cylinder No. — Bore % Stroke mm | 6-104 x 115 8-118 x 115 Total displacement o 5661 — 7.545 Compression ratio 165 182 1715 - i 1073/2000 | 126"72.100 | 17758 72.200 Output rating Kewv/min" {PS/rom) | sa52.000) | (170*72.100) | (240'%/2,2001 Eytan 519/7,600 | 590/7,600 | 824/1,800 Dae) Nemymin” tkef-m/rem} | 6377,800) | {60/1,800)_|_184/7,800) High idling (at no load) min {rom} | 2.220 (2,200) | 2,300 12,300)_| 2,386 12,385) Low idling min trom} | opp Maal Tenition order 1-6-3-6-2-4 [| ——— —— Rotating direction ey — 600 ~ Suction | 620 — Suction Cooling fan drive method om lees | ng Qblades | ___ Pauley ratio = 1.00|Pulley ratio = 0.9 Starter capacity V7Rw [24760 — 24735 Alternator capacity V/A | Batt ive, Belt drive, Belt arive, Pulley ratio = "1.88 Pulley ratio = 2.00| Pulley ratio = 1.87 16/85 | 160/080 | 168/090 “Allowable tilting angles (Front, Rear, Left, Right) ak * Engine oll volume (Oil pan capacity) Max / Min (Oil filter etc.) L [187185 (4) |< ~_ | 2872814) Coolant volume (Engine only) L 95 18 ate ceraoi] Open Close __[Open|Ciose| TW before the [63 ater the bot Valve clearance, degree | Intake valve | Incold | top dead point | tom dead point | 27 | 39 valve action timing ceonition SP ae or om oe it Exhaust valve | 0.4mm. tec ovat top cd pore| 82 | 18 botiom dead point too dead point Injection timing cegree | Tb betorethe | 17 before the | 14 before the top dead point _| top dead point _| top dead point Injection start pressure MPa kei7om®) [21.6 (220) 7.71180) Compression pressure MPa {kgf/cm} ae ee —. Thermostat action KECI| Opening : 34955 (76.5), Full oan : 363 190) Fuel consumption rate 7 ; (at rated rb) B/kW-h {e/PS-h} | 222 (163) 222 (163) 2207 (167) Engine oil consumption ee c/n (g/m) | 58.6 (61) 66.4 (60) 96 (88) Engine dimension (Lx Wx H) mmm_[1,166% 725% 901| 1.180% 851 x 604| 1,921 x 799% 091 Dry weight kg 410 480 580 1-202. DRIVING UNITS 2-1 Layout of driving unit Note : Control levers are ISO pattern in this section. 4 7 5 6 8 9 a 20 1. Air-con switches 13, Engine emergency stop knob Note 2. Left switch panel 14, Switch panel (workmode The switch in option is in- (For option switches) select & buzzer stop switches) stalled in different po 3, Safety lock lever 18, Accel dial according to the specifica- 4, Left control lever 16. Right switch panel tons. Before ae make (with horn switch) (wiper, washer, working light) Certain the specification o & Left travel ki eae switch installed on machine, ett travel lever - Starter switel The following types of switch 6. Right travel lever (with 18, Radio are provided. travel speed select switch) 4g SS Te 1. Engine control cable 7. Left travel pedal 20. Swing parking brake release switch 8. Right travel pedal ‘switch © High-reach crane switch 9, Gauge cluster 21, KPSS work mode release —_® Swing flasher switch 10. Right control lever switch ‘© Roof wiper switch (with ATT boost switch) 22, Operator seat © OPT. work light switch 11. Ashtray 23, Warm-up switch © Travel alarm switch 12, Cigar lighter2-2 Explanation of driving units oo 1 Bg ng i |) AME xa 1, Air-con Control Switch 2. Left Switch Panel (For installation of switch in option) Note : The explanation of marks 1 and 2 is given in Operator's Manual. 3. Safety lock lever ‘The left control stand is equipped with a safety lock lever (3) in order to keep the ma- chine from moving even if your body touches the control lever while getting on and off. Hydraulic function, Locking Shift all the control levers to “Neutral” position, pull up the safety lock lever (3) on the left side of seat back to “LOCK” psition, and all hydraulic fune- tions are cut. Keep the lever to “LOCK” posi- tion when not in service. Hydraulic function, Unlocking Push the lever down forward to “UNLOCK” position, and buzzer sounds for 1 second intermittently, at the same time, timer relay ex- cites the lever lock solenoid valve second later, and consequently the lock of hydraulic function is released enabling the machine to be operated. Note : The reason why delay timer is installed is to prevent the machine from actuating immediately after the control lever is touched when pushing down the safety lock lever. ; SID Wl —= Unlocking positon4,10, Control lever (ISO pattern) Control lever pattern PG © Before beginning works, operate each lever slowly taking care of the surround- ing safety, and make certain that the ac- tual operation of mac ye accords with operation pattern shown on label. © The operation of machine in an unauthor- ized manner may cause a severe accident resulting in injury or death. 4, Slewing and arm control lever 4-1 Horn switch Left control lever ] grip upper section, ing 10, Bucket and boom control lever 10-1 Attachment pressure boost switch _ [Raa control lever ] grip upper section \¢ Bucket digging 2D Horn sounds while the switch on the grip upper section is pressed, and when the switch is released the horn stops sounding. 4, Slewing and arm control lever (Left contro! lever) Slewing operation Slewing left Push down left control lever “Leftward”, Push down left control lever “Rightward”. Return left control lever to “Neutral” position. Slewing right Stop Arm operation Arm out Push down left control lever “Forward”, Pull down left control lever “Your side”. Return left control lever to “Neutral” position. Supplementary explanation Arm in Stop When strong power is required to remove the bounding stone or to dig rock-beds, etc,, press the switch on the grip upper section, and the machine provides the strong digging force. Note : Use when long arm is attached is not al- lowed. 10. Bucket and boom operation (Right contro! lever) Bucket operation Bucket digging -- Push down right control lever “Leftward”. Push down right control lever “Rightward”. * Return right control lever to “Neutral” position. Bucket dumping --- Stop Boom operation Boom lower "+--+ Push down right control lever “Forward”. Boom raise Pull down right control lever *Your side” Stop Return right control lever to “Neutral” position. The standard control lever pattern is ISO form, but it may be shipped in any other forms as de- sired or when directly delivered to user.5,6, Travel lever 7,8, Travel pedal ‘Travelling of machine is controlled with manual lever and travel pedal. A WARNING Before operating travel lever, check travel motor position, ~| When travel motor is placed on front posi- tion, the travel lever operation is reversed, © Forward -~ Position lever is pushed forward Position the toe side of pedal is pressed @® Reverse +“ Position the lever is pulled to your side Position the heel side of pedal is pressed ®Neutral » - Return lever and pedal to the neutral position, and the machine stops operating 6. Travel Ist, 2nd speed selector switch Pressing the right travel lever switch allows selection of the 2nd or 1st travel speed. When the starter switch is set from OFF to ON, the speed is set to the low speed side auto- matically. After starting the engine, s lect the desired mode. LCD display on multidisplay al- (1st speed) lows confirmation of the condi- tion of Ist and 2nd travel speed. ‘The Ist travel speed is useful to run on soft roads, slopes and narrow areas, or when the large tractive force is re- auired. 1st speed ----- 4.0km/h (SK200-6 +SK230-6) 3.4km/h (SK320-6) B= +The 2nd travel speed is useful to run on the flat and solid (2nd speed) ground. In addition, the travel speed is switched automatically from high speed to low speed, or low speed to high speed ac- cording to the road condition when travelling with auto se- lector system equipped. 2nd speed ~~ 6.0km/h (SK200-6+SK230-6) 5.8km/h (SK320-6)9. Gauge cluster © Gauge and indicator lamp @ Engine coolant temperature gauge Pointer indicates the tempera- ture of engine cooling water. ‘Temperature is normal when pointer is within the range of white color in operation. When pointer indicates within the range of red color, set en- gine to low idling and wait until the temperature lowers to the range of white color. Pointer position ---- @ 70+ 6°C © 105+ 5C Oust 5C @ Fuel level gauge Pointer indicates the level of remaining fuel. When the remaining fuel quantity reduces and pointer closes to E point, fill up fuel S006 | sica20-6 Full of fuel 340L | 560L E position 63L 100L Warning lamp lights 54L 60L @ Work mode indicator lamp By pressing any of work selector switches Bw ha 2 , (M1), (B.) on ‘switch panel, the selected work mode indicator lamp goes on green. After start-up of engine, the switch is always set to M mode. Note : To change the mode to the ri mode, see[ Page 3-25 |. The rising of B mode is not allowed. 9 of A © Mul @ Screen change switch When starter switch is turned “ON” or after the engine starts, if the electric hydraulic unit operates normally, [ OK ]is displayed on the multidisplay. pslay (Normal display) Multidisplay Note : Do For the adjustment of brightness of multidisplay, see | Page 3-25 |. « The second icon * "(Q.” from the left is displayed by switch ‘hen the swing flasher and rear working light are installed in option. Operate switch, and the multidisplay indicates the following. After the engine MONIT OH starts, “ OK” is SYSTEM OK displayed on the multidisplay. Press screen change switch one time, and the present engine speed is displayed. 2220RPM Press it one more time, and the E/G oil supply cumulative time is displayed, 256Hr AFT E/G OIL CH© Multidisplay LCD (Liquid Crystal Display) When warning is displayed on multidisplay, stop the operation immediately and check and re- pair the relevant place. Signals from various sensors and switches are treated by mechatro controller, and the gauge clus- ter has LCD display, lamp light on, and buzzer sound. The pre-start inspection should be performed not only on multidisplay but also according to Section “Inspection and Maintenance” in Operator's Manual. ‘The display function on multidisplay is classified roughly into following 8 types. 7 : ‘After E76 stars, this is displayed only when PK 1] OK display | the electric hycraulic unit operates normally PU array Gis: | The error on mechatro controller. etc. is dis- play function | played. - “The error of inpit and output system to mechatro 5x3} Sa S295 | controler tke low pressure and igh pressure Ka) shay sensor, governor mator, proportional valve, __| solenoid Valve ete. is displayed. (34 items) ice diag | The date from mechatro controller Tike pres- 4| nosis display | sure sensor detected value, proportional valve, function —_| solenoid valve command value, et (25 items) | Error history | The contents of failure after mechatro self c- splay ‘unction | agnosis is stored and displayed | Seetant’ | When adusting mecatro A, it is cisplayed by cispay function | Procedure. 7] EG oil. sup- | £76 oil supply total hours and EG speed are ply total hours | displayed. ‘Auto warming- | E/G and hydraulic oll are automatically uw function | warmed and displayed © Display marked with 3 is displayed every time when it occurs. Other displays ey) 1, Warning display (Liquid Crystal Display) Displayed on the upper part of multidisplay. Bg.) Engine oil pressure For details, see| Page 2-7 i 2, Function display with switch operation Displayed on the lower part of multidisplay. Eg.) When operating working light switch AmeIL) 3, A (Assist) mode display ‘Turn the work mode selector switch to A (Assist) mode, The mode of leveling, dig- ging, spreading, tamping and standard (travel) are displayed on the multidisplay Note : Display function with switch operation respectively. See Page 3-8 For details, see [Page 2-16 See Page 37 See Page 3-28 See Page 2-18 See Page 2-5 Service diagnosis - Trouble history Mechatro A adjustment E/G oil supply total hours 4, B (Breaker) mode display Turn the work mode selector switch to B (Breaker) mode. The delivery flow rate E/G speed corresponding to the breaker specifica- B (Breaker) mode tion is displayed on the multidisplay. delivery flow rate For details, see[ Page 2-16 1 + See Page 2-16 + See Page 2-17 1. Auto warming up© Warning display When the following failures occur, the warn- ing is displayed on the multidisplay. When the warning is displayed, it may indi- cates the severe trouble, So stop the operation immediately, and check it for possible failure and repair it, 1, Failure of mechatro controller } MECHTRO CPU_CONT. FAIL This icon will display when the mechatro con- troller equipped with various kinds of electric and hydraulic control mechanism is not func- tioning properly When this icon is displayed, take corrective ac- tion referring to [Page 2-13 |. 2. Slewing parking brake 2 SWINGBRAKE DISENGAGED This icon will display when the slewing park- ing brake can not be released during right and left slewing and arm-in operations. When this icon is displayed, take corrective ac- tion referring to Page 3. KPSS control 5 \KPSS {& DISENGAGED This icon will display when the CPU MECHATRO CONT. FAIL is displayed, and KPSS work mode release switch in the controller box on the rear side of operator seat is turned to “RELEASE” side. When this icon is displayed, take corrective ac- tion referring to [ Page 2-13 4. In engine pre-heating KV E/G PREHEAT ‘This icon will display when the starter switch is turned to “HEAT” position to make the en- gine start easier in cold weather and the en- gine preheat circuit is engaged. 5. Finishing engine preheating ", FINISH ) PREHE This icon will display when starter switch is turned to “HEAT” position, and buzzer sounds continuously and does not stop sounding. ‘Turn the starter switch to “START” position immediately, and start the engine. Note : Never operate it for 25 seconds or more continuously under the “PREHEAT” condition. 6. Engine oil pressure 8 7A LOW E/G OIL. PRESS ‘This icon will display when the engine oil level is low or the oil pressure drops below the safe operating pressure, and buzzer sounds continuously and does not stop sounding. Stop the engine immediately, and the buzzer also stops sounding. And check oil level for shortage. If the level is low, make up the short- age with the specified oil. 7. Engine coolant temperature aI HIGH E/G) COOL TEMP. ‘This icon will display when the engine coolant temperature rises 105°C (221°F) or higher, and buzzer is sounding intermittently. (Buzzer stops sounding by pressing the buzzer stop switch on the switch panel section once.) When this icon is displayed, stop the machine from operating, drop the coolant temperature while operating the engine in low idling, then stop the engine and check that the coolant level and tension of fan belt are normal, and also that the radiator has no clogging. 8, Engine air cleaner clogging Ps) REST'D AIR CLEANER ‘This icon will display when the engine air cleaner is contaminated and clogged. When this icon is displayed, stop the engine and clean or replace the element.9, Battery charge 7 This icon will display if the charging system fails in operation of engine. When this icon is displayed, check alternator, coupler, harness for possible failure and also the tension of V-belt 10, Fuel level >. Low FUEL LEVEL This icon will display when the fuel level is low, and also displays when the fuel level is low at engine starter “ON” position. Make up the shortage of fuel as soon as possi- ble. Remaining fuel level when the icon displayed Model Remaining oil level 'SK200-6 » SK230-6 Approx. 54L $K320-6 Approx. 60L 11. Hydraulic oil level SX) LOW HYD Ol on eve. This icon will display when the hydraulic oil level is low in the machine appropriate check- When this icon is displayed, press the air bleeder on the upper part of hydraulic tank and bleed the internal pressure first, and remove the cover, check the oil level with level gauge and make up the shortage with the specified hydraulic oil. 12, Engine coolant level “LOW E/G COOL_LEVEL This icon will display when the coolant level of radiator reservoir tank is low. When this icon is displayed, check the reservoir tank for shortage, and make up the shortage of coolant. 0 13, Engine oil level FETA LOW E/G OIL_LEVEL, ‘This icon will display when the engine oil level of engine oil pan is low. When this icon is displayed, stop the engine im- mediately, check the engine oil level, and make up the shortage. 14, Attachment boost pressure EBS ov This icon displays when the switch on the grip upper section of ATT right control lever is pressed. 15. Auto warming up i [OI f+ wares uP This icon will display when the engine and hy- draulic oil are automatically warmed up in the AUTO WARMING UP mode after turning the auto warming up switch “ON” and starting the engine. For details of auto warming up function, see Page 2-17 16. Finishing of auto warming up Blk isis ‘This icon will display when the auto warming up has finished, the switch turned “OFF” during auto warming up operation, and the hydraulic oil temperature switch (sensor) has sensed a temperature of 10°C. For details of auto warming up function, see Page 2-17 17, Engine oil supply total hours [CHANGE SEF Eve OL ‘This icon will display every time when 500 hours of the total engine operating time has elapsed, and notify you to change engine oil. Press buzzer stop switch, and the display dis- appears and the total hours are cleared. For changing the engine oil supply total hours, see| Page 2-18© Warning display No. ; Only] Onl Tipit it] Display of Bue Circuit wey | E/ Display condition value symbol | _Tultiisplay | ON | RUN |S (CA) 1. Weep MECHTRO QO When there is no communication for § seconds c-1 |[CPU_CONT. FAIL | from mechatro controller to gauge cluster + SOL doesn’t work by the signal of controller | SOL/V 2 | SWINGERAKE] QQ | x ° 34 j- - When slewing parking brake release switch is a EZ aD ISENGAEED ‘turned to “RELEASE* position 8 3 iz KPSS + PSV doesn't work by the signal of controller | 12V Z O | O | X | - whenkPpss work mode release switch is turned | OF less Sao SZADISENGAGED) to “RELEASE” postion ou (2-18) 4 4 E/G Oo | While starter switch (key) is turned to “HEAT” | 24. SW-1 || @) PREHEAT prsition (12-16) sis 5 geomavur aw mromnvane | 2p a When E76 oil pressure for SK200-6 and SKZ30-6 Beda) ebOw E/G is Sele r es, and is Detar less fo Sk320 | (GND SW-1 [XO OIL PRESS cg (In normal, Low 1.5/2kat/on? ~ Hi Skat/emt) | (14-2) F o-6 | Les Sp |] O | © | C1 | wnent/6 coon temperature is 106°C or more | (NO, é Sina © REAR | OO} O When E/6 air cleaner is clogged Gg, 9 | cHarGINe O When alternator generating voltage is 12V or less | /4¥ €-2 || & *IPROBLEM in E/G operation ees 10 lex 1ow olol Remaining fuel level of fuel tank eV. w | SK200-6 - SK230.6 ~~ BAL oF less or less come “Reve ever] |_| ASK920-6 eens BOL OF less (14-8) 1 3 LOW HYD Oo ‘When hydraulic oil level is low at machine oil level | Open. sw-25|[ 510] oi LeveL checking position (4-7) we2al| SC SOW S|] O When coolant level of reserve tank is low ope, W223] OOM, |] O When engine oil evel of /6 cil panis low | PPR, 14 |[® POWER 010 Wen the switch on the grip uoer section of ATT | GND SW-21 BOOST ON right control lever is pressed (4-11) aa, ran pies [lle wares wll O}O eure are warmed up in we I= — “When auto warming uo has ished | +I + When auto warming up switch is turned “OFF” sw-26|| [Oljt Fist © |X | when ‘tydrautic oft temperature switch (sen- sor) is sensed temperature 10°C or more _| 2a. CHANGE ‘When E/G total operating time has passed 1 |eerecor || O | O 500 hours atter E/G oil change ‘© E/G operation means the condition when the alternator generating voltage is 12V or more in the condi- tion where the E/G oil pressure S/W is 5kgf/em’. © Buzzer sounds or not C1: Stops sounding by pressing buzzer stop switch, X : Stops sounding automatically 5 seconds later A : Doesn't stop sounding even if buzzer stop switch is pressed, u 2-390 : For blank spaces, buzzer doesn’t sound= 2 g © fl 13 ( [ pe | NEN aE, oes, 11. Ash tray 12, Cigarette lighter 13, Engine emergency stop knob When the engine doesn’t stop even if the starter switch is turned “OFF”, pull the en- gine emergency stop knob on the lower right hand side of seat stand fully, and the engine stops rotating, Notes: 1, The insufficient pulling of the emergency stop knob may stop the engine, or make the engine restarting impossible, or keep the engine down during operation even if the engine restarts. So be sure to return the knob completely after usage. 2. Since the engine speed can not be set rightly during mechatro A adjustment, be sure to return the knob completely. See [Page 3-28 |. 2 2-10+A (Assist) mode ‘The mode is set to the optimum mode corresponding to operator's lever control. ‘The mechatro controller discriminates “ the work like digging, leveling, spreading, tamping, etc. automati- cally without turning the switch, and displays the results on the | multidisplay by 5 seconds. | ‘The engine speed is controlled con- stantly by production of power cor- responding to the load to reduce the ! noise and fuel consumption. Note : For details of A (Assist) mode, see [ Page 2-16 AE) — E\ + M (Manual) mode (car) This mode is useful for heavy load digging work which must take 14, Switch panel . recedence with the workload in high (Work mode selection, buzzer stop) Ee ee oe oem speed, in perceiving the movement Serres of the control lever sensitively. [ieee] 9 BEBE o| resistant to dust and mois- ture is employed. + B (Breaker) mode ‘The switch panel is equipped In case when the attachment in option with work mode selector like breaker, etc. is used, it is set to switch and buzzer stop the max. flow rate corresponding to switch. those in the specification. ‘The flow rate set once is always dis- played on the multidisplay by switch- ‘© Work mode selector switch ing it to B mode. After engine starts, the switch is set Note : For Max. flow rate setting, to CM) mode. It is possible to se- see{ Page 2-16 |. LJ) lect the most efficient work mode from the following three modes ac- _+ Buzzer stop switch cording to the working condition ‘The warning buzzer sounds inter- mittently when the engine coolant temperature rises abnormally, vari- the work mode indicator lamp on fe geod etreae ed coaenanae the gauge cluster is ewitched to fai l(self diagnosis), or the warning Cit)* CR) ana = lamp is lit on, Press the buzzer stop switch, and the buzzer stops sound- and working contents. Press the work mode switch, and order. ing. Note : The mode allows change into A mode on For details of self diagnosis display, See | Page 3-25 |. see| Page 3-2 ], and for details of warning dis- play, see [ Page 3-1 And for function of each switch, see [Page 2-16 |. 13 a=Ma wa i, =\ 15. Accel dial Adjust the engine speed (output). This dial is of rotary type switch, and 11 detents are applied for the positioning. Release the hand at the moved position, and the speed corresponding to the position is maintained con- stant. LO (Low idling) : ‘The engine speed is the lowest at the position where it is turned counterclockwise completely. HI (High idling) : ‘The engine speed is the highest at the position where it is turned clockwise completely. Note : Operation and control of auto accel 1. In operation, when the remote control pres- sure of control lever and control pedal does not act on for 4 seconds, if the set po- sition of accel dial is higher than 1050 rpm, the auto accel actuates automatically and the engine speed returns to 1050rpm. 2. When the auto accel set position is lower than the auto accel speed, the accel dial set speed is maintained. Auto accel release condition Operate attachment, slewing, travel control lever and control pedal, and the E/G speed re- turns to the accel dial set position gradually according to the operated variable, For how to stop the auto accel function, see[ Page “ 16, Right switch panel ‘The sheet switches which are resistant to dust and moisture are employed. The switch panel is equipped with wiper switch, washer switch and working light switch. ‘© Wiper switch Press Once more «++ Wiper moves continuously 3 times Press the switch, and the wiper of front window start moving. When the wiper switch is pressed, the symbol “ §¥" for intermittent and “ $7 ” for continuous on the lower columns of multidisplay. per moves intermittently - Wiper stops moving © Washer switch Note : Press the switch, and the washing liquid is sprayed through nozzle and wiper blade actuated while the switch is pressed. And the liquid tank is installed on the side of the cab. Pressing of the washer switch for 20 seconds or more continuously and / or using it without liquid may cause troubles of the motor, Pay attention not to use it under the above condition. © Working light Press the switch, and the working lights on the boom left side and front right side go on. Press it once more time, and the working lights on the boom and front side go off. When the working light switch is turned ON, the symbol * 75)" is displayed on the lower cofumn of multidisplay. In the case when the slewing flasher lamp and rear working light are installed in op- tion, after turning the slewing flasher switch (SW. iN Press Once more ~ 3 times ‘The Front working light goes on Front and rear working lights go on Front and rear working lights go off a rear working light symbol “"(Qy’ is displayed on the 2nd position from the left of the lower column of multidisplay. 2-1207 18 Ag — XE a 17. Starter switch This switch is used to start and stop the engine. HEAT (Preheat) If the engine is hard to start due to the cold weather, turn this key to this position, and the glow lamp of multidisplay lights up and the preheating starts. (PREHEAT is displayed.) After preheating for about 25 seconds, the multidisplay displays “FINISH PREHEAT", and buzzer sounds continuously. Consequently the engine starting is made eas- ier. Turn the key to “START” position and start the engine. OFF (Cut off) : ‘This is a position used to insert and pull out the key. ‘Turn the the key to “OFF” position before re- starting the engine or to stop the engine. ACC (Accessory) : When the engine is stopped, turn the switch to “ACC” position, and the cigarette lighter, radio, ete. can be used. ON (Input) : The current flows into all circuits, The switch is set to this position when operat- ing the engine. START : ‘Turn the key to “START position, and the en- gine starts rotating. After the engine starts, release hand from the key, and the key returns to “ON” position automatically. 15 18, Radio For the operating procedure of radio, refer to Operator's Manual. 19. Engine control cable When the gauge cluster displays “MECHATRO CONT. FAIL" or “STEP MOTOR S/PT ERROR’, if normal working and engine control are impossible, use this Engine control cable to continue working. See[ Page 2-21 20._Slewing parking brake release switch ‘The slewing parking brake release switch is set to the NORMAL position. If the slewing parking brake can not be released due to the failure, turn the toggle switch in controller box on the rear side of opera- tor's seat to “RELEASE LOCK” side, and buzzer sounds intermittently and stops sounding in 5 seconds, and the slewing park- ing brake is released. Place the machine in a safe area immedi- ately, and check the machine for possible failure and repair it. 21, KPSS work mode release switch ‘The KPSS work mode release arse]! switch is normally set to 1 work mode (KPSS) position, @ If the multidisplay displays kess|| “MECHATRO CONT. FAIL” due to the failure, turn the toggle switch in controller box on the rear side of operator's seat to “RELEASE” side, and buzzer sounds intermittently and stops sounding in 5 seconds, and the operation of machine will be made possible. Place the machine in safety area immedi- ately, and check the machine for possible failure and repair it if necessary. Notes 1. Use the release switch for emergency. (Pump delivery rate : Approx. 126L) 2. For use of back-up function, see[ Page Note: The slewing parking release switch and KPSS work mode release switch are not allowed to be used other than in case of failure. 2-12022. Operator's seat - ‘The operator's seat allows adjustment in © front and rear, and up and down, and also _. the angle of back seat. Adjust the position \ so that the control lever and control pedal. \ } can be operated with ease. Pe | \ Pay attention not to catch your hand be- \ { -— \ tween handle and seat stand when adjusting the operator's seat. ® Height adjustment/tilt lever © - 1, Pull up lever®, and the rear side of seat goes up and down. (Tilting in 5 steps) 2, Push down lever ©, and the front side of seat goes up and down. (Tilting in 5 steps) — 4h a = 3. The adjustment of seat height can be done by alternate controlling of tilt angle of the front and rear side of seat. ® Reclining angle adjusting lever @ Pull up lever @ and recline and adjust the back seat to the desired angle. After adjust- ment, release and fix the lever. ©, © Front and rear adjusting handles @,@ 1. Pull up handle @ and slide the seat forward and rearward, And after adjusting it to the desired posi- tion, release the handle and make sure that it is locked securely. (Clearance of adjustment : 160mm) 2, Pull handle @ up, and the forward and rearward adjustment of the seat and con- trol stand is allowed. (Clearance of adjustment : 120mm) © Arm rest © The arm rest can be raised rear upward. And turn the control dial on the lower side by hand so that fine adjustment of the arm rest angle at normal position can be made. 22-1 Seat belt © Head rest © Machines of Dynamic Acera Series equip the ‘The head rest can be adjusted in upward, seat belt usually. downward, forward and rearward. Adjustment to your preferred position is also possible. Hold the head rest by both hands lightly, and adjust its upper and lower position of head rest moving it up and down. And for adjustment of front and rear posi- tion, hold the head rest by both hands and adjust the position moving it to the random position. 6 2-1423 N= | 23, Auto warming up switch In cold weather, after the auto warming up switch on the left control stand is turned “ON”, the engine starts, and the switch is turned to the auto warming up mode. For details of auto warming up, see[ Page 2-17 1" 2-1 © Others 25. Hourmeter 5 This icon shows the engine total operating time, If the engine is rotated, the hourmeter runs even if the machine is stopped. When the engine is rotating, the graduation runs up 1 step to 1 hour of operating time re- gardless of the engine speed. ‘The indicated figures on the hourmeter can be used as a guideline to understand the interval for inspection and maintenance.2-3 Switch panel and New functions 1) Switch panel Work mode selector switch Buzzer stop switch ‘Work Mode Selector Switch © After the engine is started, the mode is set to ‘M mode rising. (A mode rising is also possible.) © The work mode indicator lamp is switched M — A— Bin order every time when the work mode is pressed. © The most efficient work mode can be selected from the following three modes according to the working condition and contents of work. 1. M (Manual) mode (New function) This mode is useful for heavy load digging work which must take precedence with the workload in high speed, in perceiving the movement of the control lever sensitively. 2. A (Assist) mode +The mechatro controller set to the opti- mum mode corresponding to operator's lever control. The mechatro controller discriminates and sets the work mode like digging, leveling, spreading, tamping, etc. to the optimum mode corresponding to operator's lever control automatically without turning the switch. + The engine speed is controlled constant by production of power corresponding to the load to reduce the noise and fuel consump- tion + The discriminating results is displayed on the multidisplay by 5 seconds. + The display appears several seconds later. And the results may not always be as you desired, but it should not be considered as a failure. Loos cones on mutica) waiices | ¥) Leveling, slope finishing LO+@] Spreading Cc] Tamping KK] Travelling, Weiting time OK 8 3. B (Breaker) mode (New function) If the use of breaker is required on the machine equipped with piping for breaker and nibbler & breaker in the attachments in option, the max. flow rate must be lim- ‘ited to meet the flow rate to the breaker specification. Max. flow rate adjusting procedure 1, Preparation Turn the starter switch ON (Don't start the engine.) and turn the screen change switch ON after setting it to B (Breaker) mode and release the switch, in the range of 3 to 10 seconds and it turns to the ad- justing mode. Note : It is impossible to turn it to adjust- \g after starting the engine even if the above procedure is performec 2, Max. flow rate setting (The flow rate is displayed on multidisplay.) + The last stored flow rate is displayed, but the initial value is the max. flow rate. + Press the work mode selector switch and the flow rate rises, and press buzzer stop switch and the flow rate decreases. + The increasing and decreasing of flow rate starts in 2 seconds from pressing of re- spective switch, and displayes by 10L/min. ‘And release hand when the desired value has been displayed + The flow rate is varied in the range of ‘Max. to Min. value, + Turn the screen change switch ON again, and the newly set max. flow rate is stored, and the adjusting is canceled. © Funtions of work mode selector switch and buzzer stop switch The work mode selector switch has the fol- lowing functions. @® Work mode selection M— AB ® Scrolling up of indicating items in trouble history display © Scrolling up of time when changing E/G oil supply total hours @ Increasing flow rate in B (Breaker) mode The buzzer stop switch has the following functions. ® Stop warning sound. @® Scrolling down of display items in service diagnosis display @ Scrolling down of indicating items in trouble history display @ Scrolling down of time when changing E/G oil supply total hours © Decreasing flow rate in B (Breaker) mode 2-162) Auto warming up switch (New function) ‘Turn this switch ON and start the engine in cold weather, and it turns to the auto warming up mode and the E/G and hydraulic oil are warmed up. ‘Auto warming up system 1, E/G warming up Warm up the engine for 3 minutes at auto accel speed (1050rpm.), and “WARMING UP” is displayed on multidisplay. ¢ In addition, when the auto accel dial position is set to lower than auto accel speed, the speed is the speed corresponding to the accel dial position. 2. Warming up of hydraulic oil © After warming up the engine, keep the max. flow rate pumping for 3 minutes at E/G speed 1050rpm. © Keep the max. flow rate pumping for 5 min- utes at E/G speed 1,600rpm, ‘© Keep the min. flow rate pumping and cut valve full close (in relief condition) for 5 minutes (Even if it is at low speed, the speed returns to the speed 1,600rpm. automati- cally), © Keep the max. flow rate pumping for 10 min- utes at E/G auto accel speed. In this operation, “WARMING UP" is dis- played on multidisplay. 3. Finishing warming up © After about 26 minutes of auto warming up, or in case where the hydraulic oil tempera- ture switch (installed on the tank port of solenoid.proportional valve block) senses the temperature of 10°C or higher and turned OFF, “WARM FINISH" is displayed on multidisplay, buzzer is sounding and stops sounding 5 seconds later. © Then, Turn the auto warming up switch OFF. 19 Notes : 1. 2-17 It is impossible to turn it to auto warming up mode after starting the engine even if the auto warming up switch is turned ON. If the auto warming up switch is turned OFF during auto warming up operation, the auto warming up mode is forced to stop operating. - If the lever is operated while warming up the engine and hydraulic oil, the warming up temporarily interrupts, and in and after 10 seconds of neutral condition, the warming up is restarted. When the temperature of hydraulic oil is 10°C or more, the warming up hydraulic cil is not required but warming up of en- gine is started. There is no problem mechanically even if the auto warming up switch is always turned ON. (To prevent setting it to auto warming up mode by turning this switch ON after the engine starts.)3.) How to correct the E/G oil supply cumulative time Procedure} Operating procedure Display on multidisplay (Normal) A | Turn the starter switch on. eK is displayed £76 sed dial Press the gauge cluster screen change switch Pre B i MONITOR — |__Press once _| once, and the E/G speed (rpm) is displayed. SYSTEM OK 2220RPM 6 seas dh Press once more, and the engine oil supply cu- © | muiatve time soreon is displayed. 2260RPM eee Press the screen change switch and release in | —________ —— Ep _ | therrange of 6 to 10 seconds, it returns to the |[700Hr AFT | {MONITOR L[700Hr AFT correction mode. E/G OIL _CH]”|SYSTEM OK]”|E/G OIL_CH Note) The hourmeter does not flicker. | Press the work mode selector switch and the | 100Hr AFT Cumulative time [701Hr AFT. cumulative time inereases. (once 1Hr) E/G OIL CH] inoreases [E/G OIL CH ¢ | Press the buzzer stop switch, the cumulative | | 100kir AFT The cumulative [ 9gHr AFT time decreases. (once 1Hr) E/G OIL. CH time decreases |E/G OIL CH Press the gauge cuter soreen care sith (Normal) | once the correcting time is stored, and exits | re5—-—AET—] Complete the _[ MONITOR from the correction mode and OK symbol is jr cisplayed to complete the correction. E/G OIL CH] correction “SYSTEM OK Note : 1. Press the screen change switch once after the procedure D, and the condition is stored and the correction is completed. 2. Even reaching procedure D, the hourmeter does not flicker, and even reaching procedure G, it still does not go on. 2 2-1804) Preventing overheating (New function) + The pump delivery flow rate is controlled before overheating due to the rise of coolant tem- perature, and the engine load is reduced to protect the machine from stopping due to the over- heating. + During demolition work using nibbler of which the work load is very high, if the coolant tem- perature rises 95°C or high due to the clogging of cooling unit such as radiator, etc. the circuit is switched from the conflux to single flow, besides, as the coolant temperature rises the hy- draulic oil flow rate to nibbler is automatically reduced by controlling the cut valve to prevent the overheating completely. 5) Safety Lock Lever in new type (Installed on from Dynamic ACERA Series.) After the lever lock switch turns ON, buzzer is sounding for 1 second intermittently, concur- rently the delay timer (1 second) of timer relay actuates. This timer is installed, taking the safety into consideration to prevent operation by mistake due to the involuntary touching of the control lever when the safety lock lever is moved down. After an elapse of 1 second, the safety lock lever solenoid valve is actuated, and the interrupted pilot primary pressure is re- generated, making the operation possible. 6) New governor control Note 1, This new governor control functions when the work mode selector switch is turned to A (Assist) mode, However, this control does not function when the high reach crane switch is ON. For SK320-6, this control functions when the no-load speed is higher than the ] speed in A (Assist) mode even if it is set to M (Manual) mode. 2. A (Assist) mode speed by model SK200-8 — 1,950 rpm SK230-6 — 2,050rpm SK320-6 — 2,200rpm At light load At heavy load « Fuel consumption and noise are improved by reducing the engine speed Workability is raised by outputting the max. power. {Control contents) Previously, the engine governor position was fixed, and as the load was added, the engine speed was reduced, But in case of new governor control, for example, the engine speed at no-load for SK200-6 is 1,950rpm, and when the power is required to meet with higher pumping pressure, the gov- ernor is controlled to the high rotating side to raise the engine speed with the required power. Consequently, no noise and low fuel consumption at light load are realized and the work is completely accomplished at heavy load, a wO7) New auto accel mechanism (1) Outline + The Dynamic ACERA Series are equipped with new auto accel mechanism as a standard, + When working at high idling in each mode, if the engine stops the engine speed reduces auto- matically. + There are no auto accel switch and release switch around the operator's seat, all of them are controlled automatically. * To release the auto accel function, change the following connectors for maintenance. ‘And carry out the service inspection under this condition, and after inspection return it to the original position. - (2) Oper 9 procedure + When the attachment and travel lever control pauses for 4 seconds, the respective low pressure sensor sends the signal to governor motor through the mechatro controller, and the governor motor has the engine speed reduced to the auto accel speed 1,050rpm. + The engine speed returns to the set value by regulating the accel dial. That is, the engine speed gradually rises from 1.3V (6kgf/cm*) to 2.9V (18kgf/cm*), and finally returns to the set en- gine speed by accel dial. Notes : When the accel dial set position is lower than the auto accel speed, the speed is set to the speed corresponding to the accel dial set position. (Eg. : At low idling) (3) Connector installing position for maintenance ‘The connector installing position is between the right control box rear side and the resin cover, and located on the right control box side. Connector for maintenance Operators seat (4) Service connector replaceing procedure Normal When releasing auto accel 2P connector 2P connector > mb 1P connector | Pull out 1P connector and insert it in the lower side. 1P connector 2 2-0 D8) Back-up function Engine control cable @ If “MECHATRO CONT. FAIL” and “STEP MOTOR S/PT. ERROR” are displayed on the gauge cluster multidisplay, the machine can not be controlled normally. © The machine is equipped with back-up func- tion to actuate the E/G. hydraulic pump. So perform the following procedure, and the capacity in 90% under regular condition is exhibited, enabling the continuous working. © Procedure to have back-up function 1, Stop the engine. 2, Hydraulic pump flow rate back-up function Loosen the lock nuts of two back-up screws @ installed on the hydraulic pump, and loosen also the back-up screws until it stops. Then, tighten the lock nuts. 3, When the governor motor does not function, remove the rod of governor motor, or dis- connect the wiring coupler. 4. Start the engine, and the engine speed turns into low idling, first. 5. To turn the engine speed into high idling, press the central button of engine control cable @ on the right control box, concur- rently pull the knob fully, and release the button, and the the condition is main- tained. 6. Continue working. 7. After finishing the work, press the central button of engine control cable ® and con- currently push down the knob, and the en- gine speed turns into low idling. 8. Stop the engine. Viewed from rear of machine Notes 1, The fuel level and engine water thermome- ters, working light, wiper, air-con, radio, etc. on the cluster gauge function the same as when in the normal condition. 2. Every function is performed in almost the same as when in the normal condition. 3. The back-up functioning time has no ef- fect on the performance of the machine, but the inspection and repair are required when the machine is not used. 4, When gauge cluster display, working light, air-con, wiper, etc. on the electric system fail, the fuel level and E/G water temperature are not indicated and also air-con, wiper and working light are not actuated and light up. 5. And also, for the failure shown in Article 4, it may cause the trouble in daily operation. So immediate inspection and repair are required. 6. When the hydraulic pump is set to the back-up function, the control of KPSS work mode switch is not required.9) Remo 1g radiator procedure 9-1 Removing radiator (SK200-6 + SK230-6) ‘This machine is of the construction removable only radiator. The procedure is shown below, 1) Remove one under cover on the lower side of radiator. 2) Open the engine bonnet and remove cap @® on the upper section of radiator. 3) Open radiator drain cock and drain cool- ant in container. (Coolant quantity : 9.5L) 4) Loosen 4 wing bolts @) and remove cover @ between radiator and oil cooler. 5) Loosen 4 capscrews @ (M8) and remove pad @ on the right and left shoulder of radiator. 6) Remove 4 capscrews © (M10) securing the upper section of radiator. 7) Remove 2 capscrews © (M8) securing the lower section of radiator. 8) After making sure that the coolant is com- pletely let out, loosen radiator hose band and remove it only on the radiator side. 9) Hold the upper section of radiator, shift it toward the oil cooler side, and lift insula- tion up to protect it from damaging. (Radiator : 29kg) 10) After cleaning, assemble it by the reverse procedure. En Shift it toward the oil cooler, side Lift up‘This machine is of the construction removable only radiator. ‘The procedure is shown below. 1) Remove one under cover on the lower side of radiator. 2) Open the engine bonnet and remove cap @ on the upper section of radiator. And, open the drain cock on the lower side and drain coolant in container. (Coolant Q'ty : 15L) 3.) Remove 2 wing bolts @ and pull insect proof net @) in front of the radiator up- ward and remove it. 4) Loosen 4 capscrews @ (M10) and remove pads @ on the right and left side of radia- tor. 5) Remove 4 capscrews @ (M10) on the upper and lower sections of shroud @ and remove 2 covers @. 6) Remove 4 capserews © (M10) securing the upper section of radiator. 7) Remove 2 capscrews ® (M8) securing the lower section of radiator. 8) After making sure that the coolant is com- pletely let out, loosen radiator hose band and remove it only on the radiator side. 9) Hold the upper section of radiator, shift it toward the oil cooler side, and lift insula- tion up to protect it from damaging. (Radiator : 29kg) 10) After cleaning, assemble it by the reverse procedure, Shift it toward the oil cooler side2-4 Others 1, Fuse box This box is used to protect electric equip- ment and wiring from burning out. Don’t fail to replace fuse with that of the same capacity. PNR Don’t fail to turn starter switch OFF before replacement of fuse. ‘© Replacement procedure 1, Remove cover, 2. Remove cover of fuse box keeping the cen- ter of claw on both ends of cover turning. 3, Remove fuse using a corner of fuse box or finger. 4, After replacement of fuse, install cover se- curely. Fuse capacity and circuits Fuse cover Fuse box 1 2@@ 6G ® TP 4 iE PLETE eMef tater tol Elst fa} toh 4s apap /fop/ fone foyr fay fay" fa\fay- (a) FI See she Aa as LAT Auhatian Travel alarm 5A _| Gauge cluster, Power window (Opt.) 208 | Wiper, Washi Solenoid valve 208 _| Working light (Front) elela[slajaie|e 3 Working light (Opt.) 20A_| Air-Con 5A_| Air-Con 20A_| Spare (24V) % No. [Capacity Circuits x @|_20A | Mechatro controller L A 5) 6m | Ray ley Bo ano SU @ Cigar lighter ® Tuner f ® [Horn Proper condition Fused condition ® Spare (Reserve @|_5A_| Mechatro controller (Back-up) @®| 15A | Power window (Back-up, Opt.) eae een Phe aaa S| 182 at Back-up. Opt) | spare fuse is attached on the rear side of @|_5A_| Tuner (Back-up), Dome light cover, @| 208 | Starter key switch @|_10A | Auto greaser (Opt.) ® 20a | Swing flasher unit3, INSPECTION AND ADJUSTMENT 3-1. Priority of warning display and self diagnosis display Priority of the display (In case two inputs or more exist,) @ Only the message in higher priority according to the following priority order is displayed. ® When the priority order is the same, the display is changed for every 5 seconds, Priority Display contents ep) MECHTRO op MECHTRO apy) MECHTRO- 7 [CPU CONT. FAIL [CPU_CONT. FAIL [CPU_CONT. FAIL 2 Service diagnosis A = _-\SWINGBRAKE] —[>_\KPSS. DISENGAGED DISENGAGED 4 it EG asa PREHEAT Masato 5 FAILURE MECHATRO HIGH REACH HISTORY ADJUSTMENT ADJUSTMENT et, LOW E/G 7 | HIGH E/G RESTD E/G 5 OFOIL PRESS. Gl Goo. Fave 2 OL FILTER, Fm) RESTD AIR YQ, CLEANER SELF DIAGNOSIS © Initial check Turn the muitidisplay on (black sereen), and check that there ) 7 no error. (ex.) [B1 BOOM RAISE] [ET PUMP PI ‘SENSOR (ESV pROPO-VALV "ay CHARGING ey LOW Io LOW HYD. (*]propcem FUEL LEVEL OIL LEVEL. 7 LOW E76, 57) LOW E/G Pi o COOL LEVEL. OIL LEVEL (alle wasnans uP tg Ere is Pe AN [Olle Finis 100% LOAD "8 4 POWER 2 CHANGE a 00ST ON SEF E76 OIL i 256+ AFT No. 10 is inde- E/G OIL CH Sioplays for” MONITOR isplay: ing and 2060RPM self-diagnosis. SYSTEM OK a3-2 Multidisplay self diagnosis 1 ‘The error of the control I/O signal of the pressure sensor and the proportional valve, etc. is de- tected, and the detected error item is displayed on the multidiaplay of the gauge cluster. Indication item - - Connector No.) Wire | Wire No. Contents Display of monitor re | Ne | sae 1 1 | Mechatro controll error | CPU MGCHIATRO, =| oni4-25 | 770 | R Gauge cluster > Mechatro | 1-1 - 2 | controller communication | S——e RECEIVE CN14-26 | 582) W ERROR failure 1:2 r te BAT 3 | Battery relay fail oo CN15-24 857 WG eS RELAY oa ROM DATA a | [sent] CPU FAILURE Az 4) MECHATRO 5. | Mechatro set error cpu MECHATRO | Boomrraise pressure ei BOOM RAISE | CN11-2 | 602 | Ley sensor fail SENSOR, CN11-1 952 | BR 7 | Boom lower pressure Ee BOOM LOWER | CNI1-5 | 603 | LO sensor fail SENSOR cnii-s | 953 | Brw g | Armin pressure sensor | ®3/— | ARM OUT eNi1-8 | 504) PG fail SENSOR N11-7 9654 | Bry g | Armout pressure sensor | ®4/-— ARM IN ONTI-11 | 505 | PL fail SENSOR CN11-12 | 955 | Gr 10 | Bucket cig pressure Ed BUCKET DIG. CN11-14 | 600 | LaR sensor fail SENSOR: CN11-13 | 960 | BrR 41 | Buxket dump pressure | 8S BUCKET DUMP | CN11-17 | 501 | Lew sensor fail SENSOR cnii-is | 951] BL 12 | Swing (RH) presse [87 swine (R) CN11-20 | 506) Vv sensor fal SENSOR cNnii-1g | 956 | Gre 1g | Swing (LH) pressure | 88. swine (L) CN11-23 | 607) vo sensor fail SENSOR on11-24 | 967) Br 14 | Travel (RH) pressure | 88 TRAVEL (R) cN11-26 | 508 | vy sensor fail SENSOR ON11-25 | 958) BY ag | Travel (LH) pressure |B. TRAVEL (L) CN11-28 | 609) Sb senasor fal SENSOR cn11-30 | 959 | BG 28‘Connector No. Wire Wire No. Contents Display of monitor ene Naa eae 16 | PiNega-Con pressure | 1. PINEGA-CON CN12-8 | 510) GR sensor fail SENSOR cni2-7 | 960 | BY 17 | P2Nega-Con pressure | 27. P2NEGA-CON eni2-11 | 511 | LY sensor fail SENSOR on12-12 | 961) BW B15 ’ BACK PRESS ON13-14 | 612) Sb 18 | Back sensor fail oe SENSOR CN13-13 | 962 | Gre Pant C1 PUneie! CN12-1 964 | BrB imp P1 pressure sensor 19 fail SENSOR CN1 2-2 514 VY CN12-3 g14 YL puma P2 ce PUMP P2 CN12-4 915] YR 20 | plume F2 pressure sensor CN12-5 | 615 | Sb fail 2166) SENSOR CN12-6 915 | Brl 21 | Pt By-pass cut propo-vave | 0" P1 BY-PASS CN15-4 744 | BP fail PSV _| PROPO-VALV CN15-5 745 | PW 2p | P28y-pass cut propo-valve | 2 __p2 By-Pass CN15-6 | 740 | BO fail PSV | PROPO-VALV cnis-7. | 741 | ore 7g | Travel straight D3 TRAVEL oni16-8 | 742 | BG ‘ropo-valve fail PSV] PROPO-VALV | cNis-9 | 743 | Bra 1g | Arm variable recirculation | ___ RECIRCURAT oni6-10 | 746 | Bro propo-valve fail PSV | PROPO-VALV CN15-11 747) YV E41 - i PUMP Pt oni6-17 | 748 | VR -\ fail 25 | Puno Pt prono-alve fal | [BEY] pRorovALY | cNise1e | 749 ore E2 -valve fai PUMP P2 cN15-19 | 750) Ww 26 | Pump P2 propo-valve fail PSV | PROPO.VALV eaneeo one ence ae Fl ati POWERBOOST 21 | ATT boost solenoid fai SV] SOLENOID on15-23 | 703) P ; F2 ‘Swing parking brake “2 SWING BRAKE 28 | Solenoid valve fal SV] SOLENOID a2 ae F3 Travel two-speed solenoid TWO-SPEED . 29 | valve fail SV] SOLENOID ci Oe 61 onié-1 | 771] G gp | Governor motor current step MoToR | CN15-2 | 772| B fail (@) current-nc | cuts-1s | 773] onis-16 | 774 | Ww G2 Governor motor starting STEP MOTOR 31 | point indexing fal (W osvpr.erROR | CNTI-34 | 844) CB 2 3-3No. Contents Display of monitor Connector No. | Wire | Wire G3 nl ‘ E/G REV. ©N12-20 | 580) R 32 | Engine speed sensor fail | REM] SengOR Met lees lw Ht cn11-33 | 917 | wR 33 | Accel potentio motor fail BOCeTIGEa cnti-32. | 517] P ©N11-31 | 967 | BW 2. Corrective action when error in equipment is displayed after self diagnosis. (Under the condition where the CPU in the mechatro controller is normal) No. Contents Display condition Decision level Corrective action Failure of CPU mechatro © Failure of fuse or harness (Disconnection, etc.) Replace fuse, check on line controller @ Failure of controller (Breakage, etc.) Replace controller of No. 1 for being blown out. If there is no problem, replace the controller with new one. After the key is turned ON, is there 24V input signal on Line No. 60, white/blue, Check the conti- nuity of line No. 51 in green, line No. 51 in red and line No. 51 in white, and also Check the disconnection for line No. 770 in red. check the 20A fuse Receiving error © Failure of harness between controller and cluster (Short-circuit, etc.) Check on line @ Failure of cluster Replace cluster If the ere is no problem, Check the continuity across the line No. 582 in white. replace cluster. © Failure of harness between Detected only when Check on line controller and relay itis decd i Dateced only when @® Burn-out of relay coil Ducted only whet | replace relay Failure of @ Short-circuit in the inside of relay | Dsteted only 3 | battery relay coil whan itis excited | Replace relay @ Short-circuit of harness between | Detected only ; controller and relay when iti excited | Check on line © Failure of controller inner circuit | Replace (feedback) | controller Few failures caused by No.@ and @ are actually displayed. (The conditions when the baitery relay is deexcited or the power is supplied to the controller are not satisfied, but it may be caused by the failure when the engine is rotating and the battery relay is deexcited.) Measure the resistance between coils of the relay, if the resistance is low (0.5 2 if the resistance is sufficient check the power supply side to the coil of main harness for short cir- or less) replace it, cuit. If it is not short-circuited, replace the controller. @D Not adjusted | When replacing it | 9 gist i a Adjust it 4 | Error of ROM (When replacing controller) with new controler | AHS data @ Breakage of data in EEPROM Adjust it @ Breakage of EEPROM Replace controller Adjust it first. If the display does not cancel, replace the controller. 5 Maladjustment of mechatro @ Breakage of data in EEPROM Adjust it controller @ Breakage of EEPROM Replace controller Adjust it first. If the display does not cancel, replace the controller. 30 3-40No.| Contents Display condition Decision level |Corrective action @ Failure of harness between controller i A eee and sensor (Disconnection, etc.) eee $ | pressure @ Failure of sensor I Replace sensor 20 | sensor @ hal Saya ~—— Se @ Failure of circuit in the inside of controller Replace (Sensor A/D value input section) controller Disconnect the connector of this pressure sensor, and connect it with other normal pressure sensor> 1. If the error is continuously displayed, it may be caused by the failure of No. D (No.® rarely), so check the continuity of sensor line (power supply, grounding, signal) and if there is no problem after checking of continuity and the error is not canceled, replace the controller. 2. The error display of this sensor is canceled, and if the error of the changed sensor is displayed, it may be caused by the failure of No. @) so replace the sensor (the error is displayed, first) with new one. @ Failure of harness between controller and - 21 | Receiving error |_Provortonalvahe(Dsonnectio, et) check online § | of proportional | @ Failure of proportional valve Replace propo. valve ae ele) Failure of controller internal Replace circuit (feedback) controller >5— gang 2586 1B mode 2] [Autooxel Control lever eutyal | in auto accel operation: 1060 3 When engine is rotated : LIVE, ep} jEGPRS. LIVE ‘When engine is stopped : DEAD & Operate the work “At M mode : M, At A mode : A, 5] 2 | Moc select M | mode selector switch ‘At B mode :B light up S|" | startorswiten ON ‘At the moment the starter SW : OFF Mechatro conraller_ ON At the moment the starter SW : ON "ALM mode [ ALA mode [ AEB made | The M mode can be sarted by Mode select M Mode | Operate work mode | Mmode | Amode | 8 mode | Switch ON. ‘A mode signal OFF | selector switch OFF ON. OFF | Anditis bossble 0 change B mode signal = OFF OFF OFF ON method to start the A mode.No Display ‘Operation procedure | SK2008 [ SK2306 | SK320-6 | Remarks No.8 By opraing tg act Low [HiT tow [Hi Ha Hay from/to. oov | 49v | oov | 49v s to/from HIGH, ~ Bg [ACCEL VOLT. 0.0¥ | the voltage varies. [0% | 100% | 0% | 100% 2| ‘The step number ‘var- £} | motor step ievalive ate Ass |_260 | 420 | 250 | 412 3 POS. justment. 0% | 100% 0% 98% §] [Noa Bla Gr COLA 1.08 At the moment when the ey 2) "Jo cos 1.98 Switch turns OFF. G2LIMIT OFF No. 5 . lnstriction = SOL. VALVE Operate swing lever in | At Swing and arm in operation Instructed by | 5 [F-2 SWING-BRAKE | clocewise or counter: | OFF / ON Sse. after swing lever controler a COMP. ON | clokwise, or armen eee Bastion ; | © Measured action Simultaneous arm lever I | reece neutral position played by g| fostucton- OFF S| |No6 ven iF i ds g|_|SOL. VALVE Semeeton. | g|FS W/Z TRAVEL | Operate travel speed | Ist soeed 2nd spood Braye 5 COMP. OFF | change switch OFF ON Voltage of on- & MEAS. OFF OFF ON BAe! ay g SWITCH OFF OFF OFF (ON dbring Sw atuatat) OFF = TOV s ‘Measure the volt- 3| [No.7 ATT boost SW he ne 2] /S0C, VALVE ance of sole: &| 7 [Ft POWER BOOST | Operate ATT boost ann Tun ON _|roidvalve. COMP. OFF | switch. OFF ON Perform checking MEAS, OFF OFF ON Slangin fe Con SWITCH OFF OFF ON bach or No. 8 §| |RELEY e 8 bat port ON Operate starter switch eT ON eae OFF z MEAS. ON ON OFF 2] | Key switcH_ oN ON OFF Noo Control [eer at ne When para PRESS. SENSOR | EAS" Low and| OV /0K | — — | trafposiionsor 8-1 BOOM RAISE | HIGH common: operating it at 9 O5V 0k ful Beso, OWER | E/G speed High idling itis varied. itis 82 BOOM re R | When raleving boom | 45Y/30" | — <— _ | acceptable. 2) [No.0 Corral ve at ted change Yee 8) press, sensor [£7 Soeed Ow ang] OSV/0K | <— | <— | FaMSy RS 5 10 B-3 ARM OUT HIGH common it,” 3 O5V Ok ¥ E/G speed High idling After changing 5] [BAM I | When relieving arm "| 48V/ 30K | — — _| the position, 3 Gciinc al I he dsolay Noo ol lever a changes press, sensor | EYE SE65"(%w ang] O5V/0K | <— | — | Se” B5 BUCKET DIG _ | HiGH common a OSV. Ok ae B-6 BUCKET DUMP | £/G speed High idling | 45V/ 30k | <—— | EE of 0.5V_Ok | When relieving bucket Terns 35 anNo. Disnlay Operation provedure | SK200-6 | S230-6 | SK320-8[ Remarks No.2 Control lever at neutral PRESS. SENSOR | PSE ag Low and |O5V/0k| <= ] — 5] 42| 8:7 SWING (R) | HIGH common 5] 12 2 OSV 0k] E/G soos Heh lrg 8) |e. in elieving Slew 8) ]B8 SWING (L) Viunction,or slwingar |48¥/90K| <— | <— 5 : ‘slewing full lever position é No. 13 Control lever at neutral 5| press. sensor | Pd, osv/ok} | E/G speed LOW and B[jg|89 TRAVEL (R) | HIGH common 3 O5V_ Ok [E/G speed High idling B-10 TRAVEL (L) | When rete indie run. neva ten cone ning at the travel lever full sit O5V_ Ok| Shred position tral position, or ing S| Ino Corral Tever a aural Sai postion it 2 on th 2! press. sensor |P% Seg towand — |0.7V/20k| <— | <— | isvaiied itis “ C-1 PUMP P1 HIGH common 3) 14) 0.7V 20k/E/G speed High idling, It it is not var- : (C-2 PUMP P2 when relieving ‘Doom Tals 33V/360k| << —_— ied, change the operation connector: posi- 3 0.7V 20k E/G speed High idl yn, and check = E/GSoeed High idling asv/aesk] <— | <— it After changing Pea Paeor Without N & B Piping 0.0V/0k| <— —_| fecchangi 15| 18 PI OPT. With N&B Piping osv/oK| <— | <— [Ifthe display O.5V_ Ok ya changes With N & B Piping — failure of aor When control pedal is |45V/30k] <— | <— | Sensor. 5 | 0.5V_Ok | depressed fully If he dota §] | No. 16 Control lever at neutral, a =| |press, sensor | Position E/G speed Low |22V/21k * chee re of 5| ,q| 8-11 P1 NEGA-CON | Control lever st neutral po- cate 3/6 22V 21k | sition, E/G speed HIGH |SOV/31K) <—~ | 5| |8-12 P2 NEGACON J Controt lever at full oper- | 05V/3k 7 2.2V 21k | ated, E/G speed HIGH orless | “7 | 3 Control lever at neutral No. 19 position, E/G speed Low | 28V/3k} <— | <— PRESS, SENSOR [Control lever at neutral 17) 8.15 BACK PRESS. | position, E/G speed HIGH | °9V/k O.5V 3k) When relieving arm in op- raid 16V/8k| <— | 12V/5k No. 20 Control lever at neutral 7, S| [prorova.ve [ReneS Low) anmaek| <— | <— | smeie” | 18| 0- z due —|— = Kossurea ee ope cebinaS ex E76 speed Hic ing eee cis. S| | Meas: aesma. 6k | boston, When relieving |earma25k] <— | <— Peyeey s arm out operation Wen the meas- s| [No.2 Control lever at neutral rod value var 5 x position, E/G speed LOW |350mA/6k| <— | <— | the variation of Sliglorre wr-pass | S0HIGH conan Ps 8] | COMP. S50mA 6k | ea Te ne elo Stren” oe - n relieving boom raise |647mA/25k| <— | <— | current. on the 5] | MEAS. 3t6mA 6K] operation Sreia" ot 2 Control lever at neutral ees S| |Morovarve | ostio,€/6 speed LOw|asomavek] <— | <— |tatiertions Blzo}os strave. — MAHIGH common Ssignge. °° =| | comp. asoma ox] E/SSam High aire | Checking attr 8 G1 | When relieving arm in op- 6k] <— | <— [replacing tne MEAS. SIGMA _6k| an re 3-10No. Display Operation provedure | $K200-6 | $K230-6 [ SK3206 | Remarks ©] (No.2 Control lever at neutral co fremnction Bl | propo-vALVE position, E/G speed HIGH |647mA/25k| <— | <— teeny 4 Rore idling _ controller ed aera (6 sped HIGH le ° rer i. 7 : — a 3 MEAS. 342mA 25k nue leasing arm in op- | 200mA/0k ‘367mA/8k Played by When the meas Control lever at neutral posi- a | ee vaLve | HOn/6 spied LOW icing |?00MA/2TK|T20mA/ 2 mA/Z7K issexoraingte i : Control lever at neutral pos- Ination. RI 22 ep ena spi | tion, E/G soped HI iating|7S0MA/S0K) TOMA 3th TIOMA/ 2h} ts aosaotabte. '3| | MEAS. 745ma 30K | E76 speed High ing, Mozsure ine & . When lifting RH crawler _— <— | ourrent a '$|_|_POWER SHIFT OMA} andrrotate onnectar wth 3 Control lever at neutral posi- clamo meter 3 Se ae VALVE Fon EG spend LOW iding | /2OMA/ TK} 720mA/ 28k} 700mA/27K Proportional 2 Control! lever at neutral posi- Measure the re- loa] EZ PL PUMP | tee seedling |BMA/aIK A /atK TOMA/=24 Sans E] | MEAs. 7asma 30K] E76 spond High ing, 7 Fepiacing tn hn lifting — | — | cormsetor pest POWER SHIFT. OmA| Srarotalg se Eni posse No. 39 Su Internal adjustment SW ~-- TEST B|_ |MECHATRO ADST. | itis strictly prohibited to | When the buzzer stop ----- ON 2/24] CONT. SW RUN | turn the switch to RUN ‘SW pressed =] | CONT. VOL 50% | and TEST when the starter) ynen the buzzer stop =-~-+ OPEN 3 PROG. SW OFF | switch is turned ON. ‘SW released | |No.40 When mechatro controller --- ON 3 25| RELEASE SW ‘failed s KPSS OFF ‘When slewing brake does --- ON ‘SWING BRAKE OFF not release, © The pressure sensors No.9 ~ No. 17 show only the reference value of indicating voltage. The proportional valves No. 18 ~ No. 23 show only the reference value of indicating current. (The voltage and current which turned the reference values may differ from the actual values.) When the difference of indicated value and the measured value on the proportional valves No. 18 ~ No. 23 is 20% or less, it is acceptable. Note 1, The standard source power (ESS) of proportional valve for pump on the display is OmA. (Max. power shift is lower than 150mA) ‘© When pump power shift exceeds 70mA, malfunction (slow motion etc.) of Boom, Arm and of Bucket are occurred. a) Failure of hydraulic system b) Failure of low pressure sensor © Other causes of power shift display are a) Engine power down (High altitude, poor fuel and engine failure) b) Failure of Pump (Failure of solenoid valve or regulator) ©) Mistake about “A adjustment” ote. 2. By turning the starter switch ON, concurrently the M mode is started, 3. There is the item that the No. is not matched with the Screen No. 7 3-1 ®3-5 Checking oil level of hydraulic tank and making up oil @ Inspection 1) Choose the level and solid ground to have the hydraulic oil level inspecting position (right drawing), and stop the engine. 2) Check oil level with level gauge on the side face of hydraulic oil tank, if the measured value is within H-L zone, it is acceptable. Since the oil level varies according to the temperature, check the oil level taking the following as a guide. © Before operation : Close to L level (Oil temperature 10 ~ 30°C) © During operation : Close to H level (Oil temperature 50 ~ 80°C) @ Making up 1) Press rubber cap @ on the upper surface of hydraulic tank and release the internal pressure of hydraulic tank. 2) After making sure that the internal pres- sure of the hydraulic tank is completely released, loosen capscrew @), remove cover @ and make up the specified oil to the specified position. 3) Check o-ring ® on the cover section, and replace it, if necessary. 4) Install cover @ and secure it with capscrew @ tightening to the specified torque. 5) Start the engine, and after light operation of 5 to 10 times moving every cylinder equally, return the machine in the hydrau- lic level checking position. 6) After the engine stops, check the oil level, and make up the shortage, if required. Note : Never fill the oil to H level or over to prevent the damage of hydraulic circuit and oil spouting out. 3-6 Releasing internal pressure of hy- draulic tank and system PGS The insides of hydraulic tank and hydraulic system are always actuated by internal pressure. Don't fail to carry out the inspec- tion and maintenance after releasing the in- ternal pressure completely. @ Releasing internal pressure of hydraulic system 1) After the engine stops, turn the starter switch ON (Lever lock under the work condition), operate ATT and travel right and left motions several times at full Hyd, oil checking position y filling throttling, and the internal pressure of the hydraulic system can be released. 2) Press valve with rubber cap @ on the upper surface of hydraulic tank to release the internal pressure of hydraulic tank. 3) After releasing the internal pressure of hydraulic tank and hydraulic system, carry out inspection and maintenance of hydraulic system. Note : The SKTI5SR and SRI35SR are equipped with pressure release switch, the pressure is released by the different procedure. 3-123-7 Adjusting tension of belt PGI This might cause a severe accident like being caught in the rotary sections, belt, fan, etc. After making sure of that the rotation is stopped completely, carry out maintenance, ete. ‘The engine is equipped with alternator, fan, belt for air-con. Check the belt for wearing and damage, check also the tension of belt, and adjust it correctly in order to maintain the highest performance and life of engine. Check the tension of belt pressing the center of belt by hand, and make sure that the slack is from 10mm to 15mm. Note : Never apply oil on the fan belt to pre- vent it from slippage causing the short life. 1) Open engine bonnet. 2) Loosen attaching nuts @ and adjusting nut @) to adjust the tension of belt. 3) Loosen adjusting bolt @, adjust the belt to the specified tension and tighten attaching nut @ and adjusting nut ® 4) After adjustment, operate the engine at low idling for 5 minutes, and check the tension again, 5) Close the engine bonnet. 39 Force : 98N (10kgf} Alternator Crank pulley Idle pulley Compressor Sy Fe 3-13 ‘ore Tightening torque 82.4 £9.8Nem {84> 10kgf-m) BN (10kgf)3-8 Adjusting tension of air-con belt Force: 98N (10kgf) PGS This might cause a severe accident like being caught in the rotary sections, belt, fan, etc. when checking the tension of belt. Note : The improper slack of belt may cause the performance deterioration of com- pressor, and also may cause sever dam- age. 1) Open the engine bonnet, 2) Measure the slack of belt. 3) Press the center between pulleys by hand, and if the slack is 7 to 10 mm, it is accept- able. Crank pulley Compressor 4) Loosen the lock nut © and screw the ad- justing bolt @ to adjust the belt tension. Then tighten the lock nut . 5) After adjustment, operate the engine for about 5 minutes at low idling, and check the tension again, 6) Close the engine bonnet. 0 3-43-9 Performance test 1) Tools @ High pressure gauge (500kgf/cm*) --- 2 pes @® Low pressure gauge (70kgf/em') + 1 pe @ Low pressure gauge (50kgf/em’) ---3 pes @ Tee (244423983) +3 pes (PF 3/8 (F) x PF 3/8 (F) x PF1/4(M)} © Connector (ZH22X06000) + 3 pes (PF 3/8 X PF 3/8) ® Connector (ZH22X04000) “1pe (PF1/4) ® Connector (ZH22X04006) - 3 pes (PF 1/4 X PF 3/8) @® Spanner sree +L set Surface thermometer @ Stop watch + @ Tape measure (30m) ® Angle meter ® Container (20L) 2) Warming up engine Start the engine, and warm the engine coolant to 60 ~ 90°C. (After engine start, the M mode is lit up.) Measure the temperature with the engine coolant temperature gauge (1). For the temperature of pointer position, see[ Page 2-5 3) Measuring the engine speed Press the screen change switch (2) on the gauge cluster once, and the engine speed is indicated on the multidisplay. Eg.) SK200-6 ------ 2,220rpm, 4) Raising temperature of hydraulic oil Raise the the temperature by releaving the boom raise and arm in operation. ‘Measure the temperature with a surface thermometer attached on the side face of hydraulic tank. + 45°C to 55°C Surface temperature 5) Pressure gauge attaching position Release the internal pressure of hydraulic system and hydraulic tan! For the procedure, see[ Page 8-12, © Pilot circuit Remove a7 port plug PF1/4 of gear pump, and attach pressure gauge of 70kg{/cm*, ® Main circuit Remove al, a2 port plugs PF1/4 of main pump, and attach pressure gauge of 500 kgf/cm’. a 3-15© The measurement of the following pressure are allowed even around the pump. (Reference) P1 side back-up 23 a8 mode screw Note : x} Names of port plug (EX : a7) ete. in this description agree with plug codes of hydraulic diagram. (See[ Page 4-2 to 4-3 ]) af 29 a - ow ]* © 9) Ro OF: al a2 ar ® High pressure sensor circuit Remove a5, a6 port plugs PF 1/4 of main pump, and attach pressure gauge of 500kgf/cm*. @ Pump proportional valve secondary pressure circuit P Remove a8, a9 port plugs PF 1/4 of main pump, and attach pressure gauge of 50kgf/cm’. © Pilot piston circuit Remove a3, a4 port plugs PF 1/4 of main pump, and attach pressure gauge of 50kgf/cm* @© Negative control pressure gauge when operating in back up mode Remove a3, a4 port plugs PF 1/4 of main pump, and attach pressure gauge of 50kgf/cm’. Note : Pressure @ and @ are detected same pressure. Pressure @ and © are detected same pressure. 2 3-16 @© Negative control circuit ‘Remove negative control relief Pnl, Pn2 plugs PF 3/8 of main control valve P1 and P2 blocks, and attach connector MRI OR2 ORS 7H22X04066, and then attach pressure gauge of 50kgf/cm’. Nega-Con @® Negative control back pressure circuit | pack reas Remove negative control relief Tn plug y Tat PF 1/4 of main control valve P1 block, and attach pressure gauge of 50kgf/cm*. Notes 1, The negative contro! pressure is the pressure when the negative control back pressure circuit is subtracted from the negative control circuit Nega-Con pressure. circuit 2. Marks OR1 to OR8 show the overload Pat relief valves. on om & @ Releasing auto accel function For the releasing procedure, see [ Page 2-20 6) Measurement of pressure OR? @ Make sure of every relief valve pressure mentioned in Performance Inspection Standard Table by measuring pressure according to the described measuring con- dition and motion, Nega-Con - circuit I _ ® Measure every relief valve pressure, and Pra adjust the pressure within the standard values, if necessary. @® But, overload relief valves (OR1 to OR4, OR7, OR8) should be measured after tightening main relief valve (MR1). (Because the high pressure) Setting pressure of ORS and ORS are lower than Main relief pressure. After measurement of every relief valve pressure, adjust the pressure of main relief valve (MR1) when the ATT set pressure rises to 385kgf/cm‘, and for standard to 350kgf/cm*. (Set the pressure of boost in advance) one’ Left ® Make sure that the main relief valve is set slewing to the set pressure by operating the boom raise motion. © Press ATT boost switch on the top end of ATT right control lever, and make sure of the set pressure. 7) After measurement of pressure Remove each pressure gauge and connec- tor, and attach the original plugs 8 3-1708) Measuring pilot pressure at the failed section © Release the internal pressure of hydraulic system and hydraulic tank. For the procedure, see| Page Remove pilot hose close to the main con- trol valve on the failed section, and attach tee 244473983 and connector ZH22X06000 and the pressure gauge of S0kg{/cm* @ Example of measuring secondary pres- sure of bucket digging and swing right Start the engine, operate the bucket dig- ging (PBC port) and slewing right (PBS) motions, and measure the pilot secondary pressure. The pressure is about 31.5 kgf/cm? at lever full stroke. @ After measurement, remove the pressure gauge, Tee and connector, and connect pilot hose, © Restore the auto accel function. For the procedure, see | Page 2-20 9) How to make sure of the pressure without pressure gauge @ Display the Table of Service Diagnosis on the multidisplay. For the procedure, see Page 3-8 ® Check the figure by item on the Table of Service Diagnosis. @ After completion, turn the starter switch “OFF” 10) References @ This is used to check the pressures of the slewing motor and travel motor. @ Release the internal air of hydraulic sys- tem. For the procedure, see| Page 3-12 |. @® Remove the slewing motor PA and PB port plugs PF 1/4 and attach the pressure gauge of 500kgf/cm*. @ Remove the travel motor MA and MB port plugs PF 1/4 and attach the pressure gauge of 500kgf/em’ © After fixing the slewing and travelling motion, measure the pressure operating the slewing and travelling motion. @© Incase the pressure is abnormal, check on the slewing motor and travel motor, and repair them, if necessary. @ Measure the pressure again and, if normal, remove the pressure gauge and attach plugs. Example : Attach Tee and connector to 3 section, and attach Swing PB 3-18 ®D3-10 Performance inspection standard (SK200-6) Note : When power is supplied, M mode is provided. Unless otherwise specified, the measure- ment is performed in M mode. Pressure measurement TTobranca it [Adlusting]| Measuring Inspection item boxtod Sor] Por] So tocar] Ut |“Pont®| Sten | Cleanliness of yerauli ot | Hyeauli i tank a+ i] 1] cas | — |Sanoing & | Temperature of hydraulic oil| Tank surface 80] + [8] | = _|Anbient tmraure 8 ‘Cootant temperature Radiator surface 75 | + 15] ~ 15) — |-Wwe~soe S| [iain 1000 | + 25] - 25 Low throttle 8) y [Hate wre | monn | | * 21 = ree BY 2 [Amow eroeescinias 1950 | + 25| — 2] rom | isnot [All measurements 3] lem me 20 [+ 25 - a reauired | must be performed B/a under the condition Dcelraten 060 | +25] — her acm is “OFF” Pilot primary pressure a at 0 [+ 3|- 3 PRI_[Hi idling T © |ieeaon press. |i Pat Ef Low es role | me 0 | +15] - 5 — |Hitding g PI a alec me a] mH) +5] 0 wet | Boom up Main z p_[Punp al 3 | Boost az] (88) +1)- 8 MRI | Boom up & | Dozer Pa SS = — Boo ul a | ‘OR3_[Boom Up /m R 385 ‘OR4 [Boom Down a H weve] o ORT_[Arm in 5 R 05 Rs [Arm Out 2 a H|e a 405 ORT | Bucket in I a | 285 ‘OR? | Bucket Out z tH| = ORs [Swing Left Swing 2| ws|+4| oO RH server |__| Sere at Foward BO ere a | raver rent and Travel 360] +15] 0 left simutareousiy cn : — fea ers A er = Dozer R — = Popa indicated | alate ie presare cutvave | © (Net en [inane nae c|3| 2 [voz] 69 (mA) [Barton straight vate 3| 8 Yeas! -o8 Teint aren in & [Prby-pass z| = nee ‘Approx. | theft table is the Blotvave | 2 | S| g [Noo 380 _| sane eat he B| 5 (Ammen | | & [wal G47 |EZGH ter inretra =| 8 [P2by-1 . e/flgmes [| 9) 3 [ma i a Eien! ole] B2] |, |, on |e eae Pl by-pass [5 3 eo ul stroke show Ar porns ve de to recircuation |_® Nez] 0 200 | verating codtos. 4% 3-19bucket tooth - resre easement Toerane |, [Adhstng) Meer a estn| Size | ort | [User [Lower] “| Point | constion PI proportional valve 5 No. 24 "ndated acta} puro Bl 8 ai aren q [Pena orcctinalvabe| SE | SE \No.zs) 8 | +18) ~08 ow [ete 3S Be ea ket/om? © |P1 pump proportional valve | 2& | 38 |No.24 - &/G Hi E [pj mmo renin are) ee | FE lns| 09 [+ 2] -15 eae inspection tem Standard Unit ist. speed | 226~ 249 Nee Mimode [2nd sod [16-4~ 169 sen/2re (RH&LH) Amode | 2nd. sored | 165~ 18.1 — > —— —= Up 30~ 36 Poom Down 26~32 Th 31~aT Arm +g | Culinderoverating ut 26~82 | B | time (No load) in 30238 2 Bucket Out 23~29 Down — ; a RH [Variable spoed_[|_—— cas Ch [S10 sod so~ 56 | ‘st. speed a 213 ~ 283 ee Tron Tear) 2nd. speed s “Amount of travel ~ ae 2nd, speed o~10 | m/2om Parking brake drift poi 0 mm/smin Swing inertia braking [Neal poston afer 180 Tul rift ving ay oe Performance of swing |16° slope 5 om ag | Parking brake gradient eB Tip of bucket tooth %6 5 Boom cylinder 7 & Ogee amount of Cs ore Cn ‘Arm cylinder 5 Dorer cylinder — “Amount of horizontal play atthe tip of mae | mm 46Performance inspection standard (SK230-6) Note : When power is supplied, M mode is provided. Unless otherwise specified, the measure- ment is performed in M mode. Pressure measurement Tolerance [Adjusting] Measuring Inspection item Stenderd Unit Position] size | Port Upper | Lower Point concition “| Ceaninss of haute it [Hydra otk 8 [+ 1]— 1] Cas | — | Sanpine | Temperature of hydraulic oil] Tank surface 50 | + 5|- 5] —_| Ambient termoerature 2 c 8 | Coolant temperature Radiator surface 75 | + 15| — 15] — |-we~sre E| [Loins ooo | + 25| — 25 Low throttle 2 | [eine 7300 | + 25] = 2 |jsinent | B| 2 [Amor Distay cranes switch 2100 [ + 25] — 2] rom | isnot [All mesuremenis 2] Slemox ae 70 14 lS required | mast be performed ale under the condition Deceleration| 1060 [+ 25[ = 2 wre air-con is "OFF Pilot primary pressure = a 0 [+ 3[- 3 PRI_ [Hi idling E_]Newa-con press. or |_Pit Pat \_ _ Elton es role” [re a 30 | +15) - 5 Hi ing 8 PI al § arr a0 }+5| 0 MRI | Boom up P2_|Main a 5 = Pr |Pumo al Boost L—— 385 | +10|- 5 Mp1 | Boom un P | [2 Dozer ra [— Fey = H “6 [| 0|-® (OR [Boom Up Boom al R 6 | 0/-% ‘OR4 | Boom Down ¥ H 36 | 0-3 ‘oR7_|Armin 8] jam - pera] a —- jp = e R 405 | 0] - 55 ‘ORB [Arm Out H |e 405 | 0] - 65 ORI | Bucket in Bucket 5 a} 5 R|¢ 385, o/-% OR2_| Bucket Out 22 tH| = ORS [Swing Left | Suing 2 300 | + 65| + 10 = RH 6 [Swing Right E ket/nt 5 Fowera| te RH eral ja | ravet right ena Travel t 350 | +15] 0 left simultaneously LH fone 2 — | oneration Reverse | H = Dor f- I R — |—|— — P2 by-pass indiate [alee te cut valve Bile], (2 Me inaction foe inne c | 3] 8 [now] 69 (ina) | on straight valve 2; ee " 1 The insicated current in % [Pt by-pass gis +15] -05 ‘Approx. | the et ale sth = |out vave Do} 8] 8 [No.2 360 _| save meaning as fhe =|2 a] et e7eri leer nner =| 2 farm variable a 2| Bleue fe] 2] 3 fea Toe Travel S| max, value because R straint vane| © | 3 | g [M2] %) 847 | E76 Hi and lever Pi by-pass [5 | = | © Ino a9 full stroke show ok ae various value de to variable [Arm verte | No.23 0 | 200 | operating conditions. a 3-21Pressure measurement Tolerance [Adjusting] Measuring Inspection item sition! Sze | pot |S Toscer [Lower] ONY |” point | condition Pt ertonl vave| No.2 ‘rat [oF pur proportional vave| |g 7 cr 5 |e pure proportional vaie| $2 | SS |Noz] 88 | +15) ~05) |e E ge 28 kei/om? 5 |P1 pump proportional valve| 28 | S8 |No.24 _ E/G Hi = | pe pumo proportional vale| Sy | 25 |No25| 62 | + 2) -18 380 | Max, value Inspection item Standerd_[ Unit M moe ist. speck | 23.7 ~ 262 No, of track link d 5 re Mee [end PETE yey (RH& LH) [Amode 2nd. speed | 18.2 ~ 175 Up 31~37 | [Down 28~34 7 in 38~ 44 m Cylinder operating Out ze~a4 | | time (No oad) in 34~40 2 | Bucket Out 21~27 1—Dowa — 5 Dover Up —_1 RA [Variable speed | —— meen [STD speed ga~eg | I ~ 233 — ron 2a~2 Rubber = Travel speed sec/20m lone spews |_FO® 123~ 186 | sod Rater — “Amount of travel ~ Amour 2nd, speed o~10 | m/20m 15 slope - Parking brake drift, | cient 0 mm/Smin ‘Swing inertia braking | Naural poston aftr 160" full spd rift swing % coeree Performance of swing | 15° slone . mm a | Paine trate sracient 8 Tip of bucket tooth 96 5 Boom cylinder 7 Dron aur of mm/min | (no load) ‘Arm oylinder 5 Dozer eylinder — “Amount of horizontal play at the tip of ~ aan 30~55 | mmPerformance inspection standard (SK320-6) Note : When power is supplied, M mode is provided. Unless otherwise specified, the measure- ment is performed in M mode. Presse measurenart “Tolerance aemel a oecrie! Inspection tam fetal Se [rt | SO mee] ume [Ar] Meare ~ [eanlns of fcraulio or | reali of tank [+ 1 1] Cas | — |saroing & | Temperature of hydraulic oil Terk surface 80 | 8[~ 8) | = _| Ambient temereture B | Coolant temperature Radiator surface 15 | + 15| - 15 — |-we~s0'e £| [Loiing 100 | + 20| — 60] Low thete 8 |g [Hiiting : M mode 23865 | + 20| - 30 cate elt Display change switch fester ing) B| 2 [Amato ae zo | +20} = 30) rom | isnot |All measronents Z je cster 2 8 lenew Soe reauired | must be perfrmed 8 | 0 under the conton Decleration 1060 | + 20) - 20) hee ero s “OFF” Pilat primary pressure a La so|+ 3] 0 PRI |Hi idling i Pil Pri E_]nee0-oon press. or _ [EE Low ess relict [Fe mw] @ +B] oo Hi iting Sarr ey a1 wol+5| 0 wat |Boo 3 + of é °2_| Nein 2 ° 3 loon ee S|) 35 | +10 - 5 Rt | Boo 2 I +10) - E P 2 | ne 3 [Dozer Ps | — SSsHasS = H 46 5 Boom Boom | a c = R | as | 0|- 3 Boom Down 3 H 285 = [acm in 8) lam pave} a o}- 8 3 R 5 | 0) - farm Out 2 Hq | € 405 oj - Bucket In 8] e [pune & a od als r|é a | 0|- 35 Bucket Ot £\é ow uH| 2 2 vo | +5] +10 swing Lett $ {swing = | 3 RH ‘erat Sing et 5 Fowar| = RT erad et | Travel right and Travel as} 0|-15 loft simultaneously oe i | overation Rovers H == = Dover R — = PBB Gattis presre atvow | & | 3 | Ma ra [nasi oe ale | ied vote at sramtvave| © | 3 | & [M2] 88) oo) oe oO Ete ore Sires | >) 2 | 2 how rox. | ee tate 2 loa ve &| 3 350_|sfoe meng she S| 2 [Arm variable 8 |E/G Hi lever in neutral o|S[etame | 4 | = | 8 [ex] 2 oats 3 | 3 [rer 2|3 z Ele 8) Bg) 2 ma es vo ce Travel S| ax, vale because E |siraigntvane| © |S] B [Mz] Bo) 847 E76 Hi and lever Fianss |p | = | © lem {ul stroke show ee = various value due to veribie frm varias | [male 367 [operating conditions. 2Pressure measurement “Tolerance [Adusting| Measuring Inspection item ‘sie | Port ‘Standard Unser [Lower Unit Point ‘condition > Tndiated | E76 Hi slreamepeerina vate] £4 |52 [naz] 20 |+75]-05] | SR Law ma 8 38 sevens | [poston © | Pt pump proportional valve BB | No.24 _ E/G Hi © |e aump proportional valve BR |nozs) 2) + 2) -15 858 | Max. value Inspection item Standad_[ Unit st. speed | 06 ~ 92.8 No. of track tink |M™O0 |r speed | 17.7-~ 18.7 rotation sec/3rev. (RHEL) |p moe ist. speed [93.3 ~ 955 2nd. speed | 192~ 21.2 Up 32~38 Boon Down 31~34 - | In 50~58 Cylinder operating I Out 32~38 seo | time (No oad) ii zaaul Bucket | 2 Out S Down z 3S a Up. RH [Variable speed | _—— eae 4 [STD seca so~ ee | —— ca 19.0~240 “Travel speed sec/20m a Tron TT ~ 187 Rubber = “Amount of travel oom 2nd, speed ~10 | mom 15° slope Parking brake citt | SI 0 | mm/omin Swing inertia braking |Neutral postion afar TOO" ta pad rift swing w degree Performance of swing | 18° slope ri mm ag | Parking brake gradient Q Tip of bucket tooth 10 | 3 ts 5 Boom eylinder 10 & ae mm/Smin | (no load) ‘Arm oylinder 7 fe cylinder — “Amount of horizontal play atthe tip of ~ bucket tooth ee3-11 1, Mechatro controller Adjustment and Inspection of electrical equipment © How to change the starting mode from M mode to A mode (Perform when the starter switch is turned OFF.) Procedure) Placing the controller holding the coupler side on this side. Open the cover. switch rab abthabadth a a. 1 nm |. Test/Run 3 913, ‘Two 3-pin terminals, JP2 and JP1 are on a line. ‘The left 3-pin (JP2) is short-circuited with the jumper black cap. +M mode + A mode « Cap the right 2 pins out of 3 pins Cap the left 2 pins out of 3 pins. +| ‘Coupler side Jumper black cap it JP2 JP M mode start 2. Gauge cluster Change the cap position as shown in the figure a, ds JP2 PI A mode start © Adjustment of brightness and language of the multidisplay (Perform when the starter switch is turned ON.) Adjusting brightness of multidisplay Adjust brightness by turning the driver (+) inserted trimmer VR1 clockwise and counterclockwise. Position (Figure)] Language @® Resistance measured 0 Japanese between case and 1 English N21 each terminal | 2M or more 2 qua with 500V mega tester indonesian “ee a9 Not set Dip switch Dsw Back side of gauge cluster (Remove cover) Select the language by setting the figure to the required one while turning the driver (+) inserted in dip switch DSW. 3-23. Inspection of solenoid valve and proportional valve Check the resistance between connectors of each unit with tester. (-) € 17.5 £19 is normal (+) Connection of proportional valve () (+) Connection of solenoid valve ~ Lead on (—) side Lead on (+) side Detail of connector 4, Checking on pressure sensor Check the resistance between connector pin 1 and 2 with tester. Terminal Connector No. terminal layout_| 100MQ or more is normal for all 1 | Power supply (+) | sensors. 2 Output (+) High pressure sensor a i Low pressure sensor Back pressure sensor Negative contro! sensor 5. Governor motor Check the resistance of each pin of limit switch and motor connector with tester. How to check limit switch ‘Turn starter switch OFF, apply tester to pins 5 and 6 and turn the output Lead color |Terminal 2 No. | Lead color | Terminal White COM 4 2 1 Brown Red | NO | 2 | Orange [Yellow [NC | 3 | Red 3 S 4 [a] Yellow How to check motor shaft. And if it is “OFF” when the OFF Apply tester on connector pins resistance is 00 in the range of 52 5a and 2, and 3 and 4, and the re- degree, and if it is “ON” when the re ON ON srark sistance is 5.72 + 109%, the sistance is 0Q or over when turning connectors are normal. angle is over 52 degree, the limit is normal. Detail of output shaft 82 3-2 @6. Engine speed sensor ‘The adjusting procedure for units is shown below. How to measure How to adjust speed sensor 1) Resistance 2.3kQ + 0.2kQ 2) Voltage AC range 14V ~6V Disconnect the connector of speed sensor, and measure the voltage between pins on the sensor side. When the measured voltage at high idling in the AC range is 3V or more, it is accept- able. (The voltage is set to 4V or more be- fore shipment.) Accel potentiometer Apply tester to power supply (5V) of connector and grounding, and Ring gear Speed sensor Lock nut Tighten it, and the voltage rises. Loosen it, and the voltage drops.- @ Apply Locktite # 262 on the speed sensor threaded section. @ Tighten it until the top end of speed sensor comes into contact with the ring gear lightly, and return it one and a half turn. (Space between ring gear and sensor top end is about 2.3mm.) @ After returning it one and a half turn, fix the speed sensor and tighten lock nut to the torque specified below Tightening torque 24.5 to 34.3Nem {2.5 to 3.5kgfem} measure the resistance. Resistance : The resistance 2kQ is normal Engine water temperature ‘The right Table shows the resistance measured Fig. 1 Characteristic of resistance under the measuring condition shown in Temperature (C)| 50 | 6002] 80 100 |106+0.2) 120 Resistance (2)| (80) | 86.345 (28.5) (165) [14.308] (10)3-12 MECHATRO CONTROLLER “A” ADJUSTMENT 1. When the mechatro controller requires adjustment, After replacement of the following parts, if the following display appears on the multidisplay, the “A” adjustment of the mechatro controller is performed. When the mechatro controller is required to adjust, @ When the mechatro controller is replaced, @® When the governor motor is replaced, @ When the [ROM DATA FAILURE ]is displayed on the multidisplay, @ When the[ ROM DATA FAILURE ]and[ MECHATRO SET ERROR Jare displayed al- ternately on the multidisplay, - 2. Preparation ® Warm up the engine, @ Turn the air-con switch off. ® Turn the starter switch off to stop the engine, @ Push the operator's seat forward fully, and bring the back seat down to the front side. © Remove 6 clips installing the resin cover on the rear side of the operator's seat with (+) screwdriver. ® Remove the resin cover. @ The mechatro controller is found enabling the adjustment. Note : Make sure that the knob for the engine emergency stop is pushed in. If the adjustment is done while the knob is pulled out, the engine speed can not be set correctly. 3. Adjustment Procedure HATES [_Movernent of governor motor © Remove the grommet on the unper face of the a mechatronics controller, and the internal switch wnt Mechatro controller ‘on the inside of controller from [RUN ] to (est o 4 Lest] TEST 4 E At E adjustment = Oo t Grommet Seaver reerverrrerr @ Turn the starter key switch [ON Turn the accel dial to free choice positon MONITOR ‘STEM OK Governor motor stops at position aocording to accel dial movernent. @ Press the buzzer stop switch for about 5 to 10 jcru Sie? ‘ seoonds, and release the hand ater the | STEP 11] | pty ten 1 start $ is displayed, and wait until the following symbol i Ste ee Sony Selt-trayels to the engine PU Geis} stop position.Procedure Multidisplay [Movement of governor motor @ Atter verification of the CPU [STEP 2 ]GAP (STOP) display, moves it to the engine room and s adjust the rod Assy standard length to[ Bmm | in aa order to have the clearance “A 0.1mm” between ||cpy STEF . the governor lever and the engine stop set bolt GAP (STOP) Pace ache lien oo ad be eet © Allen wrench 6mm 198 (SK320-8) © Thickness gauge © Press the buzzer stop switch onoe, and wait until the CPUL_STEP 3 ] START E/G is displayed, Selt-travels to A position (about 1000 ~ 1200rpm). © Aiter verification of CPU [ STEP 3] START A E/G display, starts the engine STEP 3 ‘Then, it is unaffected by the accel dial position. | |CPU StaRT Evo Stop at A Position. @ Press the buzzer stop switch once, and the CPU A ‘STEP 4 | MEMORY is displayed and the con- Lo troller returns from the A position of governor || oo.y STEP 4 i to the low idling position once, and then reads the MEMORY engine rpm to the high idling automatically Return from A pasition, and selt (Required time : about 3 minutes) travel to the high position. © Ater completion of the read out, wait until the “CPU FINISH 2220RPM" is displayed on the multi- (> A display. After the “CPU FINISH Z220RPM" is dis- played, the controler returns to the aooel dial | ~—= initial optional position automatically. cpu FN a Note : If the “CPU FINISH 2220RPM" is not displayed, the adjustment has failed. Turn the starter switch off, and per- a form the adjustment again, 4. Completion of the adjustment (Check engine speed again) @ Turn the starter switch [ OFF ] to stop the engine. @ Return the inside adjustment switch from the[ TEST ]to the{ RUN ] position, install grommet, and press the screen change switch on the gauge cluster once to display the engine speed. ® Change the maintenance connector for the auto accel release, start the engine, and raise the engine speed to the high idle rpm. For procedure, see Page 2-20 @ With turning the work mode on the switch panel, the mode display on the gauge cluster switches to make sure that the engine speed changes on the multidisplay. @ Return the accel dial to the low idling position, and change the maintenance connector after the engine stops, and then start the engine again in the auto accel function condition. © Turn the accel dial to the high idling position, and check the engine speed in the auto accel con- dition. @ Press the screen change switch on the gauge cluster two times, and “OK” is displayed. © Install the resin cover, and move the seat and operator's seat rearward. 55 3-23©. When the mechatro controller can not be adjusted, @ The[ CPU STEP 4 MEMORY | to [CPU CONDITION ERROR ]is displayed, making the ad- just ment impossible. A. (Display condition) @ While reading the engine speed, in the condition of the engine revolu- tion, 850rpm or higher, for the engine rpm before and after the steps of the governor, the revolution at rear step is 10rpm higher than that before step. (Cause) © The engine speed sensor has failed to read the engine speed. (Corrective action) @ After measurement and adjustment of the voltage of speed sensor, carry out the “A” adjustment. (Disconnect the sensor connector and measure the voltage.) —E 3V (AC) or more at high idling condition Specified value (Woltage available for controller to read) | Votage 1.4 to BV (AC) [4V (AC) or more at high idling condition | Resistance 2.3 £020 set in the factory] B. (Display condition) @ Whore the abnormal rotation (step out) in high idling condition. (Cause) © Governor motor link rod connection error. (Corrective action) (Corrective action) @ After verification of connection of the link rod, carry out “A” adjustment. {Link rod length : 288mm (SK200-8), 304 mm (SK230-6), 198mm (SK320-6)} If itis stepped out even after the adjustment, press the buzzer stop once just before the stepping out as an emergency measure, and the speed changes to the high idling position temporarily and the CPU FINISH 2350RPM |is displayed. ® The[_CPU CONDITION ERROR |,[ CPU MECHATRO CONT FAIL | and[_CPU ROM DATA Jare dis- played by turn, making the adjustment impossible. (Display condition) @ When the engine speed is 300rpm or lower, or 3,000rpm or higher, * The [ CPU MECHATRO CONT FAIL |is displayed. © When the engine speed is Orpm, * The| CPU ROM DATA |is displayed. (Cause) © ‘The engine sensor has failed to read the engine speed. ‘The harness of the engine speed sensor is broken. (Corrective action) @ After measurement and adjustment of the voltage of speed sensor, carry out “A” adjustment. 3V (AC) or more in high idling condition. @ The[ CPU ROM DATA FAILURE ]is displayed, ‘A. (Display condition) @ When the mechatro controller fails, (Cause) © There is the danger of breakage inside of the mechatro controller. (Corrective action) @ If the failure is not recovered after the adjustment, replace the mechatro controller with new one. B, (Display condition) @ After the mechatro controller is replaced, (Cause) © The mechatro controller is not adjusted yet. (Corrective action) @ Adjust the mechatro controller. @ The display does not go from the [STEP T CPU START ] to [STEP 2 CPU GAP (STOP) (Display condition) @ The limit switch signal (grounding) in the governor motor is not input to the mechatro controller. (Cause) © Failure of the limit switch in the governor motor © Insufficient contact of connector on the governor motor or breakage of the harness (Corrective action) @ Check that the limit switch of the governor motor goes on or off. © Check connector and harness for possible damage, and adjust it if necessary. ® Others ‘The engine oil pressure is displayed on the gauge cluster, and the engine stops. It may be caused by the failure of the engine oil pressure switch and short-circuit of the harness.4, COMPONENTS AND CIRCUIT DIAGRAM 4-1 Layout of Hydraulic components (SK200-6 ) (Battery relay) Fueltank Hydraulic tank Control valve Pump iF “i Te Engine Swivel joint [ T @ ie Travel pilot valve t = == TA/C f ' | Compressor ‘ : J Radiator & | Oil cooler : Be * \ (Receiver tank) A ‘Sub tank Pilot valve (R.H) | (Boom, Bucket) (A/C Unit) (Sensor block) (A/C Condenser) Pilot valve (L.H) Washer tank —Multiless (Solenoid proportional valve block) (Arm, Swing) control valve4-2 Hydraulic diagram of Main control valve |Code| Name Code| Name 1_| Travel straight spool 50_| Pi side by-pass circuit 2_| Travel left spool _ 51_| P1 side Parallel circuit 3_| Travel right spool 52 | P2 side by-pass circuit 4 | Swing spool _ __|[ 33 | P2 side parallel circuit 5_| Bucket spool "|| 54 [Boom conflux circuit 6_| Boom conflux spool 55 | Arm conflux circuit [7 | Boom spool J[58_| Tank circuit Lett travel “8 _| Arm spool _ 57_| Drain circuit 3_| Pt cut spool 58_| Travel right forward circuit 10_| Arm conflux spool __|[-59" [rravel right reverse ci i 11_| P2 cut spool 60_| Bucket digging circuit oto 12 | Arm variable recirculation spool || 61 | Bucket dump circuit nt eh 13_| Main relief vaive 62_| Boom raise circuit me 14 | Over load relief valve (405k) 63_| Boom lower circuit (GI 15 | Over load relief valve (385k) _||_64 | Travel left forward circuit 16_| Boom lock valve "|| 65 | Travel left revers 17_| Arm lock valve 66 | Swing right circuit ch 18 _| Boom lock selector valve 67_| Swing left circuit | | 19 | Arm lock selector valve 68_| Arm in circuit — 20 | Load check vaive 69_| Arm out circut a =e = 21_| P1 Nega-Con relief 70_| Arm recirculation circuit 15 3 iL 22_| P2 Nega-Con relief 71_| P1 Nega-Con circuit Imes 68 | 23 re 72 | P2 Nega-Con circuit j 3 [ete_te I 24 [PI Valvebody || 73 | Nega-Con back press. circuit 1 [ete [28 | P2 Valve body. a 5 Siete | Be out ortinder leas \ Tightening torque according to port size ee G Size Torque Nem {kgf+m) Size Torque N-m {kgf+m} PFI 196 ~ 245 {20 ~ 25} PF 3/8 68,6 ~ 78.4 {7 ~ 8} PF 3/4 147 ~ 176 {15 ~ 18} PF 1/4 34.3 ~ 39.2 (3.5 ~ 4) PF1/2 107.8 ~ 127.4 {11 ~ 13) M10 49 ~ 64,74 {5 ~ 6.6} [Code| Port Name Port Name Size_|[Code| Port Name Size_][Code| Port Name Size Aa | Armin port Drb | Drain port PAs| Swing left pilot port PLc2| Arm lock selector valve pilot port | PF 1/4 | Ab | Boom raise port Dre | Boom lock selector valve drain port_| PF 1/4|| PB1| Boom conflux pilot port_ Pat | Pi Nega-Con press. measuring (Blank plug) ‘Ac | Bucket dump port _ Drd| Boom lock selector valve drain port PBal Arm out pilot port Pnt’| P1 Nega-Con pilot port AL | Travel left forward port | Pi | Pi pump port PE 1 || PBb| Boom lower pilot port Pn2 | P2 Nega-Con press. measuring (Blank plug) | PF 3/8 Ar | Travel right forward port P2_| P2 pump port PBc| Bucket digging pilot port Pr2| P2 Nega-Con pilot port As | Swing left port prt |{P3 | P2 Opt. port (Blank plug) PF 1/2|| PBL [Travel left reverse pilot port | PF 3/8 || PTb| Travel straight pilot port Ba | Arm out port P4 | PI Opt. port (Blank plug) PBr| Travel right reverse pilot port T [Tank port $32 Bb | Boom lower port PA1| Arm conflux pilot port PBs | Swing right pilot port [72 [Swing motor make-up PFS/A Be | Bucket digging port [PAa| Arm in pilot port PCa| P2 cut 73 | Tank port (Blank plug) | BL | Travel left forward port PAb| Boom raise pilot port pr3/a|-Pob| Pt cut pilot port Tat | Nega-Con back press. measuring (Blank plug) | pe 4 74 Br | Travel right forward port PAc| Bucket dump pilot port Pis | Arm variable recirculation pilot port | Tn2| Nega-Con back press, pilot port Bs_| Swing right port PAL| Travel left forward pilot port PL1| ATT boost pilot port lpr iva Dra | Drain port PF 1/4\| PAr| Travel right forward pilot port PLc1] Boom lock selector valve pilot port 384-3 Hydraulic diagram(Sk200-6) 7 a 9+29 --—— 828 |_18 Main pump Gear pump (for pilot) Main control valve ‘Suing motor Boom cylinder (LH) Boom ey! inder (RH) 1 2 3 4 5_|Travel motor 6 1 8 9 Arm cylinder Bucket cylinder 10 | Srivel_joint 11. [Pitot valve(for AT 12 Pitot valve(for Travel) 13 [S10 Wultiless valve (1S0 fixed) 14 |Wulti contro! valve (Opt.) 15_|Wanifoid block 16. | Accumulator 17_| suction strainer | 18 | Solenoid-Fropo. valve block 19. | Sensor block 20 |Sy-pess valve 21_|Return filter 22_|Bleether 23, [Boost check valve 24 [Bypass check valve _| 25 _|Restrictor 27 |tiydraul ic tank 28 _| Arm cylinder (For denol ition) 29 [Bucket cylinder (For demol ition) 434-4 Layout of Electric components 1, Components related to Upper frame (SK200-6 + SK230-6) L4 ‘Swing flasher & Rear work light (RH)(Opt.) SE-23 : Pressure sensor ) = harness > R19: Flasher relay (Opt.)SE-20 Connect to Pressure sensor : P1 side (Opt.) Frame grounding SE-10: Press. sensor Travel left Cab swW-3: Travel 1,2 speed SW SE-9: Press. sensor Travel right To Air-con amplifier SE-11 : Press. sensor : P2 side (Opt.) To upper side of floor plate Viewed from rear side of floor plate To floor plate In-pane View TL (Instrument panel R.H) I — — SW-21: ATT boost SW (Yellow taping) ‘er *) {SW-10 : Horn SW (Blue taping)} . SE-16 : Accel potentio SW-2 : Switch assy (MODE, Buzzer stop) O ve i ‘SW-1: Key SW : FE | £-7 : Tuner In-pane [es SW-10: Horn SW (Blue taping) {Instrument panel LH) \— 1 {SW-21 : ATT boost SW (Yellow taping)} || +2 Maintenance View V connector w t : To Cab harness —S a =o | 8 oNS 3 swt: — Lever lock SW View V View IE F-20: Timer ‘SW-26 : OPT Work light SW SW-22 : Travel alarm SW ‘SW-17 : Roof wiper SW (Opt.) SW-41 : High reach crane SW (Opt.) ‘SW-15 : Single/Conflux select SW ‘SW-38 : Warming up SW ‘SW-18 : LMN/BH Select SW (Opt.) SW-13: Air-Con SW View WE 6 4-744 To cab harness rs \ r inst panel harness Fuse box ) ht relay E-8 : Speaker LH E-9: Speaker RH M-5 : Power wind motor (Opt.) R8: J/B(15PX4) | J/B Travel alarm / C-3 \(15P x68) relay Switch box assy 7 A °° E-4: Resistor To cab g ff work light left ©) [—aOpt. F-=o roof wiper SC-6: To inst Auto greaser panel controller lett Grounding 1) a oacomeetor 1 5° R7: Wiper relay assy View VI ‘Swing parking release SW C-1 : Mechatro controller C-3: Switch box assy le co. View Yi Safety relay ot 4-8@3. Components related to engine (SK200-s) SEA3 E/G speed sensor a | Harness, 5 : Ma: (Upper) Hf Starter motor y fob 4 egy - £2: i Alternator sw-7 E/G oil press’ zs ea Glow plug SE-14 2 E/G coolant we A nator temp. sensor E/G water temp. SW SE-26 SE-23: Pressure sensor : Pressure sensor PI Nega-Con sensor 2 pump PSV-P1: a PT pump propo. valve i E/G side 6 « Herness| Le. (Upper) SE-23: Pressure sensor : P2 pump PSV-P2 PSV-P2: P2 pump propo. PSV-PI: P2 pump propo. valve SE-22 Pt pump Pressure sensor SEZ Pressure sensor: prope, valve sez P1 pump e Pressure sensor Detail of pump & E/G ma egleume) be Harness (Upper) motor [ M2 j E/G grounding Governor motor- \ Cable (eo (starter motor) Alternator grounding {eX FT) View 1 ao a | | ‘SW-23 : i E/G oil TL level SW oelead Harness = (Upper) sw-6 CNSR En: E/G coolant Air-Con compressor temp. sensor 65 4-904, Grounding cable attaching position (SK200-6) Note : @ are connected with © by harness ©is attached to upper frame is attached to floor plate © to @ are connected with controller box. Qis attached to E/G ®is connected with E/G Cab GND. at rear right of Cab (Gauge cluster Hour meter ‘Swing flasher SW. @ |Pawer window SW. (Opt.) ® Engine GND. Alternater GND. |Switch assy (Wiper, Washer, Work light) | In control box (Wiper interlock SW ATT boost SW Horn SW Switch assy (Mode, Buzzer stop) Tuner Maintenance connector [Travel alarm SW ]Opt. work light SW (Opt.) Horn SW |ATT boost SW Timer for lever lock Safety relay [Auto greasing controller (Opt.) KPSS release SW KPSS release SW @ Wiper relay assy [Air-Con ampli [Cab work light R.H (Opt.) [Cab work light L.H (Opt.) 24V power source Roof wiper motor GND. between Cab and Controller (In control box) Battery GND. © GND of travel | GND. between Upper 1,2 speed SW at | frame and Floor. under floor plate Fuel sensor Lever fock SOL Werk light |ATT boost SOL Horn (High) Travel 1, 2 speed SOL Horn (Low) ‘Swing parking SOL Battery relay @ VA filter elosging Sw Travel alarm [Washer motor Hyd. oil level SW IE/G coolant temperature SW Boom cylinder work light [Swing flasher & Rear work light (R.H) 4-10 [Governor motor E/G oil level SW [Swing flasher & Rear work light (LH) Hyd, oil temp. SW4-5 Mechatro controller (C-1) Adjust switch Grommet for adjust Part number ent cNI2©— CN13, conta CNIS cNt6 cNt7 Note : A common mechatro controller is used for SK75UR to SK235SR and SK200-6 to ‘$K320-s. But only the software differs. er 4-1®cN-11 CN-12 het Component i MAT | Remarks || RR ‘Component or te | Remarks 11-1 [Boom raise pres sowor (GNONSES)] In | BR 12-1 [PI pump press. sensor_(GNON(SEZ2)| In | Bre 112 u (SE3)| 7 [Ley 122 a (22) 7 | V 113 7 esED)| 7 |W 128 7 nse] 7 [YL 11-4 [Boom lover pres. Sasor_(EV(SE-)] 77 | 08 12-4 [Pa pu press sor (BV)(SEZ3)| 7” | YR 15 a (e4)| 7 [LO 125 v (sez) 7 PL 16 7 rosea] [Bw 126 v (GNONSEZ)] 7” [EY 11-7 [Arm i res. sor (GNOM(SEN| 77 | Br 12:7 [Pi Nege-Gon sowsor__ (GNO)(SE28)| 1” | BY 18 v (SEn] 1 | PG 128 ” ($E26)) 7 [ GR 19 7 USED” [OL 128 7 UNSER 7 [WY 11-10] Arm out press. ewer _(EV)(SE8)| 7 | OW 12-10|P2 Nega-Oon srser —_(GND)(SE2N)| 7 [RE wat u Sea 7 [PL 211 u Sean] 7 [LY 112 ” RONSEB)| 7 | 12:12 w (eNDNSEZD| 7 [BW 11-13 Base dasng ress sear (GNOSEN] 77 [BR 12:13 | hare 7 [WR Te (EDL [isk 12:4 | Onecare ra 7 [Lo [SABE 15 7 Gs) | RB 12-16 | Starter key ON 7 We 11-16] Banet dump pres. swor_(6V)(SED)] 7 | RL 12:16 Glow 7 [ore 17 u (S27 [Lew 12-17| Travel Wwosmeed switch GW3)| 77 | PL 1116) v TENONSED)| 7 | BL 12-18 | Shing parking brake reese swith (SW-)| 7” | Le 11-19] Swing right press, sensor (GNO)(SES)) 7 [Gr 12-18] KPSS release switch (sw5)| 7 | PS 1120 u (Se8)| 7 |W 12-20| Engine sooed sensor sera] 7 PR 1121 a SEH) 7 [YB 1221 u (Se1)| 7 |W 11-22 Swing i pres. sonsor_V(SES)] “7 [YG 1222 u ied (SE18)| 7 [— 123 ” (5/7 [Ve 128 i (GNONSES)| | Br cN-13 11-25 | Travel right press. sensor (GNON(SES)| 1” | BY Pir it wre 1126) v (Sea) 7 [WY a Cut ctr Foes Ta F Bngeal Tye 73-1 [Ook Pras. sawor Pcie (GNOVGEM| In | BL [Ont 11-26 Travel pres. sensor _(6V(SE-10)| 77 [YR ae eg (serv [oo] 7 11-28) w (SE10)| 7 | So 133 uw (evoseN| 7 [RL 7 a A TeBeEIO 7 TES 13-4 | Opt, Prose. sensor Pi side @V)(SE2O)] 77 | RB | 17 11-31 [Accel potetio (GND)(SE16)] | BW. ise a (SE20)] 7 |LsR| 1” 1182 7 Emr} P| |p 36 7” CENDN(SE2O)| 7 [BW | 7 aa A neil Twa 13:7 | Ost Boom rodgres sensor (GND)(SE26)| 17 | BP [ 77 11-34] Governor motor 2] 71 68 as a (se26) 7 [WY 39 7 evnse25)) 7 PRL] 7 13-10| Ook. Boum hed press sarsor GV)(SE2A)| 7 [ RL [ 77 1311 u (E20) 7 [LeY| 7 13-12 7 eno se2] | BP | 13-13 Back pres. sensor (GNO)(SE28)] 17 [Gr 1314 7” ($E28)| 7 | 1345 7 @NSE2—)] 7 | RW. 73-16] Ook. Highreach rare S7W__(SE-4T)] 7 | GY [Gt CN-13_ If clinometer equipped [ce (Same 137 [ORL EZR & RVUM cony(se20)| in | BP [Ont a 7 aa] 7 |W 7 138 u evnse20) [RL] 13411 7 (e207 [ey] « 4-2cN-14 cN-15 if Component i te | omar || Pi Component Se 2 | Remarks 14-1 [E/G coolant switch (Sw) In [CB 15-1 [Governor motor Phase A(M2)| Out | G 142 [E76 oil press. switch wen] 7 [GY 162 a (2) 7 |B 143 | Air ft cogging switch (SW8)] 7 | Le 153 7 ‘Shield (M2) 7 | — “44 |Stroke-and proximity SW (SW-32)] 7 | Br Opt | [15-4 [PI by-pass cut pron valve (PSV-D)| 7 | BP 145 [E/G oil level SW (sw-23)| v7 | BG 165 w (Psv-D)| 7 | Pw 146 [E76 coolant level SW «sw2a)| 7 | oo 15:6 |P2-by-pass cut propo. valve (PSV-B)| 7 | BO 14-7 | ya. ol level SW (sw25)| 7 [RL 157 7 (Psv-B)| 7 [GR 148 [Feel sensor (GE18)| 7 [WW 15-8 [Travel straight prop. valve (PSV-C)] 7 [VR 149 [Wiper motor (Riso-up) Stop (MBD] 7 | L 169 7 PV-O)| 7 |B 74-10 Wiper motor (Rise-up) Reverse _(M3)| “7 | G 16-10 Arm variable recirculation valve(PSV- | 77 |BrG 34.11 [ATT boost SW wan] 7 [ers 16 ” PVA] 7 [YW 14-12 |Wiper motor (Are prevention) (W-3)] Out] LR 16-12 Mechatro coiroler back-up __(C-1)] in [ RY 1413| Winer motor (Forward relay) (M3) ” | GB 15:13 (uly [RY 114 [Wiper motor (Reverse relay) _(M3)] 7 | Gr 16-14 | Mechairo controler bask-up —_(C1)| 7 | YG 14-15 | Wash motor Mad 7 [Oe 15-15 | Governor motor Phase B (M2)| Out] R 4-16 | Work light relay (Ra) 7 [ery 15:16 7 (Mal 7 |W 14-17 | Swing flasher & Work light unit_(R-19)] 7” [we [Ont] [16-17] P1 pum pron. valve even] 7 [vr 418 Switch box assy VCS] 7 [RE 15:18 u (avn 7 [Gre 1419 a” (C2)) in [ew 16-19]/P2 pump propo. valve ___(PSV-P2)| 7 | VW 1420 w (Ca) Oa] aR 15:20 a” (Pev-PA)| | GY. 1421 7 cal 7 [ts 16-21 | Travel Zspeed solenoid vane (SV-3)| 77 [LeB 1472 7 ca) 7 [Ww 16-22 | Swing parking brake solenoid valve (SV-1)| 7 | V 1423 7 cal 7 [Ly 16-23 [Power boost so. valve eva 7 |e 14-24 7 Groxca] 7 [ow 16-24] Battery relay Rad] Out] WE 14-25 | Serial communication to gauge ouster [Out] R 16-25 | Mechatro controler Ground (C-1)|—| 8 14-26 a «cain [ w 15:26] a cule 1427 7 Grand (C2)|—[ 8 14-28 7 Shieis (623|—|— CN-16 i Component Bie | Remarks 161 162 163 164 165 166 167 168 169 16:10 16-11 16-15 | Press. switch (Claro) ‘(Sw0s] A [LW [oot 69 4-130CN-17 CN-18 Pin in- pire Pine Th [Wire ie Component ee MM | Remarks || Component Gee ear] Remarks 17-1_| Bucket contr relay AO] In [OL foot _| [78-1 Rl— 17-2. [Nibler open relay (R6)|Out| 6 [7 182 | personal computer for ROM a {= 17-3. | Swing flasher relay Rag] 7 [ow] 7 183 | programming 174 7 Ra 7 Pw |_| [ee (GNo) 17S [Nibble coserelay ——(RAB)] 7 | GL | 176 | Travel alarm relay Realy Te [7 17-7_| Power window controler cal” [ye] 7 17-8 [Hyd oil temp. SW «swan in [0 178 | Travel alarm SW «sw22)| 7 | WY [Ont . 17-10 | Swing flasher SW (swa)| 7 [Lay| 7 TTA [Lever lok SW (winy[Oat| W 17-72 [Rotary N&B_ In [Gre [oot] 17-13 | Wier Z ‘Boom potentio (VNSETD]- In | RB [Ont 179 7” mr [tls 1720 | 17-21 [Arm patentio S/n V [owe 17-22 | Grounding (GNoy(SE17-19)] 7 [BG | 7 CN-17_ Opt. Multi demolition equipped Pir Th. [Wire Ne Component ee (ere | Remarks 17-16 | Nbber rotation GVEA] In | RG [Oot | ‘Nibble rotation ~(SE30)| In [WR [Ont 17-22 [Nibber rotation (GnONSESO| in [BS [Ont 10 4-144-6 Gauge cluster (C-2) 1. Appearance Engin temperature e coolant ~ Work mode 75.28V/1.4W/2,000h Fuel meter Multi-display Leo Trimmer vrt N21 Connector oR 4[ai7(6[s Screen Dip switch change Dsw_ sw Face side Back side (Cover removed) 2. Connector CN21 No. Name Wire color ||No. Name Wire color | TXD (Serial communication) Transmit |W 5 | (Shield) = 2 | RXD (Serial communication) Receivel A 6 [GND B 3 [E/G coolant sensor YR _|| 7 | Power source (+24V) Ww 4 | Fuel sensor BrR__|| 8 [GND B 3, Serial communication Serial communication (various information) are transmitted between main controller and gauge cluster. Main controller 1x0 Xo Gauge cluster Opt. SW panel RXD, TXD || (Interference prevent fh reach cra (a) Main controller > Gauge cluster @ Switches data E/G revolution @® E/G oil replacing time : @ Warning © Self diagnosis © Service diagnosis © Trouble history ® Opt. indicator Others : Condition of mode select switches E/G speed E/G oil replacing time Failure of Machine (ex. E/G oil press, E/G coolant temp.) Output signal failure of press. sensor, propo. valve etc. : Output signal failure of press. sensor, propo. valve etc. : Trouble data : Data of UR, High reach etc. : Initial adjustment data ete. (b) Gauge cluster -- Main controller a @ Screen change signal ® Opt. switches signal © Gauge data Switch signal of gauge cluster Condition of interference prevention on High reach crane : E/G coolant and Fuel level signal 4-6 @4-7 Wire colors and types of wiring harness Wire color list [Symbol] Color [Symbol] Color |[Symbol] Color |[Symbol] Color cco B | Black || Ww | white || Br |Brown|| Vv | Violet — Light |G | Green || Y |Yellow|| to | sam | ‘Stripe L_ | Bue || P| Pink || Gr | Gray 0 |o Sb_ [Sky bi R_| Red range| cy blue} Eanes Wiring color WR WR Stripe (Red) |. Ground color (White) Ground color Stripe Indicate in order of Nominal sectional area ground color and stripe. Display 0.75 LL 1 Tr es stripe) 1.25 = L112 (line stripe) 2.0 or more = (No stripe) Surface display (O.6f, 1.251) @ VSSX 0.5F @ (OI5E, 2f) SM VSSX 0.75F Conductor Insulator Wire types and difference Types Name Performance and characteristic AV Low pressure wire for auto- | This wire is polyvinyl chloride wire used for wiring of low wire | mobile pressure circuit of automobile. Thin insulator thickness is thinner than the AV wire, and the performance characteristic is equivalent to the AV AVS | Thin insulator low pressure | wire, “And this wire is made to reduce the convergent di- wire | wire for automobile ameter of wire harness and to lighten the weight, and is suitable for wire harness, and has a sufficient flexibility. This corresponds to reduction of the wiring harness diame- vss. | Extra thin insulator low | ter, the lightning and the reduction of connector and pitch, AYSS | pressure wire for automo- | and 19 or 37 conductors are stranded in the same direction bile to have a roundness of the conductors resulting in the thin insulator. ‘Avx | Crosslinked-vinyl chloride | This wire is cross linked by applying the electron the vinyl heat resistance low pressure | insulator, and the continuous heat resistance temperature wire (10,000 hours) is 100°C. This insulator low pressure AVSSX | and crosslinked-vinyl chlo- | Same structure as the AVSS wire, made the insulator thin, wire | ride heat resistance low | and has a sufficient flexibility. pressure wire for automobile 2 4-164-8 Electric equipment (SK200-6 ) Tye] tem Name PING. Type] em Name PING. C1_| Nethalro controler 'YRZEDOOSTFT SW25 | Hyd id level SW YREZS000231 C2 | Custer gauge L.Ce9S00001F1 ‘SW26 | Work light SW (Opt) [24790118061 3B [C3 [SWhox assy "YNSQEQOO04FT ‘Sw27 © [C4 _[ Air conttionr ane. ALC Accessory ‘SW28 3B [| Poe wc (Ost) | YNZZECOOTEPY ‘SW-28| Nitbier open SW (Opt) | 2A06PS872 C6 | Auto grease control (Opt) | 2480P40 'SW-20 | Nitbler clase SW (Opt.) 1 ‘SW | Nibberstoo SW (Opt) t Ri_| Bate ray YizaShoo0iFt ‘swag | SOKE-nd proximity SW R2_| Starter relay TE/G Accessory (Opt) R3__| Glow relay E76 Aczasory "SW233 | Revolution right SW (Opt) | YNOBMOTZ3iPS Ra _| Safely relay E76 Accessory | | = | SW-34| Revolution left SW (Opt) T= R5__| Horn relay Yrcasooocert_| | 2 [Swes RO_| Work ight relay t & [Swe RT| Winer relay assy ‘YT2deDo00IF1 ‘SW | Hyd id temp. SW 2ATOROB RB | Travel alarm relay (Opt)_| YN24S00001P1 ‘SW36 | Warmup SW 24TRUTI SOFT RO | Work fight relay (Ont) | YR24S00002P1 ‘SW-38 | Nibler open ores. SW (Ont) -10_| Bucket control relay (Opt) SW40 B&R ‘SW | Fgh reach crane SW (Opt) | YNEOSOTOOADI & [R12 _| Revoion right relay (Ont | YR2ASOO0O2FT R13 _| Revolution left relay (Ont) i ‘SW-48 | Clamp holding SW (Opt) Rid 'SW-49 | Clamp releasing SW (Opt) R15 | Nibbier open relay (Ont) _| YRZ4SOO002T ‘SW50 | Press SW (Clamp) Opt.) | 2479U2010 R16 _| Nibber close relay (Opt) t SET_| Press sor Bucket digging | LOSZS0O001P2 Rei _| Fashor relay ‘Yy24S00001PI SE2_| Press sensor: Bucket dump 1 20 _| Timer retay ‘YN26S00001P1 SE3_| Pres. snsor: Boom raising 7 R-21_| Cia holding relay (Opt.) SE-4_| Press sensor: Boom lovering| i R22_| Clamp releasing rotay (Ont) SES _| Press. sensor : Swing et i SEB _| Press. sensor: Swing et t Swi Koy SW ‘YRSOSOOO2FT ‘SE-7_[ Press. sensor Arm in t SW ASSY ‘SE-B _| Press. sensor = Arm out f SW2 | (MODE, Buzzer stop) —_| YNBOEDOOUZFT ‘SE | Prss. sensor: Travel right t ‘SWS_| Two-sosed solect SW | YNOBMDIOGSPI ‘SE-10 | Press. setsor: Travel et t ‘SW-4_| Swing parking release SW_[ YTEOEDOOOIFT ‘SE-11 | Press. smsar = P2 (Opt) | LCB2S00001P2 ‘SWS_| KPSS mode release SW | YNSOSOTO03P1 SEI2 ‘SWS_|E/G water tomp. SW |E/G Accessory 'SE-13 [E76 rovlulion sawor | E76 Anmassory ‘SW1_|€/G oil press. SW E/G Accessory SE-14 | E/G coolant thermo sensor | YTS2SO0001P1 ‘SW-8_[ Air ftr restriction SW | YRTTPO0008S008 SE16 | Fuel sensor 24892671 ‘SW-3_| Swing fashor SW zaraurigoria | | § ['SE-16 | Accs potentio ‘YNSZSO00051 ‘SW-10 | Horn SW. ‘yNsoe010071_| |S ['SE17 | Boom potentio (Opt) “YRS2S00013F1 ‘SW-11 [Lever lock SW. YYNSOS0TOOTP1 E18 8 [swe ‘SE-19 | Arm potentio (Opt) “YRE2S00013P1 & | Sw | Air contioner SW LCZOMOTOTSPT ['SE-20_| Press. srsor = PI (Ont) | Lcs2s00001P2_| ‘SW-14 | Power window SW (Oot) | YNSOSOT0062 SEZ ‘SW-15 | Confa/sie sket SW (On) | 247BUT190FZ9 SE-22 | Pres. snsor Pl pump | LCS2S00000P% SWB 'SE-23 | Press. sensor = P2 puro 1 SSW-1T|| Roof wiper SW (Opt) | 24797734 'SE-26_ | Pres. sensor: Boom head(Oxt) | LCS2S00002P1 SW18 ‘SE-25_| Press. sensor: Boo ra (Op) 1 ‘SW-19 | Wiper interlock SW ‘YNSOEDOOOEPT E26 | Press. sensor : PI NegeCon | YNS2S0O0TBPT SW Assy SE2T_| Press sensor: P2 Nega-Oon 1 SW20 | Wiper, washer, gt) _| YNEOEDOOOSF S26 | Pras. sensor Bak res. | UCEZSHO00TP2 ‘SW | Power boost SW ‘YREOEDIOOTPT SE29 | F/R & LH/RH clnometr | YNE2SDO0TSPI ‘SW.22 | Travel elarm SW (Ont) | 2479UTIOOFIG 'SE30_| Nitbierrevoition L.cs2s00001P2 'SW23 [£76 oil level SW E/G Accessory ‘5-24 | /G cootant level SW | 247920356 13 4-174 4-18 Tyee] tem Name P7N Type] tiem Name PING. 3V-1_| Swine parking brake SOL | YNGEVOOOZZFT E1_| Fuse bor YYATEEDOO0EFT SV-2_| Power boost SOL i 2 | Alteraior E/G Accessory SV-3_| Twosspeed select SOL i €3_| Hour meter "YR8S00004P1 'SV-4_ | Operating lever look SOL t Ed | Resstor Lczze0100101 ‘Bucket duno out SOL 5 | Horn high 247 TO09F VS | (ot) YRGEVOO0OSFT 6 [Hon low 2ATOUTOOREZ 3V-6_| Revolution right SOL (Ont) r go [ET_| Tue AMR FM LLC54S000011 3 ['SV-7_| Revolution left SOL (Opt.) 1 'B [E7_|Tuner AM (Opt) LES4S00003P1 V8 [Ee | Sooacer lot YYNS4S00006P 1 ‘Sv.8__| Nibbier open SOL (Opt [9 _| Soesker rent t 'SV-10 | Nibber close SOL (Ost.) @ [E10_| Reciver drier YTE4SO0002P1 ‘SV-11 | Bucket control SOL (Ost) iG [E11 Air comoressor ciulch | LOST VO0001FT '8V-12 | Clamp holding SOL (Opt) E12 'SV-13 | Clamp releasing SOL (Opt) 13 _| Travel alarm (Opt) 2a7UITIO E14 _| Cigarette iihtor 2421 R16OF PSV-A rm ein ied S0.| YNSBVOOOZZFT E16 PSV-B | 2 by-pass ut poertonl SOL 1 E16 SVC | Travel rior propertongl SOL t PSV-D | Py 9s at roortonl SOL i D1 _| Dawe ‘YNOZDOTOOTPT > | PSV>PI| Pump Pt proportional SOL. | YNTOVOOOOTFT D2 _ | Diode t © | Povir2| Pump F2 proportional SOL 1 D3 | Diode: 2ATERISZ PSV [D4 | Diate t PSV 8 [bs [diate YYNOZDOIOOIPI PSV-3 5 [os | dio 1 D3 _ | Diode + Ti | Boom working ligt let | YWAOSDOOOTFT 10-10-_| Diode 1 C2_[ Frame working light rit | YNBOSOO0TOF2 ‘Swing flasher & working 43 [grt unit et (Ont | YN24E0000F1 La _| Swing fiasher 8 working t light unit right (Opt) 15 _| Room light 2ASBZILOFI z | SS) [eT ab werking tight left (Opt) | YNe0S000TOF? LB | Cab working frit (Oot) 1 9 | Boon cin work it (Ont) i 10 _| High reach rotary fight (Opt) | 2A58R467 Lit Lz La WA _| Starter motor E76 Aassory M2_| Governor motor ‘YT20sn0002F2 M3 _| Wiper motor YYTSaCHOOOAPT Med__| Washer motor 2A2TURO0 __ [MES [Power window motor (ORE) | YNO2ODTEBTET 5 Power window lock mator B|Mo_|ien'oxy ‘YNOZO01384F8 Power window lock mator MTT On ‘YN0z00138465 MB _| Grease motor (Opt) | 247008530 M3 _| Roof wiper motor (Ont) _| YT76S00001P149 Electric circuit diagram 1/4 (SK200-6 - SK230-6) i suvale [sim] P [C-1:4% koa bos : sew seta Ra ams gs Fe fat soo Ht: 2 te | roe" FL ctreanxayon [557] _v) En sm atte! one : z 1 a sn AEE] CBR E ST patente" eufie FR) oe oe a ae nlf aR. foe TE att fe or ven . orggscrmpey cee a= veo{ BLE 2g mets u seurgane £ PETES ES = wet [355] ce —(ewo) ovo 20 _ty)-21 vse [aie | Sis wa) se 0m For cca oad DOOKIE] rmracgiaargene + PL rs foe sve [ale ee a [Bee OONTE] mo ggeaane Le fam | ae rete Ee ee tes (os! 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(OPT. MRKING LiGeT gms | i +2@5, MECHATRO SYSTEM Travel 1, 2 speed 5-1 Outline of mechatro system change SW Horn SW (SW-10 be ‘SW. i. 4 ae ~~ ' TC jorn SW (SW-10) ATT boost (SW-3) by side i 4 h 4 4 a h h " att @ Travel 2 Nega-Con sensor | Mi ! Boom cylinder LH} pilot [Ru] pilot. LHRH (sE-z7) i 38 g : Boom raise conflux | valve Lo ia 33 5 cede 7 4 oOo ele) Low pressure ' 23 ge . BS) 8 fee il ‘SE-9) i | ¢ {Es a3 = zi? jega-Con | ; [Multiless sensor (SE-9) | Back-press. ! g |= 88 B|e a8] ce Arm cylinder c/v sensor 1) 8 lge % $)e]2 2 (SE-26) f —_— Arm out conflux Sensor block | [Low pressure sensor (se) | 8 les Flels|slsel3!/-el/.33 ‘ EF) LIAR in contiux (Ge SED le elelf{2| 2/2) E]sleqe(—* | . ©OO000000 TR ; L@ les ae} ae} alejelelals jes a 1 0 contro ' ' . ann valve ' LJ Wl yl Wl W A W Wl LW Wl ' =] Bucket cylinder To control E/G coolant ' i valve Hyd, oi temp. sensor : - | Fl level SW (SE4) Swing parking i (sw-37) @ brake, -4-.4 - | [Switch panel High pressure | a LO) ret speed (SW-2) Speed sensor, presser” sensor i 5 A/M/B (SE-13) (SE-22) (SE-23) ' | select Pi P2 | H L 5 Engine s|z s a |3 ele] S| =| x | Note : 22 23] 2) £] 2] 3) S| 1. themark for thec/v . ' |e (gs) 2/%) 2/3) 3] 1 Accel dial Mechatro controller (C-1) easyer motor ' elssczlsle/f|2) 5 shows only SK320-6, and potentiometer ; sifslEslz | fle E 3 for SK200-6 and SK230-6 . ' @ |r o ne alm lasta the spool is blanked off. : as | ar | a6 2 | at Gauge cluster : sv-1| sv lesv-alesvolpsv.clesv.el sv.2| eva] 2. For SK320-, it is (C-2) 5 ' i confluxed only when the ---- Proportional/sole id valve bl |A/M/B Light on P1 pump proportional valve a solenoid valve block bucket is operated {tep] (PSV-P1)___f 5) pump proportional valve - - independently. I (PSV-P2: Ouaine of system Characteristic Purpose High pressure sensor A3~ AG Propo, valve |e Control the hydraulic pump in the negative control valve, and feed a opti- (for P1 and P2 : 2pes.) : Low pressure sensor (ATT : 8pes., Travel Nega-Con press. sensor (for P1 and P2 : 2pcs.) E/G coolant temp. sensor : Hyd. oil temp. SW : Potentio meter E/G speed sensor Governor motor Nega-Con : Negative Control ” 2pes., Back-press. moce#¢ P © © ‘Al, A2, A7, AB : Sol. valve Al lever lock solenoid valve is actuated without through controller. Ipc.) Electric input signal Electric output signal ~ Mechatro signal (Propo. valve) ——-—-— Mechatro signal (Sol. valve) Hydraulic contro! signal 4 | Control P1 and P2 pumps control hyeraulic through proportional valve mum flow rate by operation. ¢ Obtain the ideal hydraulic pump power curve to prevent stalling of engine pump though 72 |Gontrol travel straight valve negative contol through proportional valve. valve a 3 [Control Pi and P2 cut vaivel [Control a part of through proportional valve ‘© Make the switching smooth and reduce the shock. control valve [Control arm variable through proportional | 4 {recirculation valve through} @ Control arm-in speed to optimum to prevent cavitation. valve. proportional valve _ _ (Control the_open/close_ of Main spool is 5 |slewing P/8 through sole-|@ In slewing and arm in operation, release the P/B in 6 seconds. controlled by [noid valve. Fcraule pressure. | | control ATT oressure rise through solenoid valve. fe In boom raise, arm in, and bucket digging operation, when A large amount of power is required, this system functions only when the ATT rise switch] is turned ON, st5-2 Operation Units List when controlling every operation Electric device Hydraulic device 5/5 Bl2l2ls /2]/e]Z], | |s Control valve Motor | Cylinder | Others 2/2) 5/2/2/818 | ale | elf s T Te 8/8) slels] sie | sie = |e.) 2/7 el.| |% SlELEVEVEVE I sid | slegigi|d jeleiglglelti sls 2/£)3|=| 2] 2/22) 2/8 | 2)siles| 3] sislz/f/sle/#) Zl s|2\2 2) 2/3) $|8| 5/82) £\.|E)eg eee |y z/.//s/2/eiz/2i2/£/2/8/2/2/2)2\2 512/28 || a [ge/e [fs| = |asife|&| 5] 2| 2 el} /2/E/ 2] 2/2] 8/8/28) 2/2) 2] 2/3] 2/2] 3 5\5 S\e2 z|E\3 8\s FE 2 s 2 Boom raise inching 0.0/0 0[0) | ofo |o Lil Boom raise full lever 0000100; 0 ofo ofo of [ol Boom lower 0.0.0 0|0, I : ofo. jo ‘Arm out inching 0000] 0 of o| 0 cl ‘Arm out full lever 000 0|0 0 Lo folo o[ o i jo ‘Arm in inching 000 0; Olo | oO. o| o| 0 : i ‘Arm in full fever 0.0/0 0| ofo, of of of 0 | I ‘Arm in heavy digging (full lover, sequence conftux) |O_O 0 O|O O|O 0 O|o, olo o| 0 oO] fo Bucket digging 0.0 0 Ojo oo O Cit Bucket dump 0.0 0 O|o. ~ofo. i ; ‘Bucket digging (Full lever, contlux), 060 010 6 O10 0 : ‘Bucket dump (Full lever, confiux) 606 oe. Cloo : Swing oo 00] 0 o| 0 Travel RH and LH (ist speed) 0.00 ,0|0 0 0/0 0 Travel RH and LH nd speed) == [OO 0 O|0 0 Tol [ofoio Travel right + Boom 0.0.0 0/0 0 0.0 O}O O|O Travel right + Bucket 0.0/0 O|O o[ Ole L o|o 0 | Travel right + Arm 0/00 ojo ofo, ofo olo o Travel right + Swing 000 0|00 oo) oo o Travel left + Boom 0000/00] 0 | o|o oo. Travel left + Bucket ooo ojo of oO | o|o 0 Travel left + Arm 0000/0 Oofo 0 olo o|o 0 Travel left + Swing 0.00,0|0 0 fololo| o]o 0 Travel RH and LH + Boom rai 0.0.0 0/00] 000 rolo olo Arm in + Swing (Swing priority) 00/0 Oo] ofo, | oO. of Oo] 0 oF I Note: 1. In boom, arm, and bucket digging operation, ATT functions through solenoid valve only when ATT boost switch is pressed. 2. Marked by [functions are provided for only SK320-6. © Travel straight and P2 cut valve are actuated when bucket is full operated independently. Therefore bucket operation is changed to conflux circuit. co © Arm T2 valve is actuated and change to return circuit of arm cylinder, when arm out is full operated.5-3 Outline of pumping control (Negative & P-@ control) P2 side Nega-Con sensor A 3 3 (SE-27) i 3 Z| PI side al |z8 z 2 =H s| Nega- 4 é 3 =| || con 2 Hes LI 3] sensor 2 el |e} |= A g| E28) aha Lé 3] LE] LE 3) 4 5) [ep Back- g Ls 2 pressure £ e 8g - sensor 2 E E (SE-28) aS < Pilot signal processing High pressure sensor (SE-22) igh pressure sensor (SE-23) PI Pz ‘Command of P1 pump propo. valve| Pilot signal processing Pi pump propo. valve (PSV-P1) ‘Command of P2 pump propo. valve Nega-Con signal processing P2 pump propo. valve Nege-Con signal processing 1 | | | | | P1, P2 pump delivery flow rate a | | | | | | | |P1, P2 side —v! Output voltage of Nega-Con sensor} {Output voltage of Back pressure _j Fig. 1 a (PSv-P2) Note: The mark 3 for the C/V shows only SK320-6, and for SK200-6 and ‘SK230-6 the spool is blanked off. P1, P2 pump output voltage| of high press. sensor P-Q control es 1 | & @, (etorsot poe] af | |e | | 2s | |&s | | ze | | —v! | —d Fig. 2Pump control system A. Negative contro! 1) With respective operation, the pilot secondary pressure switches each spool. 2) With switching of the spool, the negative control pressure varies according to the switching volume. 3) The negative control pressure is input into negative control sensors (SE26,SE27) on the P1 and P2 sides, and the back pressure (Return pressure to tank) in the control valve is input in back pressure (SE28). 4) The output pressure from negative control sensors (SE26,SE27) and back pressure (SE28) on P1 and P2 sides, is input mechatro controller, and the mechatro controller performs negative control signal processing, and computes the pump delivery flow rate corresponding to the out- put voltage. (Figure 1) B. P-Q control 1) Pland P2 pump delivery flow rate and pressure are input in P1 and P2 high pressure sensors (SE22,SE23). 2) The output voltage of Pl and P2 high pressure sensors (SE22,SE23), is input mechatro con- troller, and the mechatro controller performs signal processing, and computes the pump deliv- ery flow rate corresponding to the input voltage (load pressure). (Figure 2) C, Dec ing pump delivery flow rate 1) For the pump delivery flow rate computed by negative control and P-Q control, the mechatro controller selects the lowest pump delivery rate and outputs proportional valve command cur- rent value corresponding to the delivery flow rate. 2) Pl and P2 pump proportional valves (PSV-P1,PSV-P2) outputs proportional valve secon- dary pressure corresponding to the command current value from mechatro controller, varies the tilt angles of P1 and P2 pumps, and controls the delivery flow rate of the pump. 3) With this operation, the delivery flow rate corresponding to the negative control pressure is, fed into actuator, and even if the load pressures of actuator and pump are raised, the engine does not come down. B 5-45-4 Outline of boom raise conflux } Nega-Con signal processing ATT pilot valve T P2 side Nega-Con x * RH sensor 2 g (SE-27) 8 a é E . EHS | Pt side é & S| le z| |Z] Nega-Con 2 [= HeHeHs | sensor 3 ol ls! le! (= 'g | (SE-26) SUe le 2) 8) El NE = arer ls) |,f la) Led Ted Le aj{E g) |e 8 4 E E 2 2 2 Pilot signal processing jl Command of] | [P2 by-pass |---4P2 by-pass cut|--) cut propo. | propo. valve| | | valve PL P2 i (sv-8) a ! i Command of| | [ P1 pump --| PI pump }-+4 propo. propo. valve | | valve | svn Nega-Con signal processing | Command of L P2 pump \"P2 pump. {44 propo. propo. valve | | | valve | csv-P2y J Note : The mark 3 for the C/V shows only SK320-6, and for SK200-6 and ‘SK230-6 the spool is blanked off. Co Nega-Con signal pressing 1 ‘1 mA [Pilot signal processing tons eo] | Output voltage —>V of low press. sensor _ P1 side Output —>V voltage of Nega-Con sensor} P2 side Output —>v| voltage of Nega-Con sensor) loe ll o¢ | lest et 1] fs [is | | 188 || ee il Se i \32 i! && ji ee i ge 2s ae les jlzs jl se | |e i! iI | | dt | Fig. 3Boom raise conflux system 1) With boom raise operation, pilot secondary pressure switches boom spool and boom conflux spool, and is sent into low pressure sensor (SE3). 2) The output voltage of low pressure sensor (SE3) is input into mechatro controller and the mechatro controller performs signal processing, and outputs the command current corre- sponding to the input voltage into P2 cut proportional valve (PSV-B). (Fig.1) 3) P2 cut proportional valve switches P2 cut spool with the proportional valve secondary pres- sure corresponding to the command current from the mechatro controller. - 4.) With switching of the boom spool and P2 cut spool, the negative control pressure varies and inputs in P1 and P2 negative control sensors (SE26, SE27) and back pressure sensor(SE28). 5) The output voltage from the Pi and P2 negative control sensors (SE26, SE27) and back pres- sure sensor (SE28) is input into mechatro controller, the mechatro controller performs nega- tive control signal processing, and outputs command current corresponding to the input voltage into P1 pump proportional valve(PSV-P1) and P2 pump proportional valve (PSV-P2). (Figures 2 and 3) 6) Pl pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) varies P1 and P2 pump delivery flow rate with the proportional secondary pressure corresponding to the command current from the mechatro controller. 7) The boom spool and boom conflux spool are switched by pure hydraulic pressure command, ‘and P2 cut spool is switched by hydraulic oil command from mechatro controller, and P2 pump delivery oil is confluxed in Pl pump delivery oil in boom raise operation.5-5 Outline of Arm in & Sequence conflux control ATT pilot valve poy ° P2 side Nega-Con « * RA sensor 2 fe oe a 5 Pt side g E EH 8| Nega- ow § : z 2116 pressure| 3 & : a} |g] Con sensor 2 BH U i (SE-3) 3 F 2 z||E 3 5 3| (SE-28) er] < & =| LE} La} [a & 2 by-pass cut Pilot signal processing hh [Arm conflux command of semen recirculation porpo. valve [Arm Variable} reticulation propo. valve| ilot signal proc sing 7. (PSV-AY sensor (SE-23) lot signal pro — Command of| | [Pt by-pass Pt by-pass cutt-{--| cut propo. — propo. valve} j | valve + (PSVD) lot signal processing | — Command of] | [Travel travel straight}-4--| straight propo. valve | j |propo. valve so) ja-Con signal processing ! I Command of| ; [ PI pump Ne - Pi pump |-l--| propo. propo. valve| | | valve | @svrny a-Con signal processing i Command of| ; [ P2 pump | P2 pump }-!--| propo. propo. valve | | valve | caver) Mechatro controller (C-1) _ = “<4 Note The mark % for the C/V shows only SK320-6, and for SK200-6 and ‘SK230-6 the spool is blanked off.Cy 1 3 lL 1 SBMA [Piet sional processing] | |= mA [Pilot signal prosssing]| | ma [Plt sional procssre]) ¢3 23 ijzs ize t iiget iigef } lBEe| \ ibe. | |E§ \ lzZs Viz lise | [283 lle iS | ges ie Hel \g&e 118 | (gs } | —+v | |P2 pump —+y| |°* —v! i Output voltage |, joutput voltage of high press, sensor] | P2 pump output voltage | L____.of low press. sensor; Output voltage of low pres t f high press. sensor 5 Fig C— = 1 ——| js ma [Plecsanotorewssna)) | [Renders roing]) | [eter srl nea] ig. f lief lief [BBs i] 3 i] 3 | lza8 I] 22 I] 22 | less || as || 23 | IsEE |i xe |; 28 i | —+VvI |pt side —>V! |po side —v\ i P2 pump output voltage | | Output voltage of Nega-Con sensor] | Output voltage of Nega-Con sensor| iL.—.of high press. sensor | | Qutput voltage of Back pressure _j {Output voltage of Back pressure _j Fig. 4 Fig. 5 Fig. 6 Arm-in & sequence conflux control A. Recirculation control (Regularly at recirculation position) 1) With arm-in operation, pilot secondary pressure switches arm spool, and is sent into the low pressure sensor (SE7). 2) The output voltage of low pressure sensor (SE7) is input into mechatro controller and the mechatro controller performs signal processing, and outputs the command current corre- sponding to the input voltage into arm variable recirculation valve (PSV-A). (Fig-1) 3.) Arm variable recirculation valve (PSV-A) switches arm variable recirculation spool with the proportional valve secondary pressure corresponding to the command current from the mechatro controller. 4) With switching of the arm spool, it is input into P2 negative control sensor (SE27) and back pressure sensor (SE28). 5) The output voltage from the P2 negative control sensors (SE27) and back pressure sensor (SE28) is input in the mechatro controller and the mechatro controller performs negative con- trol signal processing, and outputs command current corresponding to the input voltage into P2 pump proportional valve (PSV-P2)(Figure 6) 6) P2 pump proportional valve (PSV-P2) varies P2 pump delivery flow rate with the proportional valve secondary pressure corresponding to the command current from the mechatro controller. 7) The arm spool is switched by genuine oo ; hydraulic pressure command, and arm Recirculation circuit to Return oil from variable recirculation spool ig switched Atm cylinder head side Arm cylinder rod side by hydraulic oil command from mechatro controller, and recirculates in H 5 [_4——-Pis P2 pump delivery oil as a return oil car from the arm cylinder rod side. 8) With the arm-in operation, the exciting signal from mechatro controller to slewing parking brake solenoid valve is, cut off, and consequently the slewing a5 32 parking brake is released. egeegels Operated condition of Arm variable recirculation co 5-8Notes : 1, When the arm variable recirculation valve is in the E/G no-load condition, the mechatro con- troller outputs command current to arm variable recirculation proportional valve (PSV-A), and the arm variable recirculation spool is turned to the forced recirculation position at full stroke. 2. With the arm-in operation, the command current corresponding to the lever stroke is output into arm variable recirculation valve (PSV-A), and the arm variable recirculation spool re- turns to the regular recirculation position. 3. When the arm-in load pressure rises to A kgf/cm’ or more, the arm variable recirculation spool returns more, and finally returns to the return recirculation position. (A shows SK200-6--160, SK230-6, SI320-6--+200.) B. Recirculation cut contro! (Recirculation cut position) 1.) When the P2 pump delivery pressure rises to A kgf/cm* or more in Arm-in operation, the output voltage of high pressure sensor (SE23) is input into mechatro controller, and the mechatro controller performs the pilot signal processing, and outputs the command current corresponding to the input voltage to arm variable recirculation proportional valve (PSV-A). (Figure 2) (A shows for SK200-6---160, SK230-6, SK320-6---200.) 2) The arm variable recirculation valve (PSV-A) outputs proportional valve secondary pressure corresponding to the command current from mechatro controller, and returns the arm vari- able recirculation valve further to the recirculation cut position. (Figure 2) C. Sequence conflux control (Recirculation cut position) 1) When the load pressure rises and the P2 pump delivery pressure rises to B kgf/cm’ or more, the output voltage of P2 pump high pressure sensor (SE23) is input into mechatro controller, and the mechatro controller performs the pilot signal processing, and outputs the command current corresponding to the input voltage to travel straight valve (PSV-C) and P1 cut pro- portional valve (PSV-D). (Figures 3 and 4) GB shows for SK200-6, SK230-6:"+220, SK320 250.) 2) The travel straight valve (PSV-C) and P| cut proportional valve (PSV-D) output proportional valve secondary pressure corresponding to the command current from mechatro controller, and switches the travel straight spool and P1 cut spool. 3) With switching of travel straight spool, the parallel circuits on Pl and P2 sides are connected, and P1 cut spool is switched and consequently P1 and P2 pumps delivery oil is confluxed. This function is called as Arm-in sequence conflux control. Note 1. When travelling 2. Arm-in pilot secondary pressure is 16kaf/cm’ or less, 3. When operating bucket dumping motion, 4. P2 pump delivery pressure is kept 80kgf/cm’ or less for 0.2 seconds or more, 5. When High reach crane SW in option is ON, When any of the above items is actuated, the sequence conflux control does not function. 8 5-95-6 Outline of Arm in anti-cavitation control Note : ATT The mark 3 for the C/V shows only SK320-6, Le and for SK200-6 and SK230-6 the spool is an 1 blanked off. rR. Nega-Con « ‘ sensor 3 8 (SE-27) i g PI side Low § 5 z 27781 Ceo" 8 z 5 on pressure| $| eS a| |Z SI 18 sensor 2 gn2 2 | (SE26) (SED) 3 . : 3||s E 3) Se O84 a7 [E 3 ELE a] 4 | [epP-A Back- g ® : pressure | ¢| e 8 sensor A | PoE (se28) LE 4 = Accel potentio meter (SE-16) ilot si Gommand.ct| | [Arm variabl arm variable|...-..Recirculation| Propo. valve propo. valve] (PSV-A) Pilot signal processing ~— Nega-Con signal processing ‘Command of P2 pump Ne P2 pump propo. | propo. valve valve (PSV-P2) i | i i i | | \ | | i i i i Mechatro controller (C-1) 3 im 1 js Ema [inti pecaia)) (5 ma [Picton pocesna]) |g, [Meet soul rena) £2 3h ij 2 ize f | 188 i] lgee lees lls | Hel LotR, SH) NN A BES ea \EES | gee || ed oda oda | = | —v | | | [Pa side —V| i Acal potentio meter | | |_| Ouput valtage of Nega-Con sensor Le Output voltage _ Lo ‘output of Back pressure |Outline of arm-in cavitation protection control 1) With arm-in operation, the pilot secondary pressure switches the arm spool, and concurrently is inputs into low pressure sensor (SE-7) 2) The engine speed command output by accel potentiometer (SE-16) is input into the mechatro controller. 3) The output voltage from low pressure sensor (SE-7) is input into the mechatro controller, and the mechatro controller performs pilot signal processing, and outputs the command current corresponding to the input voltage into arm variable recirculation proportional valve (PSV-A). (Figure 2) 4) And also, it outputs the command current corresponding to the input voltage from accel po- tentiometer (SE-16) into arm variable recirculation proportional valve (PSV-A). (Figure 1) 5) The arm variable recirculation valve (PSV-A) outputs the proportional valve secondary pres- sure corresponding to the command current from the mechatro controller and switches the arm variable recirculation spool. 6) The output voltage from negative control sensor (SE-27) and back pressure sensor (SE-28) on 2 side is input into mechatro controller, and the mechatro controller performs negative con- trol signal processing and outputs the command current corresponding to the input voltage into P2 pump proportional valve (PSV-P2). (Figure 3) 7) P2 pump proportional valve (PSV-P2) outputs the proportional valve secondary pressure cor- responding to the command current from the mechatro controller, and varies P2 pump deliv- ery flow rate. 8) The arm variable recirculation spool is controlled to the spool stroke corresponding to the en- gine speed, and consequently the engine speed is low by varying the recirculation rate. Even if the P2 pump delivery flow rate is low, cavitation is not generated. 9) And, with arm-in operation, the exciting signal from mechatro controller to slewing parking brake solenoid valve (SV-1) is cut off, and the slewing parking brake is released. Note : For items 3) and 4), the mechatro controller performs the pilot signal processing, selects highest pressure and output the command to arm variable recirculation proportional valve. 8 5-105-7 ATT pilot valve Outline of Arm out conflux (SK200-6 + SK230-6) Boom conflux Travel straight 2 side Nege-Con [swing [Arm é P1 by pass cut PI side Nega-Con Boom [Travel right | Pi side sensor (SE-26) A. m7 ‘Command current of Pt cut propo. valve -— P2 by-pass cut “frarm conflux Pilot signal processing PI by-pass cut propo. valve Nega-Con signal (Psv-D) ( P1 pump propo. valve (PSV-PI) P2 pump propo, valve (PSV-P2) Pilot signal processing |) Nege-Con signal procesing P1 pump delivery oY | IPt side Output voltage of low press. sensor | [N —>Vv! |prside Output voltage of Nega-Con sensor] | flow rate —v| Output voltage of Nega-Con sensor] {Qutput voltage of Back pressure _j Loa vt Back pressure _jOutline of Arm-out conflux system 1) With arm-out operation, the pilot secondary pressure switches arm spool and arm conflux spool, and concurrently is input in low pressure sensor (SE8). 2) The output voltage from low pressure sensor (SE8) is input into mechatro controller, and the mechatro controller performs pilot signal processing, and outputs command current corre- sponding to the input voltage into P1 cut proportional valve (PSV-D). (Figure 1) 3) The Pl cut proportional valve (PSV-D) outputs proportional valve secondary pressure corre- sponding to the command current from mechatro controller, and switches the PI cut spool. 4) With switching of arm spool and P1 cut spool, the negative control pressure varies and the pressure is input in the negative control sensors ($E26,SE27) and back pressure sensor (SE28) on P1 and P2 sides. 5) The output voltage from the negative control sensors (SE26, SE27) and back pressure sensor (28) is input into mechatro controller, and the mechatro controller performs negative control signal processing, and outputs it into P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2). (Figures 2 and 3) 6) Pl and P2 pump proportional valves (PSV-P1,P2) output the proportional valve secondary pressure corresponding to the command current from the mechatro controller, and varies P1 and P2 pump delivery flow rates. 7) The arm spool and arm conflux spool are switched by genuine hydraulic pressure command, and P1 pump delivery oil is confluxed in P2 pump delivery oil by switching the PI cut spool ac- cording to the mechatro hydraulic pressure command a 5-135-8 Outline of Arm out conflux (SK320-6) ATT pilot valve Cc P2 side Nega-Con 2 sensor 3 3 (SE-27) 3 a P1 side 5 z . =H 8 | Nega- 3 s S| Je z| | 4) Con Z Es Z| sensor afelile z a] 2 5 acu") aap le & &| LE 8] 1s) le a = g 8 = E ; 2 E i J jot signal processing P1 by-pass Command of LA ---|Pt by-pass cut}-1--| cut propo. propo. valve i { | valve PI P2 mG) zz Nega-Con signal processing Command of] ; [ PI pump --| Pi pump propo. | propo. valve valve (avi) processing Command of P2 pump P2 pump propo. ( propo. valve valve (PSv-P2) —————<—— OO) ——| [Bg mA [Pet sonelprecesina)) | Negron Saal proming]| j a [NegeGon Sel prs] igs f it ligt i [3g I) 3 | 3s | (Es 1 23 at 8 | \e8 I] as || 2s \ iSz || r= || #2 | | —>v! |pt side —>Vv | |e side —v! | Output voltage | [Output voltage of Nega-Con sensor] | Output voltage of Nega-Con sensor] ___2f low press. sensor _j Output voltage of Back pressure} [Output voltage of Back pressure __j Fig. 1 Fig. 2 Fig. 3 2 5-14Outline of Arm-out conflux system 1) With arm-out operation, the pilot secondary pressure switches arm spool, arm conflux spool, and arm T2 spool, and concurrently is input in low pressure sensor (SE8). 2) The output voltage from low pressure sensor (SE8) is input into mechatro controller, and the mechatro controller performs pilot signal processing, and outputs command current corre- sponding to the input voltage into PI cut proportional valve (PSV-D). (Figure 1) 3) The P1 cut proportional valve (PSV-D) outputs proportional valve secondary pressure corre- sponding to the command current from mechatro controller, and switches the P1 cut spool. 4) With switching of arm spool and P1 cut spool, the negative control pressure varies and the pressure is input in the negative control sensors (SE26,SE27) and back pressure sensor(SE28) on P1 and P2 sides. 5) The output voltage from the negative control sensors (SE26,E27) and back pressure sensor (28) on P1 and P2 sides is input into mechatro controller, and the mechatro controller per- forms negative control signal processing, and outputs it into P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2). (Figures 2 and 3) 6) Pl and P2 pump proportional valves (PSV-P1,P2) output the proportional valve secondary pressure corresponding to the command current from the mechatro controller, and varies P1 and P2 pump delivery flow rate. 7) The arm spool, arm conflux spool, and arm T2 spool are switched by genuine hydraulic pres- sure command, and P1 cut spool is switched by mechatro hydraulic pressure command, and P1 pump delivery oil is confluxed in P2 pump delivery oil. 8) And, since a lot of oil is remained in the arm cylinder head side, one spool is not enough to pre- vent the back pressure. So the arm spool and arm T2 spool are used to return the oil remained in the head side into the tank circuit. 98 8-155-9 Outline of Bucket digging system (SK200-6 + SK230-6) ATT pilot valve rR. 5 z 3 2) PI side AAs E . EH 8| Nega- g 8 S| |e =| |) con 2 eUsH 3| sensor 3 2 . (SE-26) = E 2 Aa 3 a7 : z 3 ELE s| [zE--“” = E & < Nega-Gon signal processing Command of i P1 pump --} Pt pump propo. propo. valve | | valve | (svi) Bucket digging system rc | , [eeton inet psa 1) With bucket digging operation, the pilot secondary pres- | = t i sure i 4 i 2) With switching of bucket spool, the negative control pres- | 2 i sure varies and the pressure is input in the negative control j § © i sensor (S26) and back pressure sensor (SE28) on Pl side. jg 3 i 3,) The output voltage from the negative control sensors \P1 side —v/ (SE26) and back pressure sensor (SE28) on P1 side is input | Output voltage of Nega-Con sensor| into mechatro controller, and the mechatro controller per- {Output voltage of Back pressure.__j forms negative control signal processing, and outputs it Fig. 1 into P1 pump proportional valve (PSV-P1). (Figure 1) 4) P1 proportional valves (PSV-P1) outputs the proportional valve secondary pressure corresponding to the command current from the mechatro controller, and controls Pl pump delivery flow rate. 5) The bucket spool is switched by genuine hydraulic pressure command, and P1 pump delivery flow rate is varied by the negative control. 9 5-165-10 Outline of Bucket conflux system control (SK320-6) ATT a Bucket dump P2 side Nega-Con . RH] sensor 4 g $ - 3 = 3 (sea) q 8 a PI side BH §] \eF 5 z EL 8| Nega- &| |e§ 5 é Back- |g! |2é| 3 Bl le | fle | Con pressure) 8 HsHetay 8) Senor (SE-28) | F el |e] |sl lz Ee 2 | (SE-26) ajay lg 3 LE] (E] Le 2) 4 5| [eb Low zg " : pressure £ e e sensor g 2 2 (SE) | Bucket digging! P2 Command of] | {P2 by-pass| |__| feebvines cut cut propo. propo. vaive| || valve (PSV-D) lot signal processing Command of Travel LA” +++ travel straight}-—+}_ straight propo. valve | | |propo. valve| Nega-Con signal processing Command of Pl pump Ne --| Pl pump propo. valve propo. valve (PSv-PID Nega-Con signal processing | 7 | | | T | sve) | A | | | Jj I | Command of P2 pump PX. fe} Pepa propo. propo. valve valve (PSV-P2) Mechatro controller (C-1) j 95 5-17| Output voltage of low press. sensor vi Output voltage | of low press. sensor | = — = we Pilot signal processing rs mA [Pilot signal processing]) is iB, | et al | IEE Zee | \e3 lege igs i8EE | | | a — poor i I |, [Renters rena] i Neg-Con sigal proesig | ig | | | ls | i3 | | Bs a: | 23 | ez | | ze | | 2 | IP side | Ip side —v! [Output voltage of Nega-Con sensor] | Output voltage of Nega-Con sensor] iQutput voltage of Back pressure | iQutput voltage of Back pressure _j Fig. 3 Fig. 4 Bucket conflux system 1) With bucket digging and dumping operation, the pilot secondary pressure switches bucket spool, and is input in low pressure sensors (SE1,SE2). 2) The output voltage from low pressure sensors (SE1,SE2) is input into mechatro controller, and the mechatro controller performs pilot signal processing, and outputs command current corresponding to the input voltage into P2 cut proportional valve (PSV-B). (Figures 1 and 2) 3) The P2 cut proportional valve (PSV-B) and travel straight proportional valve (PSV-C) out- puts proportional valve secondary pressure corresponding to the command current from mechatro controller, and switches the P2 cut spool and travel straight spool. 4) With switching of bucket spool and P2 cut spool, the negative control pressure varies and the pressure is input in the negative control sensors (SE26,SE27) and back pressure sensor (S28) on P1 and P2 sides. 5) The output voltage from the negative control sensors (SE26,SE27) and back pressure sensor (SE28) on P1 and P2 sides is input into mechatro controller, and the mechatro controller per- forms negative control signal processing, and outputs it into Pl pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2). (Figures 2 and 3) 6) Pl and P2 pump proportional valves (PSV-P1,P2) output the proportional valve secondary pressure corresponding to the command current from the mechatro controller, and controls P1 and P2 pump delivery flow rates. 7) The bucket spool is switched by genuine hydraulic pressure command, and travel straight spool and P2 cut spool are switched by mechatro hydraulic pressure command, and P2 pump delivery oil is confluxed in P1 pump delivery oil in bucket digging and dumping operation. Note The bucket conflux system is used only when the bucket is operated independently and on condi- tion that pilot secondary pressure is 15kgf/cm* or more 96 5-185-11 Outline of Arm in Swing priority control Note : ad The mark 3 for the C/V shows only SK320-6, tae and for SK200-6 and SK230-8 the spool is ° P2 side blanked off. Nega-Con x 2 LH sensor 3 H (SE-27), 5 a PI side + A § E . BH 8 | Nega- Back, | é S| |. =| |Z] con ipressurd Les 8) sensor sensor. |= ae 3 | (Se-26) (SE-28) | 3 2} |e] ]s] }sl lal le Low Oe sé 3) LE} LE] LE} [8] Lé] 4s] leh pressure| 3 « = sensor e 8 8 (SE-7) | E E “© x 2 4 i P2 Rem'varigeto|.|_ Arm variabl -Arm variable|...1..|Recirculation| Propo. valve] | |propo. valve | (Psv-ay Pilot signal processing i i | Nega-Con signal processing | | Command of i P2 pump PZ pump |---1-| propo. propo. valve} | valve | evra) Mechatro controller r (C- 1) j 3s 1 1 ——————_ 1" j5EmA [Pietsionat procasing]}) js Ema [Plot sont prosesna]) | | [Maron sal wensva]) ie t ||88 lief | +] EB i2 lBee l las || 3 | \Ees llges \| 28 | |ESs | |E8s [| 2 | ge | |SEE |] 28 l8a8 825 |e | —v! | —v! | —rvI | Output voltage I] Output voltage | P2 side Output voltage | of low press. sensor} | _of low press. sensor | | of Nega-Con sensor a Fig. 2 5-19Arm-in slewing priority control 1) With slewing operation in arm-in operation (or Arm-in operation in slewing operation), the pilot secondary pressure switches arm spool and slewing spool and concurrently is input in pressure sensors (SET, SE6). 2) The output voltage from sensors (SE7, SE) is input into mechatro controller, and the mechatro controller performs pilot signal processing, and outputs command current corre- sponding to the input voltage into arm variable recirculation valve (PSV-A). Figures 1 and 2) 3) The arm variable recirculation valve (PSV-A) outputs proportional valve secondary pressure (Highest select) corresponding to the command current from mechatro controller, and switches the arm variable recirculation spool. 4) With switching of arm spool, the negative control pressure varies and the pressure is input in the negative control sensor (SE27) and back pressure sensor (SE28) on P2 side. 5) The output voltage from the negative control sensor (SE27) and back pressure sensor (28) is input into mechatro controller, and the mechatro controller performs negative control signal processing, and outputs it into P2 pump proportional valve (PSV-P2). 6) P2 pump proportional valve (PSV-P2) outputs the proportional valve secondary pressure cor- responding to the command current from the mechatro controller, and varies P2 pump deliv- ery flow rate. 7) The arm spool and slewing spool are switched by genuine hydraulic pressure command, and P2 pump delivery pump flow rate is regulated by hydraulic oil command and regulates the stroke of arm variable recirculation spool. 8) The arm variable recirculation spool moves at full stroke resulting in the forced recirculation position (Highest select), and the return circuit to the tank is restricted and the return oil from arm cylinder rod side is recirculated and supplied to head side. 9) With this operation, the arm cylinder rod pressure rises , and the P2 pump delivery oil is used on the slewing operation side where the pressure is low in preference to others, and since the arm cylinder is operated with the recirculated oil, it can be operated maintaining the mini- mum speed. 10) With the arm-in and slewing operations, the exciting signal from mechatro controller to slewing parking brake solenoid valve (SV-1) is cut off, consequently the slewing parking brake is released. Note: The mark > shows only SK320-6, and for SK200- and SK230-6 the spool is blanked off.5-12 Outline of Travel straight system control Note 1) With the operation (with boom, arm, bucket and slewing) while travelling right and left, the The mark 3 for the C/V shows pilot secondary pressure switches each arm spool, and concurrently is input in low pressure sensor. only SK320-6, and for SK200-6 and 2) ‘The output voltage from each low pressure sensor is input into mechatro controller, and the ah $K230-6 the spool is blanked off. mechatro controller performs pilot signal processing, and outputs command current corre- ; sponding to the input voltage into each proportional valve. pilot valve (3) Attthe same time, when the mechatro controller receives the input corresponding to the combi- 2 2 P2 side nation shown in the List from low pressure sensor, the controller decides it as a signal of travel Travel al fan) Nega-Con x . straight, and the travel straight signal turns ON. pilot valve! sensor 3 g 4) After the travel straight signal turns ON, the following commands are output to each propor- La RH 2s] (SE27) 5 2 i poet ele: (psy. § 4 3 a Pl side @ Travel straight proportional valve (PSV-C) command (Figure 1) g 8) As E e BH 8 | Nega- For the secondary pressures when running and operating ATT, the highest pressure is se- 4 £7 Back- |% é Bll. zl} |$] con lected, and the switching pressure corresponding to the selected pressure is output and S5—| | pressure | 3 ee) LU Senn switches the travel straight spool. 5e8 sensor, 1S alec | (se.26) | © Pleut proportional valve (PSV-D) command (Figure 2) i A82| 28) |3 el |s Bile 3 For the pilot secondary pressures when running left and operating block ATTs (arm and ate E B\\£ £| |3| | 8 LA. slewing) on P2 side, the highest pressure is selected, and the switching pressure corresponding om ay |s <) |x ¥ FJ l#) [2 a) & to the selected pressure is output and switches P1 cut spool. a ~ = ® Pi cut proportional valve (PSV-B) command (Figure 3) bressur g & 8 For the pilot secondary pressures when running right and operating block ATTs (arm and sensor a E u E slewing) on PI side, the highest pressure is selected, and the switching pressure corresponding (SE-10) = < < to the selected pressure is output and switches P2 cut spool. Boom | Bucket | Arm | Slewing | Plout | P2cut Travel right (ou me) — = =—T9 r Travel left = = Oo oO o i | Travel both directions | _O ° (oe Ke) O° oO i i | 5) And, with switching of exch ATT spool and Pl and P2eut spool, the negative control pressure : i varies, and the pressure is input into negative control sensors (SE25, SE27) and back pressure I ona traiahe ! sensor (SE28) on Pi and P2 sides. signal ensor i | 6) The-output voltage from the negative control sensors (SE26, SE27) and back pressure sensor Pilot signal processing i (28) on Pl and P2 sides is input into mechatro controler and he mechatro controller per- i jorms negative control signal processing, and outputs it into Pl pump proportional valve i | (PSV-PL) and P2 pump proportional valve (PSV-P3). ! {Command (o# ||) patce 7) Pland P2 pump proportional valves (PSV-P1, P2) output the proportional valve secondary I straight jh i travel straight} +) straight pressure corresponding to the command current from the mechatro controller, and varies Pl propo. valve | j |propo. vale and P2 pump delivery flow rates. | + (PSV-C) 8) The travel right and left spool and the operated ATT spool are switched by genuine hydraulic | lot signal processing | ee ! i "Land P2 pump delivery . i i Soamena i] | [Pr a oil is regulated by the [5 mA [Pilot signal precessing]| | . mA. [Pilot signal processing] i 7 hatro hydraulic pressure | = lz Vi LZ {Pt by-pass cut|+-|cut propo. command and switches j 8 lis | i propo.valve| | | valve travel straight spool and | EE [15 | i (avd) Pl & P2 cut spools. Bee iis ! i ; } 8) Inthe travel straight con- [2 £3 | iz | i Pilot signal processing i dition, PL pump delivery ls25 {lz | H oil is! used to operate | ES 8 iz i \ Command of] | [P2 by-pass| ATTs and P2 pump deliv- | § © & | |g | in --|P2 by-pass cut}-+-| cut propo. ay cll igused to travel, [OP ic i £y 0 a) | WE propo. valve valve 10) With this operation, the j i i TpavB) travel speed slows down, Output voltage | ! . of low press. sensor i nen . allowing ATTs to be op: |_,__._ of !ow press. sensor. i ! processing erated without deviation. 1 | Command of] ; [ P1 pump i ———<— lo =e 1 i | P1 pump propo. 1S, mA [Pitot signal processing || @._[Nege-Con signal processing || | _[Nege-Con signa processing] | i propo. valve valve lg2 ile { ile { | i en (PSv-PI) IES i| 2 jl 2 j : i Nega-Con signal processing iss i il? i ee il Se il ee i i ‘Command of | [ P2 pump lee i! af j |g | : P2 pump propo. jee ilee il as i i prope-vave |! | valve [oe ze |e | ! (PSV-P2) | — vl pt side —v! ipa side vi | Output voltage | output voltage of Nega-Con sensor|_! Output voltage of Nega-Con sensor] L. pt ~ L____of low press. sensor} [Output voltage of Back pressure _j [Output voltage of Back pressure _j ca Fig. 3 Fig. 4 Fig. 5 56. HYDRAULIC CIRCUIT DIAGRAM IN OPTION 6-1 Breaker (Option) Explanation 1, Pilot circuit @ The pilot gear pump delivery oil flows into P1 port of sole- noid proportional valve (18). ® The lever lock actuates, and the delivery oil flows into pilot valve (52) for breaker and pilot valve for ATT through A port. @ With the operation of pilot valve (52), the delivery oil acts on a serial add-on valve PBO port of main control valve (50) and switches the spool. @ Concurrently, the voltage output by low pressure sensor (SE-11), negative control sensors (SE-26, SE-27) and back aie pressure sensor (SE-28) is sent to mechatro controller. © The command current from mechtro controller acts on P2 cut proportional valve (PSV-R) on solenoid proportional valve block (18) and switches the P2 cut spool. ‘The command current from mechatro controller acts on P1 pump proportional valve (PSV-P1) and negative control sensor (SE-26) has the Pl pump delivery flow rate to the minimum reduced. O Oke nage Bo LLem B oaratteh ora © The command current from mechatro controller acts on P2 pump proportional valve (PSV-P2), and the negative con- trol sensor (SE-27) and back pressure sensor (SE-28) have 2 pump delivery flow rate increased. oem When boom raise and breaker operation are carried out concurrently, P1 pump acts on boom raise operation, mak- ing the boom raise operation possible. 2. Main circuit © P1 pump delivery oil flows through P port of main control valve (50), and flows into P2 by-pass circuit on the upperstream of the travel straight section. @® P2 by-pass circuit is closed because P2 cut spool is moved. ‘Therefore the delivery oil opens load check valve CP2 and st 20 flows into P2 parallel circuit. Toe @ And the delivery oil opens load check valve LCo2 on the se- rial add-on valve and flows into the breaker spool. Note: @ Because the breaker spool is moved, the delivery oil flows * through around the spool, and is fed into the breaker 1. Code No.50 of main control valve and No.53 of return filter through Bo? port of main control valve (50) and stop valve differ from the standard ones. GD. io aia control esl) © The return oil from the breaker returns into return filter Negative control relief valve replaced (53) used directly and specially for the the breaker of hy- Serial add-on valve added draulic tank through stop valve (51). © Return filter . | Replaced with special part for breaker ieee etal re poguonalveieg 50, Main control valve 2. For serial add-on valve overload relief valve in Code No.60 51, Stop valve of main control valve, the pressure must be adjusted ac- 52. Pilot valve (For breaker) cording to the specification of breaker in use. 53. Return filter (For breaker only) 100 66-2 Nibbler & Breaker (Option) ivan heme nh ounem ape Peis 1 1 ! 1 r | 1 7 c + 7 TPT 7 1 23s vom | i | oc Z — oe i ag = aa iPS ie ' r it ae 2 am st 30, hed, --—— ___ J" oo 101 Selecting condition and proportional val single flow and breaker are in use. Ive command when nibbler conflux & Explanation A. Breaker circuit 1, Pilot circuit © The pilot gear pump delivery oil flows into P1 port of solenoid proportional valve (18). @ The lever lock actuates, and the delivery oil flows into pilot valve (63) for nibbler and breaker and pilot valve for ATT through A1 port. @ With the operation of pilot valve (52), the delivery oil acts on a serial add-on valve PBo2 port of main control valve (50) and switches the spool. @ Concurrently, the voltage output by low pressure sensor (SE-11), negative control sensors (SE-26, SE-27) and back pressure sensor (SE-28) is input into mechatro controller. © The command current from mechtro controller acts on P2 cut proportional valve (PSV-B) on solenoid.proportional valve block (18) and switches the P2 cut spool. @® The command current from mechatro controller acts on Pl pump propor- tional valve (PSV-P1) and negative control sensor (SE-26) has the P1 pump delivery flow rate to the minimum reduced. @ The command current from mechatro controller acts on P2 pump propor- tional valve (PSV-P2), and the negative control sensor (SE-27) and back pressure sensor (SE-28) have P2 pump delivery flow rate increased. ® When boom raise and breaker operations are carried out concurrently, P1 pump acts on boom raise operation, making the boom raise operation possi- ble. 2. Main ci @ P2 pump delivery oil flows through P2 port of main control valve (50), and flows into P2 by-pass circuit on the upperstream of the travel straight sec- tion. @® P2 by-pass circuit is closed because P2 cut spool is moved. Therefore the de- livery oil opens load check valve CP2 and flows into P2 parallel circuit. @ And the delivery oil opens load check valve LCo2 on the serial add-on valve and flows into the spool. @ Because the breaker spool is moved, the delivery oil flows through around the spool, and is fed into the breaker through Bo2 port of main control valve (0) and stop valve (52) @© The return oil from the breaker returns into return filter (64) used directly and specially for the the breaker of hydraulic tank through stop valve (51). Note 18 41. Code No.60 of main control valve and No.64 of return filter differ ! Commend signal from proportional vale from the standard ones. ~ ——-- et ith : ©, Without : — i i i | Conflux & F © Main control valve Negative control relief valve replaced single flow | Switching | py) pz | travel) pr | 2 Serial add-on valve added selector | valve (51) | PumP | Pump |straight) cut | eut © Return filter is replaced with special part for breaker. 18. Solenoid proportional vane Nibbler | Conttux ON a o | o | o | o | © | 2. Theswitch added in instrument panel is used to switch the nib- 50. Main control valve eonfiux! | _ bler conflux and single flow, and the breaker single flow. BI. Sel Nibbler | Conflux OFF -—|o - | 0 Beet ae valve single flow | COlUx a Lo 3. For serial add-on valve overload relief valve in Code No.80 of . Stop valve = ‘ ° ee Ea cI Se Eee) rare | era 3 —Toetl-tft-—tlo ea contral ava, the pressure should be adjusted according to 54. Return filter (For breaker only) a nearer 6-2B. Nibbler circuit 1. Pilot circuit @ The operation in Items © and @) are the same as the breaker circuit. ® With the operation of pilot valve (53), the delivery oil acts on a serial add-on valve PAo? port of main control valve (50) and switches the spool. @ The operation in items @ and © are the same as the breaker circuit. @ Besides, turn the conflux & single selector switch in the inside of instrument panel, and the mechatro controller outputs the command current to travel straight, and P1 and P2 cut pro- portional valves respectively and respective spool is switched to conflux circuit. ® The command current from mechtro controller acts on Pl pump (PSV-P1) and P2 pump (PSV-P2) proportional valves, the negative control sensors (SE-26, SE-27) and back pressure sensor (SE-28) has P1 and P2 pumps delivery rates increased. © When boom raise and nibbler are operated concurrently, P1 pump delivery pressure acts on boom raise operation, making the boom raise operation possible. 2. Main circuit @ PI pump delivery oil flows through P1 port of main control valve (50), and flows into the travel straight section, and finally enters into P1 and P2 parallel circuits because the spool is moved. @® The delivery oil in Pi parallel circuit opens load check valve CT2 and flows downstream, but is closed by the P4 port. @ The delivery oil opens load check valve CT2 and flows into P2 parallel circuit. @® P2 pump delivery oil flows into the travel straight section through P2 port of main control valve (50), and flows into P1 and P2 by-pass circuits because the spool is moved. @® Because P1 cut spool is moved, P1 by-pass circuit is closed, the delivery oil opens load check valve CP1 and flows into P1 parallel circuit, but is closed by the P4 port. © Because P2 cut spool is moved, P2 by-pass circuit is closed, the delivery oil opens load check valve CP2 and PI and P2 delivery oil is confluxed in P2 parallel circuit. © The delivery oil opens load check valve LCo2 on the serial add-on valve through P2 parallel cir- cuit and flows into spool. ® Because the spool is moved, the delivery oil flows through around the spool, and is fed into the nibbler cylinder through Ao? port of main control valve (50), selector valve (51) and stop valve (52). @ The return oil from the nibbler cylinder flows into main control valve (50) through stop valve (52) and into spool through B02 port. @ Because the spool is moved, the delivery oil flows through around the spool and returns into hydraulic tank through tank circuit and oil cooler. 102 6-37. HYDRAULIC COMPONENTS 7-1 Hydraulic pump 1. Appearance Bolt for Back-up (M8) a3 Dr PN1/ a8 PSV2 PH2 a6 ra = - a& PHI PSV1 a9 PN2 af Bolt for Back-up (M8) Psvi 28 PSV2 py ab @ { ° °F) 6 I eR Ok. oe ——— 1 5 Drs at 87 at Bla Code Name of Port Size Remarks Al, AZ Delivery port ‘SAE 6000 3/4 BI Suction port ‘SAE 2500 2% Dr Drain port PF3/4__| Plugged PSV1, PSV2 | Servo-assist port PFI/4 PN1, PN2 __| Servo-assist port PFI/4 PH1, PH2 _| Pressure sensor port PF 3/8 al~ad __| Gauge port PF1/4 _| Plugged 3 Gear pump delivery port | _ PF3/8 B3 Gear pump suction port PF 3/4 Dra Gear pump drain port PF 3/8 108 1-102. Hydraulic diagram of main pump (FRONT) — PSV1 Psv2 (REAR) a8 PNT | al Al AZ a2 | PNZ ab et] abt Dr BI B3 Dr3. A3 Unit Model $K200-6 $K230-6 SK320-6 Model Main pump | K3V1120-1RAP-STIL | KAVI120T-1RAP-STOL | KIVI12T-1RAP-STOS eee Gear pump | ZX10LGRz2-06D | __—_— " 105 X 2/10 115 X 2/10 Displacement ee/rev | (Gear pump) (Gear pump) Rated speed 2,200 {2,200} (Rotation direction) min™ {rpm} | (Clockwise viewed from shaft end) 2,100 {2,100) 2,200 {2,200} High idling min~ {rpm) [2,220 {2,220} or low|2,00 (2,300) or low|2,385 {2,385} or low Rated pressure [Main pump | 34.3 (350) —— —— MPa {kgf/cm*} | Gear pump 4.9 {50} —— ATT boost press. MPa {kgf/cm*} 37.8 {385} Max. flow rate (at 80kgt/em) L/min | 210 x 2/20 (6. .P) | 238 X 2/21 (G.P) | 250 x 2/22 (G.P) 106.6{145}(include | 129{175}include | 177{240}(include Max. input power KW {PS} | gear pump input torque) | gear pump input torque) | gear pump input torque) /3.4 {4.6} gear pump)|/3.4 (4.6}(gear pump)|/3.4 {4.6)(gear pump) 509.6{52}(include | 588.4 {60}(include | 735.3{75}(include Max. input 1 ‘em)} | gear pump input torque) | gear pump input torque) | gear pump input torque) torque Nem (koe) | 7445 (s8) oa pan) [7141 (1-8 gear punp)| 714. (1.8) ar pp) Inner pressure 3) | Average 0.1 {1} limit of casing MPa kaf/em | surge” 0,39 (4) Oil quantity in casing L 28 Control characteristic Nega-Con/Total power shift control Mai 125 Weight kg [Emenee = 126 —— Gear pump. 1.6 Note : G.P is Gear pump. 108 1-203, Structure 1) Main pump [Code Name (O'ry| [Cod Name [a'ty [Code] Name ory) 11 | Shaft (Front) 1 |[313| Valve plate (Front) | 1 ||725 | O-ring (wis B2aoi-P11) | 7 113 | Shaft (Rear) 1 |[314| Valve plate (Rear) | 1 ||728| O-ring (wis B24ot-P24) | 4 14 1_|[25| Cover 1 2 123 | Roller bearing 2 |[401| Socket boit (Ma0xz10) | 8 1 124] Needle bearing 2 |[405| Socket bott (Méx20) | 4 || 45] Back-up ring ; 127 | Bearing spacer 4 |[407| Socket bolt (M6x30) | 3 (JIS B2407-P18) 141 | Cylinder block 2 [406 | VP plue PF 174) | 2 |_| Back-up ring 2 151 | Piston 18 ||468 | VP plug (PF3/4) | 4 (JIS B2407-G35) 152| Shoe 18 ||490| Plug (Meck) 20 || 806 | Nut (m6) 2 163 | Retainer —_[ 2 [[s31 | Titting pin 2 |[ 08 | Nut (M20) 2 186| Spherical bushing | 2 ||832| Servo piston 2 |[e24] Snap ring 2 157 | Cylinder spring 18 || 534 | Stopper (Large) 2 || 885 | Pin ($8x12L) 2 211 | Shoe plate 2_||535 | Stopper (Small) 2_|[886 | Spring pin 4 212 | Swash plate 2 ||546 | Spacer 2_|[901 | Eye boit (Mio) 2 214| Tilting bushing 2. |[ 548 | Feed back pin 2 |[953 | Set screw 2 251 | Support [ 2 |] 702 O-ring 2 |[964] Set screw 2 261 | Seal cover 1 |[710| O-ring (ois B2401-Ga5) | 1 || 981 | Name plate 1 271 | Pump casing 2 |[717| O-ring (ais Baor-Grs) | 4 || 989 | River 2 312| Valve block —_ [1 [724] o-ring Gis B2401-P8) [16 - 105 1-302) Regulator © Structure of regulator View oe res 727 467 Dr Bolt for back-up (Regular position) at nS Bolt for back-up “Un back-up condition) Section EE(Code! Name ty | [Code] Name [ow ‘412 | Socket bolt (M8 x 50) 2_ || 730 [O-ring (IS B2401-P22) 1 413 | Socket bolt (M8 x 70) 2_| | 732 | O-ring (Is 82401-P16) 2 418 | Socket bolt (MB x 12) 2_| [733 | O-ring (Is 82401-P20) 2 436. | Socket bolt (M6 X 60) 5_| [734 | O-ring (IS B2407-G25) 1 438 | Socket bolt (M6 x 20) 4 | [753 [O-ring GIs B2401-P3) 1 439 | Socket bolt (M6 x 40) 4_| | 755 [O-ring (is 82401-P11) 6 466 | VP plug (PF 1/4) [3 | [756 | O-ring Gis 82401-P26) 2 467 | Plug (PF 3/8 x MB) 1_|| 763 | O-ring (JIS 82401-635) 1 | 496 | Plug 18 || 801 | Lock nut (Ma) 3 51 | Seat 2_| [814 | Snap ring (Jis 82804 SR-15) | 1 543 | Stopper 1 2_| | 836 | Snap ring 1 545 | Ball 2_| [858 | Locking ring WIS 82804 RR-15) | 2 601 | Casing _ 1_| {874 [ Pin (64x 11.71) fa 611 | Feed back lever 1_| | 876 | Pin (94 x aL) _ 4 612 | Lever (1) 1_| [387 [Pin mm) 613 [ Lever (2) 1_| [897 | Pin (4x 191) 1 614 | Fulcram plug 1_| [ 298 | Pin (6.5 x 9L) 1 615 | Adjust plug 1_| | g24_[ Set screw 1 621 | Compensating piston 1_| | 925 | Set screw (a1) 1 622 | Piston casing 1 623 | Compensating rod 1_| {079 | Solenoid valve la 624 | Spring seat (C) 1 625 | Outer spring 1 626 | Inner spring 1 627 | Plunger (C) 1 628 | Adjust screw (C) 1 629 | Gover (C) 1 630 | Lock nut 1 631 | PF sleeve 1 641 _| Pilot cover 1 642 | Rod 1 643 | Pilot piston 1 644 | Spring seat (Q) 1 645 | Plunger (Q) 1 646 | Pilot spring 1 = ae ; Tightening torque pool [653 | Spring seat 1 Code size | yen team) 654 | Return spring 1 | Faz a3 me 29.4 (3) 665 | Set spring 1 450 | Port plate 7] | 436.438, 439 | M6 11.8 {1.2} 708 | O-ring (JIS B2401-G75) 1 || 466 PF 1/4 36.3 {3.7} 722_| O-ring (JIS B2401-P6) 2 || 467 PF 3/8 73.5 {7.5} 724 | O-ring (JIS_B2401-P8) 12 | a96 NPTF 1/16 38 (0.9) 725 | O-ring (JIS B2401-P10) 1 721 | O-ring (JIS B2401-P14) 1 || 880 30/215] OSE TETD 728 | O-ring (JIS 62401-P18) 1 | [801 ma 16.7 (1.6) 1m 71-8® Operation of regulator COMPENSATING LEVER NEGATIVE CONTROL LEVER (lL FLOW 7 CONTROL PART \FEED BACK LEVER, Necarve CONTROL SPOOL SPOOL COMPENSATING PISTON COMPENSATING ROD (ex % | iy SERVO PISTON] 1, Feed back lever is connected with 3 pins, spool attaching pin ®. Tilting pin ©) attaching to servo piston, and pin @) reaching to large holes of negative control lever, and control lever. 2. The negative control lever is connected with 2 pins, a pin fixed on casing ®, and pin © in contact with negative control spool groove part. 3. ‘The compensating lever is connected with 2 pins, a pin fixed on casing @, and a pin ® in contact with compensating rod groove part. 108, 7-8® Conceptual diagram for pump operation 109 Flow rate up Flow rate down Left Right Large diameter side Small diemeter side © sult-pressure >] servo piston Self-pressure © Tank ‘Swash plete Cylinder block 1. This is the mechanism to vary the inclination resulting from moving servo piston right and left. 2, That is the right movement of servo piston makes the swash plate vertical slightly reducing the flow rate, and the left movement makes the inclination of swash plate larger increasing the flow rate. 3, The diameters of servo piston on right and left sides differ, and are referred to as the “small diameter side” and “large diameter side” for explanation. 4, On the small diameter side, the self-pressure is always given. Now, the self-pressure is given to the large diameter side like the small diameter side. As a result, the servo piston moves rightward due to the difference of area reducing the flow rate, 6. By connecting the large diameter side to tank, the servo piston moves leftward due to the difference of pressure increasing the flow rate, 7, The pump having these actions is called a variable displacement pump.