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Shop Manual 460,480 - 8
Shop Manual 460,480 - 8
MAINTENANCE SPECIFICATIONS
SHOP SK460-8
MANUAL model SK480LC-8
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
0-2
SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.
0-3
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
0-4
SK460-8
INDEX SK480LC-8
Book Code No. Index
Title
Distribution Year–Month No.
MAINTENANCE SPECIFICATIONS
S5YN0118E01
2007-07
OUTLINE 1
S5LS0211E01
2007-07
SPECIFICATIONS 2
S5LS0311E01
ATTACHMENT DIMENSIONS 3
2007-07
S5LS1111E01
TOOLS 11
2007-07
S5LS1211E01 STANDARD MAINTENANCE
2007-07
12
TIME SCHEDULE
S5LS1311E01 MAINTENANCE STANDARD
2007-07
13
AND TEST PROCEDURE
S5LS2111E01 MECHATRO CONTROL
2007-07
21
SYSTEM
S5LS2211E01
2007-07
HYDRAULIC SYSTEM 22
S5LS2311E01
SYSTEM
2007-07
ELECTRIC SYSTEM 23
S5LS2411E01
2007-07
COMPONENTS SYSTEM 24
S5LS2511E01
2007-07
AIR-CONDITIONER SYSTEM 25
_
S5YN3118E01 DISASSEMBLING
DISASSEMBLING
S5LS4611E01
2007-07
BY ERROR CODES 46
S5LS4711E01
2007-07
BY TROUBLE 47
_
S5LS5111E01
ENGINE 51
2007-07
_
LS10-02001~
YS10-01501~ APPLICABLE MACHINES
0-5
NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.
• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
0-6
1
1. OUTLINE
TABLE OF CONTENTS
1-1
1. OUTLINE
1-2
1. OUTLINE
1.1 GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and
begin a meeting before starting the work.
MAKING REPAIRS
3) Before starting inspection and maintenance
1.1.1 PREPARATION BEFORE stop the engine.
DISASSEMBLING
4) Confirm the position of first-aid kit and fire
extinguisher, and also where to make contact
Read Operator's Manual
for emergency measure and ambulance to
before disassembling
4) Visible oil leak, water leak and damage 3) Pipes with plugs or caps to prevent oil leaking,
entry of dust, etc.
5) Clogging of filters, oil level, oil quality, oil
contamination and looseness. 4) Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
6) Examine the problems on the basis of monthly
and gear oil before putting them on working
operation rate with the last inspection date and
bench.
records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Since performance and function of hydraulic
1) Tools required for repair work.
equipment after disassembly and assembly
2) Prepare the places to put the disassembled
results in immunity from responsibility on the
parts.
manufacture’s side, disassembly, assembly
3) Prepare oil pans for leaking oil, etc. and modification without permission are strictly
prohibited.
1.1.2 SAFETY WHEN DISASSEMBLING AND
ASSEMBLING 2) If it is unavoidably necessary to disassemble
and modify, it should be carried out by experts
or personnel qualified through service training.
WARNING
3) Make match mark on parts for reassembling.
(1) Safety 4) Before disassembling, read Disassembling
1) Wear appropriate clothing, safety shoes, safety Instruction in advance, and determine if the
helmet, goggles, and clothes with long sleeves. disassembly and assembly are permitted or
not.
1-3
1. OUTLINE
1-4
1. OUTLINE
(6) Engine key off before touching terminals of starter (2) Flexible hose (F hose)
and alternator. • Even if the connector and length of hose are the
(7) Remove battery grounding terminal before same, the parts differ according to the
beginning work close to battery and battery relay withstanding pressure. Use proper parts.
with tools. • Tighten it to the specified torque, and check that
(8) Wash machine with care so as not to splash water it is free from twist, over tension, interference,
on electrical equipment and connector. and oil leak.
(9) When water has entered in the waterproofed
1.1.6 WELD REPAIR
connector, the removing of water is not easy. So
(1) The weld repair should be carried out by qualified
check the removed waterproofed connector with
personnel in the specified procedure after
care to protect it from entry of water. If moisture
disconnecting the grounding cable of battery. If the
adheres on it, dry it completely before connecting.
grounding cable is not disconnected, the electrical
equipment may be damaged.
(2) Remove parts which may cause fire due to the
Battery fluid is dangerous. entry of spark beforehand.
The battery fluid is dilute sulfuric acid, and causes (3) Repair attachments which are damaged, giving
scald and loss of eyesight by adhering on eyes, particular attention to the plated section of piston
skin and clothes. When the fluid has adhered on rod to protect it from sparks, and don’t fail to cover
them, take an emergency measure immediately and the section with flame-proof clothes.
see a doctor for medical advice.
1.1.7 ENVIRONMENTAL ISSUES
• When it has adhered on skin ;
Wash with soap and water. (1) Engine should be started and operated in the place
where air can be sufficiently ventilated.
• When it has got in eyes ;
Wash in water for 10 minutes or more (2) Waste disposal
immediately. The following parts follows the regulation.
Waste oil, waste container and battery
• When it has spilled out in large quantity ;
Use sodium bicarbonate to neutralize, or wash (3) Precautions for handling hydraulic oil
away with water. Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
• When it was swallowed ;
Drink milk or water. • When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
• When it has adhered on clothes ;
Wash it immediately. • When it was swallowed ;
Don’t force him to vomit it, but immediately
1.1.5 HYDRAULIC PARTS receive medical treatment.
• When it has adhered on skin ;
Wash with soap and water.
(4) Others
(1) O-ring For spare parts, grease and oil, use KOBELCO
• Check that O-ring is free from flaw and has genuine ones.
elasticity before fitting.
• Even if the size of O-ring is equal, the usage
differs, for example in dynamic and static
sections, the rubber hardness also differs
according to the pressure force, and also the
quality differs depending on the materials to be
seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and
bend.
• Floating seal should be put in pairs.
1-5
1. OUTLINE
1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations
Introduction Table1-4
Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA
of SI units system is described here. Frequency hertz Hz 1Hz=1/s
Given hereinunder are an excerpt of the units that are Force newton N kg • m/s 2
related to this manual : Pressure and
pascal Pa N/m2
1. Etymology of SI Units Stress
English : International System of units Energy, Work
2. Construction of SI Unit System and Quantity of joule J N•m
heat
Base units Power watt W J/s
Table 1-1
Derived units Quantity of
coulomb C A•s
Supplemen of base units electricity
SI units tary units Table 1-3
SI unit Table 1-2 Electric
system Derived units potential
Derived bearing peculiar
designations difference,
units volt V W/A
Table 1-4 Voltage, and
Electromotive
Prefixes of SI
(n-th power of 10, where n is an integer) force
Table 1- 5 Quantity of
static electricity
(1) Basic Units farad F C/V
and Electric
Table1-1 capacitance
Electric
QUANTITIES DESIGNATION SIGN ohm V/A
resistance
Length Meter m
celcius
Mass Kilogram kg Celcius
degree or C
° (t+273.15)K
Time Second s temperature
degree
Current Ampere A
Thermodynamic Kelvin K Illuminance lux lx l m/m2
temperature
(5) Prefixes of SI
Gram molecule Mol mol
Luminous intensity Candela cd Table1-5
PREFIX
(2) Supplementary Units POWER
DESIGNATION SIGN
Table1-2 Giga G 109
QUANTITIES DESIGNATION SIGN Mega M 106
Plain angle Radian rad Kilo k 103
Solid angle Steradian sr Hecto h 102
Deca da 10
(3) Derived Units of Basic Units
Deci d 10–1
Table1-3 Centi c 10–2
QUANTITIES DESIGNATION SIGN Milli m 10–3
Area Square meter m2 Micro µ 10–6
Volume Cubic meter m3 Nano n 10–9
Velocity Meter per second m/s Pico p 10–12
Acceleration Meter per second / second m/s2
Density Kilogram per cubic meter kg/m3
1-6
1. OUTLINE
1-7
1. OUTLINE
[MEMO]
1-8
2
2. SPECIFICATIONS
TABLE OF CONTENTS
2-1
2. SPECIFICATIONS
2-2
2. SPECIFICATIONS
BOOM CYLINDER
BUCKET
CYLINDER
SLEWING BEARING
CAB
SWIVEL
JOINT SLEWING MOTOR
IDLER LINK
FUEL TANK
CONTROL VALVE
BUCKET LINK
HYDRAULIC TANK
MUFFLER
HYDRAULIC
PUMP
BUCKET GUARD
MONITOR PANEL
FRONT IDLER
2-3
2. SPECIFICATIONS
Unit : mm (ft-in)
3000 (9'10")
R3
(12 670
'0.5
")
12030 (39'6")
3670 (12'05")
3570 (11'9")
3310 (9'10")
*1340 (4'5")
1200 (3'11")
(20.1")
*510
36
(1.4")
Lower roller Q'ty : 8 pcs. or [9 pcs.]
600 5110 (5450) [16'9" (17'11")]
(23.6") 2750 (9'0")
6230 (6400) [20'5" (20'12")]
3350 (10'12")
2.2.2 SK460-8/SK480LC-8 [7.00m (23ft-0in) Boom+3.00m (9ft-10in) Short Arm+2.10m3 (2.75cu•yd) Bucket
Shoe]
Unit : mm (ft-in)
12080 (39'7.6")
3670 (12'0.5")
3800 (12'5.6")
3310 (9'10")
1200 (3'11")
36 *1340 (4'5")
(1.4")
2-4
2. SPECIFICATIONS
2.2.3 SK460-8/SK480LC-8 [7.00m (23ft-0in) Boom+4.90m (16ft-1in) Long Arm+1.35m3 (1.77cu•yd) Bucket
Shoe]
3670 (12'0.5")
4410 (14'5.6")
3310 (9'10")
1200 (3'11")
*1340 (4'5")
36
(1.4")
5110 (5450) [16'9" (17'11")]
2-5
2. SPECIFICATIONS
2-6
2. SPECIFICATIONS
Unit ; kg (lb)
Model
SK460-8 SK480LC-8
Item
4. Lubricant and water (Assembly of following :) 934 (2,060) ←
4.1 Hydraulic oil 311 (686) ←
4.2 Engine oil 41 (90) ←
4.3 Fuel 541 (1,193) ←
4.4 Water 41 (90) ←
2-7
2. SPECIFICATIONS
2.4 TRANSPOTATION
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER
Model
SK460-8 SK480LC-8
Item
Width 600mm (23.6in) shoes 3,350 (10ft-12in) 3,350 (10ft-12in)
Weight 27,900kg (61,520 lbs) 28,900kg (63,725 lbs)
Unit : mm (ft-in)
2800 (9'2")
292 (11.5")
3310 (10'10")
3970 (13'0")
(3'4")
1020
(26")
660
2-8
2. SPECIFICATIONS
Type
7.00m (23ft-0in) Boom
Item
Length×Height×Width 7.27 × 1.99 × 0.926
m (ft-in)
L×H×W (23'10"× 6'6"× 36.5")
Weight kg (lbs) 4,650 (10,253)
H
L
(2) Arm
Type
3.00 m (9ft-10in) Arm 3.45 m (11ft-4in) Arm 4.90 m (16ft-1in) Arm
Item
Length×Height×Width 4.20 × 1.20 × 0.65 4.71 × 1.16 × 0.65 6.14 × 1.26 × 0.65
m (ft-in)
L×H×W (13'9"×3'11"×25.6") (15'5"×3'10"×25.6") (20'2"×4'2"×25.6")
Weight kg (lbs) 2,490 (5,490) 2,610 (5,755)
H 3,270 (7,210)
2-9
2. SPECIFICATIONS
(3) Bucket
Hoe bucket
L H
H
H
L W
2-10
2. SPECIFICATIONS
2.5.2 ENGINE
2.5.4 WEIGHT
Unit : kg (lbs)
Fully equipped weight 46,400 (102,310) 47,300 (104,300)
Upper structure 20,230 (44,607) ←
Lower machinery
16,500 (36,382) 17,200 (37,926)
(600mm grouser shoe)
Attachment
7.00m (23 ft-0in) Boom+3.45m (11ft-4in) Arm 9,820 (21,653) ←
+1.9m3 (2.48cu•yd) Bucket
2-11
2. SPECIFICATIONS
Use 600mm (23.6") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate
with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
2-12
2. SPECIFICATIONS
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
2-13
2. SPECIFICATIONS
2-14
2. SPECIFICATIONS
Condition to be measured: The net value is indicated, measuring without cooling fan.
marks show the rated point
SHAFT TORQUE
SHAFT OUTPUT
2-15
2. SPECIFICATIONS
[MEMO]
2-16
3
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
3-1
3. ATTACHMENT DIMENSIONS
3-2
3. ATTACHMENT DIMENSIONS
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING
J
d4
I
X
d3
d1
D C H
E B
F
G
X
d2
SECTION X-X
Fig. 3-1 Boom dimensional drawing
Unit : mm (ft-in)
STD —
7.0M (23ft) BOOM
LS02B00129F1 —
No NAME DIMENSION
A Boom length 7000 (23') —
B Boom foot width 926 (36.5") —
C Boom end inner width 449.8 (17.7") —
D Boom end outer width 627 (24.7") —
E Height of boom cylinder rod pin 1,162 (3'10") —
F Height of arm cylinder (head side) pin 1,476.8 (4'10") —
G Distance between pins of boss R3,069 (10'1") —
H Distance between pins of bracket R3,530 (11'7") —
I Arm cylinder (head side) inner width 166 (6.54") —
J Outer width of bracket on the arm cylinder (rod side) 638 (25.1") —
mounting
d1 Boom foot pin dia. ø 120 (4.72") —
d2 Boom cylinder (rod side) pin dia. ø 120 (4.72") —
d3 Pin dia. of boom end. ø 120 (4.72") —
d4 Arm cylinder (head side) pin dia. ø 120 (4.72") —
Weight kg (lb) 3,640 (8,026) —
3-3
3. ATTACHMENT DIMENSIONS
A
C
Unit : mm (in)
Standard value Clearance
Sym- Bushing Repaira
Item Pin part No. Pin dia. Standard Service Remedy
bol Pin dia. i.d. ble
tolerance value limit
tolerance level
+ 0.020 + 0.205 + 0.225
ø 120 (+0.0008) (+0.0081) (+0.0089)
A Boom foot LS02B01341P1
(4.7244) - 0.020 + 0.098 + 0.078
(-0.0008) (+0.0039) (+0.0031)
0 + 0.229 + 0.269 More
Replace
Boom cylinder ø 110 (0) (+0.0090) (0.0106) than 2.5
B LS02B01344P1 bushing
(Head side) (4.3307) - 0.04 + 0.103 + 0.103 2.0 (0.1)
or pin
(-0.0016) (+0.0041) (+0.0041) (0.08)
Boom cylinder + 0.020 + 0.230 + 0.250
C LS02B01345P1
(Rod side) ø 120 (+0.0008) (+0.0091) (+0.0098)
Arm cylinder (4.7244) - 0.020 + 0.105 + 0.085
D LS02B01473P1
(Head side) (-0.0008) (+0.0041) (+0.0033)
3-4
3. ATTACHMENT DIMENSIONS
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable Service
No. Size No. Length
value level limit
926
Boom
(36.5)
0.5 (0.02) 921
A-A Boom foot L1 PL1
932 or less (36.3)
Upper frame
2.0 2.5
(36.69 )
(0.08) (0.10)
150
Boom cylinder
Boom cylinder (5.91) 0.6~1.0 284
B-B L2 PL2
(Head side) 156±1 (0.02~0.04) (11.2) Shim
Upper frame
(6.15±0.04) adjust
140 ment
Boom cylinder L3
Boom cylinder (5.51) 0.6~2.0 3.0 4.0 810
C-C PL3
(Rod side) 638 (0.02~0.08) (0.12) (0.16) (31.9)
Boom L3'
(25.1)
160
Arm cylinder
Arm cylinder (6.30) 0.6~1.0 2.0 2.5 274
D-D L4 PL4
(Head side) 166 (0.02~0.04) (0.08) (0.10) (10.8)
Boom
(6.54)
3-5
3. ATTACHMENT DIMENSIONS
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
SECTION Z-Z
SECTION Y-Y
3-6
3. ATTACHMENT DIMENSIONS
E F
D, D'
B
C
G
Unit : mm (in)
Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.256 +0.316
(+0.0101) (+0.0124)
A Arm point
–0.020 +0.084 +0.104
(-0.0008) (+0.0033) (+0.0041)
LS12B01507P1
–0.060 +0.216 +0.276
Bucket link (-0.0024) (+0.0085) (+0.0109)
B
(Bucket side) +0.070 +0.090
(+0.0028) (+0.0035)
3-7
3. ATTACHMENT DIMENSIONS
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
L3 PL5 X6 L6
X3
X5 L5
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction
3-8
3. ATTACHMENT DIMENSIONS
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable
No. Size Service limit No. Length
value level
450
Arm
(17.71) 1.0 (0.04) 2.0
A-A Arm point L1 PL1
452 or less (0.08)
Bucket
(17.80) 702
450 (27.6)
Link side
(17.71)
B-B Bucket link L2 — — PL2
453
Bucket
(17.83)
446 With in 2.5
Idler link Arm 1.0
C-C L3 (17.56) 0.5 (0.10) PL3
(Arm connection) (0.04)
Link side - (0.02)
Bucket link Rod side -
D-D (Idler link L4 446 578
Link side
connection) (17.56) (22.8)
0.6~1.0 2.0 Shim
160 PL4
Rod side (0.024~0.04) (0.08) adjust
Bucket link (6.30)
D’-D’ L4’ -ment
(Rod side) 166
Link side
(6.54)
160
Head side
Bucket cylinder (6.30) 332
E-E L5 PL5
(Head side) 166 (13.1)
Arm
(6.54) 0.6~2.0 3.0 4.0
160 (0.024~0.08) (0.12) (0.16)
Rod side
Arm cylinder (6.30) 367.5
F-F L6 PL6
(Rod side) 166 (14.5)
Arm
(6.54)
444
Arm With in
(17.48) 1.0 2.5 665
G-G Arm foot L7 0.5 PL7
449.8 (0.04) (0.10) (26.2)
Boom (0.02)
(17.71)
3-9
3. ATTACHMENT DIMENSIONS
3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
Unit : mm (ft-in)
Type Hoe bucket
[STD]
1.35m3 1.60m3 2.10m3 2.40m3
Capacity 1.90m3
(1.77 cu•yd) (2.09 cu•yd) (2.75 cu•yd) (3.14 cu•yd)
(2.48 cu•yd)
Part No. LS61B00045F1 LS61B00007F1 LS61B00008F1 LS61B00059F1 LS61B00062F1
A R630 (24.8") ← ← ← ←
B R1,780 (5'10") ← ← ← ←
C 1,475 (4'10") 1,033 (3'4.7") 1,183 (3'10.6") 1,559 (5'1.4") 1,788 (5'10.4")
D 552 (21.7") ← ← ← ←
E 452 (17.8") ← ← ← ←
F 1,667 (5'5.6") 1,225 (4'0.2") 1,375 (4'6.1") 1,751 (5'9") 1,980 (6'6")
G 1,339 (4'4.7") 890 (35") 1,040 (3'5") 1,423 (4'8") 1,652 (5'5")
H 1,546 (5'0.9") 1,096.5 (3'7.2") 1,246.5 (4'1.1") 1,630 (5'4.2") 1,859 (6'1.2")
I 339 (13.3") 303 (11.9") 353 (13.9") 360 (14.2") 417 (16.4")
IO 339 (13.3") 303 (11.9") 353 (13.9") 360 (14.2") 417 (16.4")
d1 ø 100 (3.94") ← ← ← ←
d2 ø 100 (3.94") ← ← ← ←
3-10
3. ATTACHMENT DIMENSIONS
J
M
LS12B01054P1
VIEW I
E
N
A
F
H
9
25 (0.354")
(0.984")
SECTION A-A
Fig. 3-8 Dimension of lug section
Unit : mm (ft-in)
Lug plate thickness
Boss width.
Boss width.
Screw dia.
Capacity of
Hole dia.
A B D E F G H J M N
[STD]
1.90 (2.48) LS61B00045F1
Hoe 1.35 (1.77) LS61B00007F1 100 36 120 16 220 22 195 28 170
bucket M20
(3.94") (1.42") (4.72") (0.63") (8.66") (0.87") (7.68") (1.10") (6.69")
1.60 (2.09) LS61B00008F1
2.10 (2.75) LS61B00059F1
2.40 (3.14) LS61B00062F1
3-11
3. ATTACHMENT DIMENSIONS
gh
ou
thr
ILL
DR
G
Unit : mm (ft-in)
Capacity of
Type of Part No. of Part No.
bucket øA øB E F øG
bucket bucket of boss
m3 (cu•yd)
1.90 (2.48) LS61B00045F1
1.35 (1.77) LS61B00007F1
Hoe 139.8 103.8 25 40 21
1.60 (2.09) LS61B00008F1 LS12B01054P1
bucket (5.50") (4.09") (0.984") (1.57") (0.827")
2.10 (2.75) LS61B00059F1
2.40 (3.14) LS61B00062F1
3-12
11. TOOLS
11
TABLE OF CONTENTS
11-1
11. TOOLS
11-2
11. TOOLS
11-3
11. TOOLS
11-4
11. TOOLS
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 M36 55
M8 13 M42 65 d
M10 17 M45 70
M12 19 M48 75
(M14) 22 M56 85
M16 27 (M60) 90 B
(M18) 27 M64 95
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
(M3) 2.5 M20 17
(M4) 3 (M22) 17 @
(M5) 5 M24 19
M6 5 (M27) 19
M8 6 M30 22
M10 8 M36 27
*
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10
11-5
11. TOOLS
11-6
11. TOOLS
SLEEVE NUT
B
d
d
11-7
11. TOOLS
11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)
Applicable
tube Plug parts No.
O. D : A
A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000
(3) Nut
Applicable
A
11-8
11. TOOLS
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29
(2) PT screw
B
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
PF screw
PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36
screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E
11-9
11. TOOLS
#
$ %
() !
, -+./0
&# *+( "
'& *+( "
'& *+( "
Female
11-10
11. TOOLS
70(2.76)
16 22
15 (0.591) 2421T160 27 (0.630) (0.315) (0.866)
70(2.76)
42(1.65)
19 22
18 (0.709) 2421T138 32 (0.748) (0.866)
12.7 (0.500 )
22(0.866)
70(2.76)
48(1.89) 11.5(0.453)
23 22
22 (0.866) 2421T130 36 (0.906) (0.866)
12.7 (0.500 )
109(4.29)
60(2.36)
14.5(0.571)
29 22
28 (1.10) 2421T115 41 (1.142) (0.866)
12.7 (0.500 )
32 (1.26) 2421T232 50
81(3.19) 90(3.54)
20.5(0.807)
11-11
11. TOOLS
Additional M10 X 22
threading
for M10 eye bolt
Plug ZE72X16000 For slinging the
1
PF1 swing motor
O-ring
PF1
M12
M8 Eye bolt
Plug ZF83P22000
(Nominal
tube dia. 22)
3 Reference nut Flare hose
Reference
Eye bolt ZS91C00800
M8 X 18
Nut ZF93N22000 Addtional
threading for
M8 Eye bolt
M8 Eye bolt
M8 X 18
Additional
Plug YN01H01002P1 threading
Nominal
4 1 3/16-12UN HEX 36 Flare hose
M8 Eye bolt
M8 18
Additional
Plug YN01H01003P1 threading
Nominal
5 1 7/16-12UN HEX41 Flare hose
11-12
11. TOOLS
Table11-4
No. Tools name Tools No. Shape Applicable
M8 Eye bolt
M8 17
Plug ZE72X12000 Additional
PF3/4 threading For slinging the
6
swivel joint
Eye bolt ZS91C00800 PF 3/4
11-13
11. TOOLS
Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle
#262 1374
compound strength
High
#271 1305
strength
Sealing
#515 1215 Sealing
compound
11-14
11. TOOLS
2 Nut
3 Cover
4 O-ring
11.9.2 DIMENSION
50
(1.97")
R8
158 (6.22")
2
M8 NUT
O8 (1.315")
600 (23.6")
(0.374")
9.5
0 0
139 -0.3 (5.47" -0.012 )
M8
(0.787")
152 0.2
20
(5.98" 0.008)
ROD COVER
Fig. 11-2 Dimension of suction stopper
Applicable
SK460-8
model
Part No.
24100P978F3
11-15
11. TOOLS
(14ft1in
4.3m
)
(1.
R6
30 ")
18
(1.
57
40 )
2 PIN S40C 2
"
(4.
12 2")
3 CAPSCREW - 2 M10 X 85
7
0
4 HOLDER POK40 2 REAR SIDE
19(0.748") 19(0.748")
(1 R50
")
.97
4
30(1.18")
(2.36")
60
(31.5")
800
1
(4.13")
19 100 19
105
1 (2.56")
(0.748") (3.94") (0.748") (5. 46 65
75 (1.97")
(1.18")
")
50
30
(5.91") (0.866")
22
(13.8")
350
(1.97") 50
130
(5.12")
150
22 22 50
40 +0.05 (1.5748" +0.0020 )
120 120
+0.0079
(4.72") (4.72")
(2 60
2
")
11.5(0.453")
.36
DRILL
40+0.2
(2.36")
60
5
C ")
11.5(0.453") 7 178(7.01")
9
(1 R50
178(7.01") 1
")
DRILL 15 0. 125(4.92") 50
.97
(0.591") 125(4.92") (
30 19 19 10 (1.97")
(1.18") (0.748") (0.748") (0.394")
11-16
11. TOOLS
Material : wood
5 Unit ; mm(inch)
(1.97)
(1.18)
(11.8)
3 2 1
1 1 piece 2 1 piece
1010 (39.8)
400 (15.7) 140 320 (12.6)
(5.51)
90 (3.54)
250 (9.84)
(10.04
R255
494 (19.45)
)
380 (15.0)
260 (10.24)
240 (9.45)
240 (9.45)
480 (18.9)
3 1 piece 5 1 piece
1010 (39.8)
380 (15.0)
380 (15.0)
240 (9.45)
t40 (1.57)
t40 (1.57)
440 (17.3)
11-17
11. TOOLS
[MEMO]
11-18
12. STANDARD MAINTENANCE
TIME TABLE
12
TABLE OF CONTENTS
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST
(TEMPORARY EDITION) ................................................................................................12-15
12.2.1 MEASURING METHOD .........................................................................................12-15
12.2.2 WORKING CONDITION .........................................................................................12-15
12.2.3 STANDARD TIME CONSTITUENT ........................................................................12-15
12.2.4 MEANING OF WORDS IN USE .............................................................................12-17
12-1
12. STANDARD MAINTENANCE TIME TABLE
12-2
12. STANDARD MAINTENANCE TIME TABLE
PREFACE
(1) Working Conditions
1) Workers :
More than one worker shall be 1st class service technician (having five years or more of field experience and
having received training in the operation).
2) Equipment :
Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The
maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for
specific self inspection activities.
3) Place :
A flat land where work may be performed and to which a service car or a truck crane is accessible.
(2) Range of standard maintenance time
1) Standard maintenance time=Direct maintenance time×Preparation time
2) Direct maintenance time : Net time actually spent for maintenance
3) Spare time :
Time needed to move machines for service, prepare safety operations, discuss work, and process the needs
of the body.
(3) Extra time (not included in the standard service time)
1) Repair time :
Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting.
2) Items excluded from service time because of uncertainty in time :
Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults,
diagnosis, and inspection.
3) Indirect time :
Time for ; field work, preparation of necessary parts before leaving for work, return for field work, waiting time
because of user’s convenience in the field, paper work after returning to shop, and preparation of bills.
4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately.
5) Separate calculation : The operating time for service cars, trucks with a crane and crane trucks.
(4) Applicable machine for estimation of standard maintenance time
1) Standard machine
2) A well maintained and controlled machine with a standard combination of attachments which is used in a
general environment.
12-3
12. STANDARD MAINTENANCE TIME TABLE
12-4
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 1.2
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.3
04 • Bucket drive pin Detach/attach 1 0.3
05 • Bucket sling and movement Preparation 1 pc. 0.3
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 5.0
07 • Tooth Replace 1 pc. 1.2
08 • Side cutter Replace 1 pc. 2.5
09 • Bushing Replace 1 pc. 1.2
12-5
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
71 • Pin bushing Replace 1 set Include seal. 2.0
80 Boom cylinder O/H 2 10.0
01
12-6
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
50 Under cover relation See 33.1.5
51 Cover (1) Detach/attach 1 pc. 0.1
52 Cover (2) Detach/attach 1 pc. 0.1
53 Cover (3) Detach/attach 1 pc. 0.1
54 Cover (4) Detach/attach 1 pc. 0.1
55 Cover (5) Detach/attach 1 pc. 0.1
56 Cover assy (6) Detach/attach 1 pc. 0.1
02 Cab & Guard
12-7
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
44 • Inter cooler hose & tube Detach/attach 2 pcs. 0.5
(E/G to inter cooler)
45 • Radiator lifting or hoisting Detach/attach 1 pc. 0.3
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.2
12-8
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
96 • Cleaning and sealant Cleaning 1 set 0.4
97 Swing motor O/H 1 pc. 5.0
98 Swing reduction gear O/H 1 pc. 6.0
12-9
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
143 • Fuel hose Detach/attach 1 pc. 0.1
144 • Others Detach/attach 1 set 0.7
145 • Mounting bolt Detach/attach 1 pc. 0.7
146 • Engine slinging Detach/attach 1 set 0.4
147 • Cleaning Cleaning 1 pc. 0.6
148 Engine O/H 1 set Reference for engine (Chapter 51)
Other necessary works Detach/attach 1 set Removing and installing guard 1.0
Detach/attach 1 set Removing and installing Counterweight 1.2
Detach/attach 1 set Removing and installing pump 3.5
Detach/attach 1 set Removing and installing air cleaner 0.5
1 set Removing and installing muffler 0.7
03 Swing frame
Detach/attach
12-10
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
34 Idler ASSY O/H One side 2.0
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0
Diode
06 Electric equipments
12-11
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
D-19 Diode Replace 1 0.3
D-20 Diode Replace 1 0.3
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner AM & FM (OPT) Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air compressor Replace 1 Include Counterweight removing and installing. 1.0
E-12 Battery Replace 2 0.4
E-13 Travel alarm (OPT) Replace 1 0.3
06 Electric equipments
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-3 Swing flusher & work light (left) Replace 1 0.2
L-4 Swing flusher & work light (right) Replace 1 0.2
L-5 Room light Replace 1 0.2
L-6 Boom cylinder work light (right) Replace 1 0.2
Motor
M-1 Starter motor Replace 1 Include Counterweight removing and installing. 1.0
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-8 Grease motor (OPT) Replace 1 0.5
M-9 Skylight wiper motor (OPT) Replace 1 0.5
Proportional valve
PSV-A Arm variable recirculation proportional valve Replace 1 0.5
PSV-B P2 bypass cut proportional valve Replace 1 Include proportional valve block removing and installing. 0.5
PSV-C Travel straight proportional valve Replace 1 0.5
PSV-D P1 bypass cut proportional valve Replace 1 0.5
12-12
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
06 Electric equipments
Sensor
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
SE-9 Pressure sensor : Travel right Replace 1 Include under cover removing and installing 0.5
SE-10 Pressure sensor : Travel left Replace 1 Include under cover removing and installing 0.5
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover removing and installing 0.5
SE-13 Engine speed sensor Replace 1 Include under cover removing and installing 0.5
SE-15 Engine water temperature sensor Replace 1 Include guard removing and installing 0.5
SE-16 Accel potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side : P1 side (OPT.) Replace 1 Include under cover removing and installing 0.5
SE-22 Pressure sensor : P1 pump Replace 1 0.5
SE-23 Pressure sensor : P2 pump Replace 1 0.5
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-2 Attachment boost pressure SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-3 2-speed travel SOL Replace 1 Include proportional valve block removing and installing. 0.5
12-13
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
SV-4 Safety lever lock SOL Replace 1 Include proportional valve block removing and installing. 0.5
Switch
SW-1 Key switch Replace 1 0.3
06 Electric equipments
12-14
12. STANDARD MAINTENANCE TIME TABLE
12.2.3.1 STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD
ALLOWANCE TIME
(1) Net working time
The time workman works actually and the time required for measurement, cleaning, and so on is included, but
the time required for troubleshooting is not included
(2) Standard time
Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts
and so on, and for the work site clean-up.
(3) Standard allowance time
Calculate the allowance time directly required for workmen from the following equation.
Net standard time × HINO allowance rate
Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position
and so on.
12-15
12. STANDARD MAINTENANCE TIME TABLE
12-16
12. STANDARD MAINTENANCE TIME TABLE
12-17
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
Timing adjustment
Completed
1 00101 Engine adjustment A set Valve clearance adjustment 3.8
machine
Include; Replacing and installing retarder assy
Completed A set and nozzle adjustment.
2 00103 Engine adjustment B set —
machine Include; Replacing and installing retarder assy
Include; Engine warm-up, valve clearance
Completed adjustment, removing air cleaner element,
3 00111 Compression measuring 7.3
machine battery specific gravity measurement
and removing and installing retarder assy
4 00152 Compression measuring Single unit 2.7
Completed
5 00121 Removing and installing Engine Include; Function check 20.5
machine
Completed
6 00122 Removing and installing Engine Include; Function check and reprogramming 21.0
machine
Completed Exclude; Installation of accessory
7 00123 Reinstalling rebuild engine 21.0
machine Include; Function check and reprogramming
Include; Retightening of Water pump, Oil
pump, and Cylinder head, Valve lapping, Test
Completed run, Cleaning of air cleaner
8 00124 Engine overhaul 99.3
machine Exclude; Electric equipments, Water pressure
test, Overhaul of engine retarder assy and
clutch
Include; Removing and installing engine,
Replacing cylinder, block, piston, Completed
9 99012 function check, Retightening of head bolt, Air 75.7
ring and liner simultaneously machine
cleaner cleaning and test run
Include; Removing and installing engine,
Replacing crank shaft, piston, Completed
10 99013 function check, Retightening of head bolt, Air 73.1
ring and liner machine
cleaner cleaning and test run
Include; Removing and installing engine,
Completed
11 00125 Replacing cylinder block function check, Retightening of head bolt, Air 72.7
machine
cleaner cleaning and test run
Include; Removing and installing engine,
Completed
12 00126 Replacing crank shaft function check, Retightening of head bolt, Air 67.7
machine
cleaner cleaning and test run
Include; Removing and installing of engine,
Replacing crank shaft main Completed Function check, Air cleaner cleaning and test
13 00127 67.7
bearing machine run, Removing and installing of engine retarder
assy
Replacing crank shaft thrust Completed
14 00128 Exclude ; Removing and installing of engine 2.7
bearing machine
From engine is removed condition
Include; Adjustment of water pump, oil pump,
valve clearance, valve lapping and
measurement/cleaning
16 00151 Engine overhaul Single unit 77.0
Exclude; Replacing of injection pump,
electrical equipment, water pressure test,
clutch overhaul, Replace of valve guide, and
Overhaul of engine retarder assy
17 00132 Engine retarder assy overhaul Single unit 2.3 1.9
18 00133 Engine retarder assy overhaul Single unit 4.2
From piston & connecting rod are removed
19 00153 Replacing piston Single unit 0.5 0.5
conditions
12-18
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
12-19
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
12-20
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
Unit of 1
92 00375 Replacing valve spring From cylinder head is removed condition 0.2 0.2
cylinder
93 00334 Overhaul of engine retarder assy A piece 2.3 1.9
94 00335 Overhaul of engine retarder assy Single unit 4.2
Removing and installing engine
95 00338 Single piece 1.0 0.5
retarder assy
Removal and installing supply
100 00406 One set Include; Function check 6.0
pump
101 00402 Replacing tappet chamber cover One set 0.7 0.5
Replacing tappet chamber cover
102 00403 One set 0.7 0.5
gasket
Removing and installing oil
103 00404 One set 2.3
cooler assy
Completed Include; Removing and installing of engine
104 00411 Tightening oil pan 0.4
machine under cover
Completed Include; Removing and installing of engine
105 00412 Removal and installing oil pan *3.3
machine under cover
Completed Include; Cleaning of block bottom and
106 00413 Replacing oil pan *3.3
machine Removing and installing of engine under cover
Completed Include; Removing and installing of engine
107 00414 Replacing oil pan gasket *3.3
machine under cover
108 00421 Replacing oil pan drain cock One set 0.6
Replacing oil pan drain cock
109 00422 One set 0.6
gasket
113 00444 Replacing oil level gauge One set 0.2 0.2
124 00511 Replacing flywheel One set 9.0
125 00512 Replacing fly wheel housing One set 11.4
126 00513 Replacing ring gear One set 9.6
127 00514 Reposition of ring gear One set 9.6
Replacing crank shaft rear oil
128 00515 One set 9.4
seal
Replacing cam end plug (without
132 00519 One set 11.8
PTO)
143 00551 Replacing ring gear Single unit From flywheel is removed condition 0.6
Replacing crank shaft rear oil
144 00552 Single unit From fly wheel is removed condition 0.6
seal
Replacing crank shaft rear oil
145 00553 Single unit From flywheel is removed condition 0.4
seal retainer
Replacing crank shaft rear oil
146 00554 Single unit From flywheel is removed condition 0.4
seal retainer gasket
Removing and installing air
150 00601 One set 1.0
cleaner
151 00602 Replacing air cleaner One set 1.0
152 00603 Replacing air cleaner element One set 0.3
Cleaning of air cleaner element Note: Do not clean wet and viscous type air
153 00604 One set 0.4
(only dry type) cleaner
154 00605 Replacing air cleaner dust pan One set 0.2
155 00607 Replacing dust indicator One set 0.2
One side of
Removing and installing intake
156 00611 completed -
manifold
machine
12-21
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1 by 1 each
12-22
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1 by 1 each
12-23
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
12-24
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
333 00911 Replacing O-ring of oil filter cover One set 0.5 0.1
Removing and installing oil
338 00931 One set 2.3
cooler
339 00932 Replacing oil cooler One set 2.3
340 00933 Replacing oil cooler casing One set 3.0
Replacing oil cooler casing
341 00934 One set 2.3
gasket
342 00935 Replacing oil cooler element One set 3.0
Replacing oil cooler element
343 00936 One set 3.0
gasket
344 00937 Replacing oil cooler safety valve One set 0.3
Replacing oil cooler safety valve
345 00938 One set 0.3
spring
346 00941 Removing and installing oil pan One set Include; Removing and installing of oil pan 1.9
347 00942 Replacing oil pump One set Include; Removing and installing of oil pan 2.5
348 00944 Replacing oil pump gear One set Include; Removing and installing of oil pan 2.5
349 00943 Overhaul of oil pump One set 3.2
350 00946 Replacing suction strainer One set 2.0
Replacing O-ring of suction
351 00947 One set 2.2
strainer
Completed
358 01001 Adjusting V-belt 0.3
machine
Completed
359 01002 Replacing fan belt Exclude; Removing and installing cooler belt 0.6
machine
Completed
361 01008 Replacing coolant *0.6
machine
Completed
362 01009 Refilling coolant 0.2
machine
Completed
363 01010 Replacing antifreeze *0.6
machine
Completed
364 01011 Refilling antifreeze 0.2
machine
Completed
365 01012 Filling antifreeze *0.6
machine
Completed
367 01014 Replacing long life coolant *0.6
machine
Completed
368 01015 Refilling long life coolant 0.2
machine
372 01021 Removing and installing radiator One set *7.8
373 01022 Replacing radiator One set *8.3
375 01024 Replacing drain cock One set 0.7
376 01025 Replacing radiator cap One set 0.2
Removing and installing fan Completed
377 01026 1.0
shroud machine
Completed
378 01027 Replacing fan shroud 1.0
machine
Removal and installing water
379 01028 One set *3.0
pump
380 01029 Replacing water pump One set *3.0
381 01030 Overhaul of water pump One set 2.8
384 01036 Replacing cooling fan One set 1.6
12-25
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
12-26
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
12-27
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
12-28
12. STANDARD MAINTENANCE TIME TABLE
SK460-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
Completed
525 01820 Replacing acceleration sensor Include; Function check 1.5
machine
Removing and installing Completed
526 01821 Include; Function check 1.2
computer machine
Completed
527 01822 Replacing computer Include; Function test and Reprogramming 1.8
machine
Completed
530 01825 Check of System function Include; Use of DST-1 personal computer 1.0
machine
Replacing pressure pipe
Completed
532 01827 (Between Common rail and Include; Function check 1.5
machine
Supply pump)
Completed Include; Function check and Removing and
533 01828 Replacing fuel leakage pipe 3.4
machine installing of retarder assy in P11C engine
Completed
535 01830 Replacing supply pump coupling Include; Function check 6.4
machine
Completed
536 01831 Replacing supply pump bracket Include; Function check 6.4
machine
Checking of high pressure fuel Completed
537 01840 Include; Function check 1.2
leak machine
Replacing main engine speed
539 01901 One set Include; Function check 1.2
sensor
Replacing sub engine speed
540 01902 One set Include; Function check 1.2
sensor
Replacing coolant temperature
541 01903 One set Include; Function check 1.2
sensor
542 01904 Replacing accel sensor One set Include; Function check 1.5
Removal and installing EGR
543 01908 One set Include; Function check 2.4
valve
544 01909 Replacing EGR valve One set Include; Function check 2.4
Removal and installing EGR
547 01916 One set 2.4
cooler
548 01917 Replacing EGR cooler One set 2.4
Removal and installing closed
549 01918 One set 0.5
ventilator
550 01919 Replacing closed ventilator One set 0.5
12-29
12. STANDARD MAINTENANCE TIME TABLE
[MEMO]
12-30
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ..........13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE.....................................................13-4
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6
13.3.1 MEASUREMENT OF ENGINE SPEED..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.3 PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12
13.5.1 TRAVEL SPEED.....................................................................................................13-12
13.5.2 DEVIATION OF TRAVEL .......................................................................................13-12
13.5.3 PERFORMANCES OF PARKING BRAKE .............................................................13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR.......................................................................13-14
13.6 MEASURING SWING PERFORMANCES.......................................................................13-15
13.6.1 SWING SPEED ......................................................................................................13-15
13.6.2 PERFORMANCE OF SWING BRAKE ...................................................................13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ..................................................13-16
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18
13.7.1 OPERATING TIME OF CYLINDERS .....................................................................13-18
13.7.2 OIL TIGHTNESS OF CYLINDERS.........................................................................13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20
13.9 MECHATRO CONTROLLER...........................................................................................13-21
13.9.1 ENGINE CONTROL INPUT / OUTPUT ..................................................................13-21
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B ADJUSTMENT) 13-21
13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO
CONTROLLER .......................................................................................................13-26
13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-2
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition
Class
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23) °
C — Atmospheric temp
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — 50°C~-10°C (122°F~14°F)
not required
Adjustment
Measure the engine
B mode Hi idle 1850 + 30 - 70 Perform all
speed at multi display on min-1
A mode Hi idle 1850 + 30 - 70 measurement with
the gauge cluster.
Decel 850 + 25 - 25 the air-conditioner
S mode Hi idle 1750 + 30 - 70 "OFF".
Pilot primary pressure circuit G pump a3 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure
P1 a1
Main relief
Arm a2
H PF1/4 34.8 (5050) 0 - 1.0 (-145) MPa OR7 Arm in
R 34.8 (5050) 0 - 1.0 (-145) (psi) OR2 Bucket dump
Bucket a1
H 36.3 (5260) 0 - 2.5 (-360) OR1 Bucket digging
RH 25.0 (3625) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 25.0 (3625) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 35.8 (5190) 0 - 2.0 (-290) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 35.8 (5190) 0 - 2.0 (-290) RH and LH
RV —
13-4
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Standard
Inspection item Unit
value
1st speed 37.8 ~ 34.6
Track link revolution STD
2nd speed 22.7 ~ 20.7
(RH,LH) sec / 3 rev
1st speed 40.1 ~ 36.9
(H mode) LC
2nd speed 24.1 ~ 22.1
Up 3.3 ~ 3.9
Boom
Operating speed
37 ~ 77 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 180
ATT amount of drift Boom cylinder 6.0 mm / 5min (At no load)
Arm cylinder 12
Amount of horizontal play at the bucket tooth 40 ~ 80 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out
13-5
13. MAINTENANCE STANDARD AND TEST PROCEDURE
NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OF
F
MODE HM
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V
13-6
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-7
13. MAINTENANCE STANDARD AND TEST PROCEDURE
MACHINE
FRONT
MACHINE
FRONT
OR2:BUCKET(R) OR3:BOOM(H)
13-8
13. MAINTENANCE STANDARD AND TEST PROCEDURE
A3
13-9
13. MAINTENANCE STANDARD AND TEST PROCEDURE
: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)
: 6 mm
: 41 mm,
Tightening torque : 98 N•m (72.3 lbf•ft) Fig. 13-8 Main relief valve
(Travel section, ATT common section)
: 30 mm,
Tightening torque : 59 N•m (43.5 lbf•ft)
: 13 mm,
Tightening torque : 3.0 N•m (2.2 lbf•ft)
: 4 mm
13-10
13. MAINTENANCE STANDARD AND TEST PROCEDURE
: 14 mm
Tightening torque : 157 N•m (116 lbf•ft)
(5) Travel over load relief valve
This valve was adjusted by valve maker. Do not
replace any inner parts except for O-ring.
13-11
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-12
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(3) Preparation
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket
is lifted by about 30cm (1ft). A
(4) Measurement 20m (66ft)
1) Measure the max. deviation distance of the
circular arc in the 20m (66ft) length, excluding
Fig. 13-15 Measuring method
the preliminary run of 3~5m (10~16ft).
2) Operate the travel lever at the same time. Travel deviation Unit : mm (in) / 20m (66ft)
Measuring Reference value
position Standard value for remedy Service limit
A 240 (9.45) or less 480 (18.9) 720 (28.4)
C
GUIDE FRAME
Fig. 13-17 Method of measurement
13-13
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-14
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-15
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Fig. 13-22 Measuring position of swing brake
performances
Swing brake performance Unit : degree
Measuring Reference value
position Standard value for remedy Service limit
Swing 180 77 or less 85 93
13-16
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-17
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-18
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-19
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-20
13. MAINTENANCE STANDARD AND TEST PROCEDURE
E-27:
C-8: EMERGENCY
ACCEL
ENGINE CONTROLLER
INJECTOR
E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
13-21
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.9.2.3 PREPARATION
(1) Raise the oil temperature to about 50°C (122°F) to warm up the engine.
(2) Turn the air-con OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the adjustment data
is not entered.
A215, A225, A015, A025
As the error codes other than those shown above may suggest failures of machine, repair the machine into the
ordinary operating condition according to Error Code List.
For machines equipped with lifting magnet, turn the generator OFF.
13-22
13. MAINTENANCE STANDARD AND TEST PROCEDURE
MULTI DISPLAY
WASHER SWITCH
WIPER SWITCH
SELECTOR SWITCH
4) After starting engine, press selector switch on gauge cluster, and "MEMORY
MEMORY ENG
ENG" is displayed, the engine speed is automatically increased, and the ENGINE SPEED
800rpm
adjustment of engine is performed. PUMP PRESSURE
C-1 01.0M C-2 01.0M
(When trying to limit engine speed, press selector switch on gauge cluster at STEP
140
the speed as it is, and the adjustment of engine is terminated. The torque
adjustment and unloading adjustment required later are not performed, and
default value is written.)
5) When normal HIGH idling speed is detected, the adjustment is completed. And
FINISH ENG
"FINISH ENG" is displayed. ENGINE SPEED
1850rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared, PUMP PRESSURE
C-1 2.0M C-2 2.0M
and the adjustment of engine is completed. The torque adjustment and STEP
400
unloading adjustment required later are not performed, and default value is
written.)
13-23
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(3) Corrective actions taken when the adjustment can not be performed;
ERROR ENG.
1) In cases where the adjustment of engine can not be performed; And ERROR ENGINE SPEED
1850rpm
ENG" is displayed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
STEP
Judging condition: The read engine speed is 50rpm lower than the last value. 400
It is conceived that the error is caused by the speed read error, pump load
applied to the engine and unusual acceleration command voltage applied to
the engine controller in the course of adjustment.
a. Checking speed sensor: Check that it is free from wrong reading of speed
due to engine vibration.
b. Checking load applied to pump: Check that it is free from abnormal
increase of pump pressure during adjustment of engine through
adjustment screen.
c. Checking acceleration command voltage: Measure the acceleration
command voltage output from mechatro controller to engine controller.
Check that signal is regularly input to the engine controller by actual
measurement of voltage or with failure diagnosis tool of engine controller.
13-24
13. MAINTENANCE STANDARD AND TEST PROCEDURE
2) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
1850rpm
Judging condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
P1 and P2 average pump pressure at the time when the adjustment is PROPO-VALVE
E-1 300mA E-2 300mA
For machines equipped with lifting magnet, turn the generator OFF.
13-25
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Operating procedure:
1) Set the emergency acceleration to NORMAL position.
2) Start engine.
3) Turn the emergency acceleration to HI side and control the engine speed.
4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping.
Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed does not increase.
When the machine does not operate, set the emergency acceleration to NORMAL position.
The emergency mode should be used in only case of emergency. We recommend that the defective section is
repaired by troubleshooting as early as possible.
13-26
21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
21-1
21. MECHATRO CONTROL SYSTEM
21-2
21. MECHATRO CONTROL SYSTEM
PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the
conditions before and after each conversion, refer to the hydraulic system and the electric system.
Though this machine is equipped with the "Unload" valve as well as other series, the function of the "Unload" valve
of this machine is different from the "Unload" valve of other models. In the series (PDA in general) of other models,
the "Unload" function is used as hydraulic control. But in this machine, it is used only for the pressure release. The
meaning of "Unload" used in this machine differs from other models. And do not confuse it, though the same word
"Unload" is used.
21-3
21. MECHATRO CONTROL SYSTEM
$
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21-4
21. MECHATRO CONTROL SYSTEM
SE-29
ARM
OUT DOWN RIGHT DIGGING DOWN ARM OUT
(8) (4) (6) REVERSE REVERSE (1) (4) (8) SV-13
PL1
SELECTOR VALVE
TRAVEL STRAIGHT
)
P2 BYPASS CUT
P1 BYPASS CUT
(ATTACHMENT
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
BOOST
N&B
BUCKET
OPTION
SWING
SOL
P2 P1
(7) (3) (5) FORWORD FORWORD (2) (3)
ARM IN UP LEFT DOWN UP
L2
SOLENOID VALVE
L3
L4
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
P1 BYPASS CUT
P2 BYPASS CUT
L5
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
21-5
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-6
21. MECHATRO CONTROL SYSTEM
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
21-7
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting boom up operation, boom up operating pilot pressure switches boom 1 speed spool and boom 2
speed spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate.
(4) With original hydraulic pressure command, boom 1 speed spool and boom 2 speed spool are switched, and also
with the command by mechatro controller, P1 and P2 pumps are switched and consequently the delivery oil on
P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
21-8
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
21-9
21. MECHATRO CONTROL SYSTEM
21-10
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low
pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot
signal processing and outputs command according to the input voltage to P2 pump proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve
for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump
delivery rate is low due to low engine speed.
21-11
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is
input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by mechatro controller, P1 and P2 pump proportional valves are switched, and consequently
the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
21-12
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
P2 P1
PILOT
VALVE
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P2 BYPASS CUT
PROPORTIONAL
VALVE PSV-B
MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves and P2
bypass cut proportional valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P2 bypass cut valve of the
control valve.
(4) P2 pump delivery oil confluxes into parallel passage of center section because the center bypass passage of P2
is blocked.
21-13
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
PILOT
P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ACCEL
POTENTIO BUCKET DIGGING PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P2 BYPASS CUT
PROPORTIONAL
VALVE PSV-B
MECHATRO
P1 PUMP PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-14
21. MECHATRO CONTROL SYSTEM
(1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches bucket spool and
is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves.
(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate.
(5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary
pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump
delivery rate is low.
(7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the
pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the
stroke limit of bucket spool.
21-15
21. MECHATRO CONTROL SYSTEM
PILOT
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
VALVE
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
SWUNG
PRIORITY P2 P1
VALVE
LOW
PRESSURE
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
VALVE PSV-P1
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure
sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot
secondary pressure switches swing spool and swing priority valve, and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and inverse
proportional valve for arm 2 spool.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches arm 2 speed spool.
(4) Arm 1 speed spool, swing spool and swing priority valve are switched by pure hydraulic pressure command. And
also arm 2 spool is switched by the command of mechatro controller ; consequently the return oil on arm cylinder
rod side is recirculated into arm cylinder head side.
(5) Because the pump delivery circuit of arm head side is restricted and the return oil on the arm rod side is
recirculated, the working pressure is raised and pump delivery rate is used for swing operation by priority, and
operated by the recirculated oil, making the operation with minimum speed drop possible.
21-16
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C
21-17
21. MECHATRO CONTROL SYSTEM
21-18
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
GAUGE CLUSTER PILOT P2 P1
VALVE
SE-23 SE-22
ENGINE
PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS UNLOAD
DIRECTIONAL
VALVE SV-31
MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER SECONDARY PRESSURE
(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot,
accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum
tilt angle.
2) Outputs command of pressure release and outputs command of pressure release control to ECU and fixes
engine speed to pressure release control speed.
3) Switches unload solenoid directional valve and open the opening of unload by pushing travel straight valve
from back side.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to
be released by operating each control lever and switching spool with the unload opening of travel straight valve
opened.
21-19
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SWING
SE-29 VALVE
STRAIGHT
SOLENOID
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
21-20
21. MECHATRO CONTROL SYSTEM
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
PILOT VALVE
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
21-21
21. MECHATRO CONTROL SYSTEM
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)
21-22
21. MECHATRO CONTROL SYSTEM
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25 For the work with breaker, select "B mode" without fail.
A mode
10:25 For the work with crusher (nibbler), select "A mode".
For the work with breaker, select "B mode" without fail.
The work with breaker in any mode other than "B mode" may cause damage to the hydraulic equipment and
breaker.
21-23
21. MECHATRO CONTROL SYSTEM
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 370L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.
10:25 Flow
rate 370 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 370 L/m rate 370 L/m
A B
(b) (c)
21-24
21. MECHATRO CONTROL SYSTEM
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
ASIA 2,000 Hr
Hydraulic oil
OCEANIA 5,000 Hr
• The display automatically changes to the main screen, if switch is not operated for 30 seconds.
• For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the 21.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE.
21-25
21. MECHATRO CONTROL SYSTEM
MACHINE CONDITION
H
MULTI DISPLAY INDICATIONS
1) Display function for operator ......... Screen usually displayed during operation
1.1 Clock display function ......... Current time is displayed.
1.2 Self-diagnosis display ......... When abnormality is detected on mechatro system like sensor, proportional
valve, etc., this displays error code.
1.3 Warning display ......... When machine was thrown into dangerous state, or was failed, displays warning
contents with the symbol and statement. (For warning contents, see items
shown below.)
1.4 Machine condition display ......... Displays machine operating condition.
2) Display function for maintenance ......... Displays remaining time up to replacement/change of following
items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3) Failure history display function ......... Stores abnormality occurred on mechatro system in the past and
displays in order of recent occurrence.
4) Mechatro adjustment display ......... Displays procedure for adjustment of mechatro system like output
adjustment and unload adjustment, etc.
5) Service diagnosis display ......... Displays information like pressure sensor sensed value, proportional valve
command, etc. output by mechatro controller
6) Failure diagnosis mode display function ......... Specifies failed section automatically for failures which are
not detected by self diagnosis and displays the results.
HIGH ENG
AUTO IDLE STOP WATER TEMP.
W006 CHARGE ERROR
WARM FINISH WARM-UP DRAIN WATER SEPA W010 WARM AUTO WARMING UP
DATA
CPU COMMUNICATION CLOGGED AIR FLTR W008 CHANGE ENG OIL
ERROR
SWING BRAKE
W001 ENGINE STOP
DISENGAGED
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
21-26
21. MECHATRO CONTROL SYSTEM
!
12
Swing flasher
13 right relay
Swing flasher
14 left relay
Travel alarm
15 relay
P1 side option AIS relay 2
16
P2 side option Engine stop
17 relay
Safety lock
18 lever relay
19
Adjustment Safety relay
21 data sector 1
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust data
Cluster
31 communication
Refer to next page (Engine)
21-27
21. MECHATRO CONTROL SYSTEM
Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.
21-28
21. MECHATRO CONTROL SYSTEM
21-29
21. MECHATRO CONTROL SYSTEM
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 2205 No load setting rpm B-1 BOOM RAISE
MEAS1 2201 Actual rpm 1 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS2 2201 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 2.6M Sensor voltage / Pressure converted value
WATER TEMP 100 OFF Coolant temperaturre sensor B-3 ARM OUT
MODE HM Work mode 3.5V 2.6M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage B-4 ARM IN
POS. 100% Voltage % indication 3.5V 2.6M Sensor voltage / Pressure converted value
ECU OUTPUT 0.5V Accel output voltage to engine B-5 BUCKET DIG
controller 3.5V 2.6M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
3.5V 2.6M Sensor voltage / Pressure converted value
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL(R)
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL(L)
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
B-19 DOZER 2
3.5V 2.6M Sensor voltage / Pressure converted value
21-30
21. MECHATRO CONTROL SYSTEM
7 16
NO.7 P.SENSOR PROPO-V NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-3 BOOM-HEAD B-13
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-4 BOOM-ROD B-14
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
PROPO-VALVE B-15
E-3 OPT RELIEF 1 Set value in computer / Converted value from pressure 3.5V 12.6M Sensor voltage / Pressure converted value
COMP. 600mA 14.5M Measured value / Converted value from pressure B-20
MEAS. 600mA 14.5M 3.5V 12.6M Sensor voltage / Pressure converted value
E-4 OPT RELIEF 2 Set value in computer / Converted value from pressure
COMP. 600mA 14.5M Measured value / Converted value from pressure
8 NO.8 PROPO-VALVE
18
NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI2 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI6 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI9 OFF ON/OFF indication
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI11 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI12 OFF ON/OFF indication
DI13 OFF ON/OFF indication
DI14 OFF ON/OFF indication
9 19 NO.19 DIGITAL INPUT
NO.9 PROPO-VALVE
E-1 P1 PUMP DI15 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI16 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI17 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI21 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI22 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 OFF ON/OFF indication
DI26 OFF ON/OFF indication
DI27 OFF ON/OFF indication
DI28 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
4.5V 90 Fuel level DI30 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI31 OFF ON/OFF indication
4.5V 30 Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW OFF Glow switch DI33 OFF ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 OFF ON/OFF indication
WATER SEPA. OFF Water separator clogging DI35 OFF ON/OFF indication
ENG OIL FILTER LIVE Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 OFF ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI39 OFF ON/OFF indication
HEATER OFF Command from air heater DI40 OFF ON/OFF indication
ENG OIL LEVEL OFF Engine oil level DI41 OFF ON/OFF indication
COOLANT LEVEL LIVE Coolant level DI42 OFF ON/OFF indication
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value DO5 COMP. OFF Set value in computer
F-6 MEAS. OFF Measured value
COMP. OFF Set value in computer DO6 COMP. OFF Set value in computer
MEAS. OFF Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
12 22
NO.12 POTENTIO. NO.22 DIGITAL OUTPUT
H-2 BOOM DO8 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
H-3 ARM DO9 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
DO10 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO11 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO12 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO13 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO14 COMP. OFF Set value in computer
MEAS. OFF Measured value
21-31
21. MECHATRO CONTROL SYSTEM
31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
B-1 BOOM RAISE 1.9M Boom up pressure sensor D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL(R) 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVEL(L) 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot pressure at travel straight (P1 side)
Pi-P2 13.9M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
D-3 S-TRAVEL 600mA Command current D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARM OUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B-4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux/ Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current
21-32
21. MECHATRO CONTROL SYSTEM
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
15mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 2040 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 600mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 137 137 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 137 137 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 137 137 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 137 137 Angle adjustment
21-33
21. MECHATRO CONTROL SYSTEM
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
21-34
21. MECHATRO CONTROL SYSTEM
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 30.5~33.5 M C-1 P1-PRES 5.0~9.0 M
C-2 P2-PRES 30.5~33.5 M C-2 P2-PRES 5.0~9.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 720~750 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 720~750 mA
D-1 P1-UL(BPC) 300 mA D-1 P1-UL(BPC) 300 mA
D-2 P2-UL(BPC) 300 mA D-2 P2-UL(BPC) 300 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 200 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1800~2000 G-3 ENG SPEED 1800~2000
POWER SHIFT 0 mA POWER SHIFT 0 mA
21-35
21. MECHATRO CONTROL SYSTEM
21-36
21. MECHATRO CONTROL SYSTEM
21-37
21. MECHATRO CONTROL SYSTEM
21-38
21. MECHATRO CONTROL SYSTEM
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
All the stored items are erased. It is impossible to erase data partially.
21-39
21. MECHATRO CONTROL SYSTEM
time is stored. H
1. After displaying the display for setting by pressing the display change switch, set the respective maintenance
time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not
sound.
21-40
21. MECHATRO CONTROL SYSTEM
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
AUTO IDLING STOP
(d)
AUTO WARM-UP AUTO IDLE STOP AUTO IDLE STOP
OFF OFF ON
(c)
(e)
AUTO IDLE STOP AUTO IDLE STOP
OFF ON
OFF ON OFF ON
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST"
select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
3. In operation of FEED (4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
4. In operation of FEED (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
(e) is displayed.
5. Switch from "OFF" to "ON" in operation of FEED (4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
21-41
21. MECHATRO CONTROL SYSTEM
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).
21-42
21. MECHATRO CONTROL SYSTEM
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555)
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH
STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5. Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).
21-43
21. MECHATRO CONTROL SYSTEM
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option Does left rotation pedal use?
attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Optional flow rate limitation, relief pressure limitation, combination of return
Setting of optional equipment
selector adjustment)
Engine speed ON/OFF of engine rpm display
Adjustment the type of the engine speed of auto deceleration runs up
Auto acceleration
abruptly.
Change of starter mode Change of start mode
Low temperature mode forcible
Low temperature mode release
release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
21-44
21. MECHATRO CONTROL SYSTEM
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
24 RXD3 Reception RS232C communication
25 DL EARTH / OPEN(5V
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Rotary light (yellow) Output EARTH/OPEN
33 DO 24 Rotary light (green) Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
21-45
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A28 Spare Input 0.5~4.5V
21 +5VA Power output 5V
22 D1 37 Spare Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
15 +5VA Power output 5V
16 Reserved
21-46
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A18 Boom rod Input 0.5 4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A20 Spare Input 0.5~4.5V
12 GA 0V
13 A21 Spare Input 0.5~4.5V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
17 A23 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
21 +5VA Power output 5V
22 +5VA Power output 5V
23 A25 Spare Input 0.5~4.5V
24 GA 0V
25 GA 0V
26 A26 Spare Input 0.5~4.5V
27 +5VA Power output 5V
28 DI 1 Cab slow up and down Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN105 1 +24V Battery relay output side 20~32V
2 +24V Battery relay output side 20~32V
(sensor analog output)
3 +24V Battery relay output side 20~32V
4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 Travel 1,2 speed select valve Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
9 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 bypass cut Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 bypass cut Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
21 GND Battery (-) 0V
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ Cab slow stop valve Output +0~800mA
26 D7- -0~800mA
27 D8+ Spare Output +0~800mA
28 D8- -0~800mA
29 D9+ Spare Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
21-47
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase (spare) Output +24V 1.5A
4 F1- Accel motor A phase (spare) Output +24V 1.5A
5 F2+ Accel motor B phase (spare) Output +24V 1.5A
6 F2- Accel motor B phase (spare) Output +24V 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
13 D13+ Spare Output +0~800mA
14 D13- -0~800mA
15 D14+ Spare Output +0~800mA
16 D14- -0~800mA
17 GND Battery (-) 0V
18 D12+ Spare Output +0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication
Connector No. Pin No. Port name Function Input/putput Signal level
CN107 1 DI 3 Key switch (GLOW) Input +24V/OPEN
2 DI 8 Spare Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Stroke end check Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
8 DI 14 Spare Input EARTH / OPEN
9 DI 15 Spare Input EARTH / OPEN
10 DI 20 ECU main relay Input EARTH / OPEN
11 DI 28 Spare Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Spare Input EARTH / OPEN
15 DI 40 Spare Input EARTH / OPEN
16 DI 41 Spare Input EARTH / OPEN
17 Reserved
21-48
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Spare Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 Spare Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Nibbler open check SW Input GND / OPEN
10 DI 21 Elevator cab up check Input +24V / OPEN
11 DI 22 HYD. VLC. Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation / Input
clamp open or close GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Hand control breaker Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 Spare Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
22 DI 34 Spare Input +24V / OPEN
23 DI 35 Spare Input +24V / OPEN
24 Reserved Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Accel signal 2 0~5V
28 H2- 0V
Connector No. Pin No. Port name Function Input/putput Signal level
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Bucket move limitation Output GND / OPEN
6 DO 6 Travel straight (Unload) Output GND / OPEN
7 DO 12 Rotary light (RH) Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Spare Output GND / OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Tranmission RS232C communication
18 RXD2 Reception RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shiled GND
22 DO 10 Cab up and down switching valve SV 24V/OPEN
21-49
21. MECHATRO CONTROL SYSTEM
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
No. Item name Wire color No. Item name Wire color
Gauge cluster → Mechatro
GND source (+24V Battery Yellow /
1 controller (RS232C White 5
direct connection) Black
communication)
Mechatro controller → Gauge
2 cluster (RS232C Red 6 GND Black
communication)
Source (+24V starter switch
3 Reserved — 7 White
ON)
GND (RS232C
4 Reserved — 8 Black
communication)
3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
21-50
21. MECHATRO CONTROL SYSTEM
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
21-51
21. MECHATRO CONTROL SYSTEM
2) Circuit diagram
21-52
21. MECHATRO CONTROL SYSTEM
21-53
21. MECHATRO CONTROL SYSTEM
21-54
21. MECHATRO CONTROL SYSTEM
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
VIEW A
19 21.9 HEX
O-RING P11
PF1/4 Tightening torgue
34.3N.m (25.3lbf.ft)
21-55
21. MECHATRO CONTROL SYSTEM
[MEMO]
21-56
22. HYDRAULIC SYSTEM
TABLE OF CONTENTS
22.1 SUMMARY.......................................................................................................................22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS...............................................................22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS........................................22-8
22.4 NEUTRAL CIRCUIT.........................................................................................................22-8 22
22.5 TRAVEL CIRCUIT ...........................................................................................................22-10
22.6 BUCKET CIRCUIT...........................................................................................................22-12
22.7 BOOM CIRCUIT ..............................................................................................................22-14
22.8 SWING CIRCUIT .............................................................................................................22-18
22.9 ARM CIRCUIT .................................................................................................................22-20
22.10 COMBINED CIRCUIT ......................................................................................................22-26
22.11 PRESSURE DRAINING (RELEASING) CIRCUIT ...........................................................22-30
22-1
22. HYDRAULIC SYSTEM
22-2
22. HYDRAULIC SYSTEM
22.1 SUMMARY operability, safety, mass volume handling and low fuel
consumption.
The hydraulic circuits are built up with the following
functions and features in order to achieve easy
Table22-1
Perfor- Device
mance Function Features
Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever
Attachment
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Multi control valve (Oceania) Changeable to 4 operating pattern with only 1 lever.
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others
Positive flow rate control Flow control by positive pilot control pressure
Hydraulics backup control Backup control by hydraulic when the electric flow controlled
variable displacement pump fails.
Boom up conflux circuit Speed up of boom up operation
Attachment
Micro
22-3
22. HYDRAULIC SYSTEM
22-4
22. HYDRAULIC SYSTEM
22.2.1 STANDARD
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P
3
P
4 5 6 7
P P
8
4pa2
5pb3 BUCKET DUMP 34.8MPa 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
LS01Z00065P1 01
19 A
UNLOAD
22-5
22. HYDRAULIC SYSTEM
R2 R1
M
MAIN CONTROL VALVE
P2
pc
P1
50
A DR
53
T
5pb3
5B3 OPTION 1
HYD.TANK 5pa3
5A3
Ps C PL
P SE29
51
RIGHT BREAKER
LEFT NIBBLER
Po
52
NIBBLER PILOT VALVE
P
T
B C1 C2 A
CLOSE P SE11
OPEN
S,W
SW29
NOTE:
1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT.
2. SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR BREAKER IN SERVICE.
LEVER LOCK
SOL/V BLOCK A1 SV-4
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
SELECTION
(W: , W/O: )
CONFLUX / SINGLE FLOW ELECTROMAGNETIC COMMAND SIGNAL P1 P2 TRAVEL
CHANGEOVER SWITCH OF SELECTOR VALVE (ITEM 50)(W:O,W/O:-) PUMP PUMP STRAIGHT P1 CUT P2 CUT
CONFLUX FLOW OF NIBBLER CONFLUX "ON"
P1 P2
SINGLE FLOW OF NIBBLER CONFLUX "OFF"
T BREAKER CONFLUX "OFF"
22-6
22. HYDRAULIC SYSTEM
22-7
22. HYDRAULIC SYSTEM
22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT 22.4.2 PUMP POSITIVE FLOW CONTROL resulting in the reduction of tilt angle. Similarly,
when the servo piston moves rightward, the
FOR HYDRAULIC CIRCUITS This section describes the following. (1) Type :
Electric flow controlled variable displacement spool (652) is moved leftward by the feedback
Blue (1) Safety lock lever and pilot circuit
pump. lever.
Feed, drain circuit (2) Pump positive flow control The operation is maintained until the opening of
less than 0.44 MPa (64 psi) (2) Principle :
(3) Pump P-Q (Pressure-Quantity) curve control spool sleeve is closed.
Green The current command I to the pump’s solenoid
Return, make up circuit, 22.4.1 SAFETY LOCK LEVER AND PILOT proportional valve controls the delivery rate of the 22.4.3 PUMP P-Q CURVE CONTROL
0.44~0.59 MPa (64~86 psi) CIRCUIT pump. OPERATION
Purple (1) Purpose : (3) Operation : (1) Type :
Secondary pilot pressure, To protect attachment from unexpected movement 1) Flow rate rise operation (Eg. P1 pump) Electrical flow control type variable pump
(including proportional vlave) for safety. By operating any of control levers, the (2) Principle :
0.59~5 MPa (86~725 psi) operating secondary pressure of pilot valve
(2) Principle : Perform an operation of the value from pump high
Red rises, and the rising pressure is transformed to
Cut pressure source of pilot valve for operation. pressure sensor to P-Q curve control value, and
Primary pilot pressure, the rise of output voltage corresponding to the
(3) Operation : send a command to the pump solenoid proportional
(including proportional vlave) pressure input by the low pressure sensor.
If the safety lock lever (red) is pushed forward after valve.
5 MPa (725 psi) Mechatro controller signal-processes this
the engine starts, the limit switch (SW-11) is turned (3) Operation :
Orange change of voltage, resulting in rise of command
on. The timer relay is actuated one second later The pump high pressure sensor converts the
Main pump drive pressure, current value I to the pump proportional
which causes the solenoid (SV-4) of the solenoid pressure to the output voltage corresponding to the
5~34.3 MPa (725~4970 psi) solenoid valve and consequently the pump flow
valve block (13) to be energized and makes the pump delivery pressure.
Blue tone rate rises. This is called "Positive Control
pilot operating circuit to stand by. The mechatro controller converts the voltage output
At valve operation System".
by the high pressure sensor to the P-Q curve
Red valve As the pump command current value rises, the
control value. On the other hand, select the pump
When solenoid proportional valve (reducing) secondary pressure of proportional solenoid
positive control command current value from the
is operating valve also rises. On the regulator attached on
low pressure sensor in lower order, and the values
Red solenoid the pump, the spool (652) through piston (643)
are output to respective pump proportional valve as
In active and exciting is pushed leftward, and stops at the position
a command current.
Displaying the flow circuit and standby circuit when where being in proportion to the force of pilot
With this operation, the pump power is controlled so
operating. spring (646).
as not to be exceed the engine power, therefore
Regarding the electrical symbols in this manual, refer to The tank port connected to the large bore of
engine dose not stall.
the electric circuit diagram. servo piston (532) opens, and the piston
moves leftward by delivery pressure P1 of the
small bore resulting in the increase of tilt angle
( ).
The servo piston and spool (652) are
connected to feedback lever (611). Therefore
when servo piston moves leftward, the spool
(652) also moves rightward by means of
feedback lever. With this movement, the
opening of spool sleeve closes gradually, and
the servo piston stops at the position the
opening closed completely.
2) Flow rate reduction operation
As the current value I of mechtro controller
reduces, the secondary pressure of solenoid
proportional valve reduces, and spool (652) is
moved rightward by the force of pilot spring
(646). With the movement of spool, the delivery
pressure P1 usually flows into the large bore of
piston through the spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of area,
22-8
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
652
BGD F E AC
611
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
532 GB
643 646 a3 GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P
3
P
4 5 6 7
P P
8
4pa2
5pb3 BUCKET 34.8MPa
DUMP 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
22-9
22. HYDRAULIC SYSTEM
22-10
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P
3
P
4 5 6 7
P P
8
4pa2
5pb3 BUCKET 34.8MPa
DUMP 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.
22-11
22. HYDRAULIC SYSTEM
22.6 BUCKET CIRCUIT 22.6.2 AUTO ACCELERATION OPERATION 3) With the function of pilot circuit, the oil flow is
(1) Principle : switched from bucket spool, and is fed into
This section describes the following.
Auto acceleration actuates according to signals bucket cylinder head side through AB2 port of
(1) Bucket digging pilot circuit
from low pressure sensor. C/V (2). On the other hand, the return oil from
(2) Auto accel operation cylinder rod (R) side is throttled by bucket spool
(2) Operation :
(3) Flow control in the work mode and returns to tank circuit from 4A2 port of C/V
<When lever is set to neutral position>
(4) Bucket digging travel straight main circuit (2).
In the event where the sensor does not receive
(5) Bucket spool stroke limiter signal for 4 seconds or more even though the References :
acceleration dial is set to MAX position, the engine • When dumping bucket, the P2 by-pass cut valve
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING
speed should be raised to 850rpm. closes and the oil becomes conflux flow in the
(1) Mechatronics : <When lever is operated> same manner as bucket digging. But P1 pump
1) When the operation for bucket digging is When the pressure 0.6MPa (87psi) is input to low on the conflux side delivers the minimum flow
performed, the pilot proportional secondary pressure sensor in STD specification (travel, rate.
pressure is delivered through port 1 of the right bucket, swing, arm), proportional voltage from low • When bucket operation is combined with any
pilot V (10), flows to 4pb2 port, and acts on the pressure sensor inputs in mechatro controller, and other operation, P2 by-pass cut valve does not
low pressure sensor (SE-1), and at the same then the engine speed returns to the dial set work, and the bucket is controlled by single flow.
time the bucket spool is switched. position corresponding to the lever operation.
22.6.5 BUCKET SPOOL STROKE LIMITER
2) The voltage output by low pressure sensor
22.6.3 STAND-BY CURRENT CONSTANT
inputs in mechatro controller. The mechatro (1) Purpose :
CONTROL
controller performs signal processing and To secure simultaneous operability of boom and
(1) Principle : arm on boosting up attachment pressure (Pump
outputs current corresponding to the increase
When the engine speed is intermediate speed or flow rate decreases.) and to prevent cavitations at
of pump flow rate to pump proportional valves
lower, command current value to have the pump low engine speed
(PSV-P1) and (PSV-P2) on the P1 and P2
delivery rate constant is output.
pump sides. (2) Operation :
And at the same time, the command current is (2) Operation : On boosting up attachment pressure, pilot primary
output to P2 center bypass cut proportional Even if the engine speed specified by acceleration pressure exerts on 4pc3 port of C/V(2) through
valve (PSV-B). potentiometer is low speed, as the delivery rate attachment booster solenoid valve, operates stroke
In the following pages, the relation of operation corresponds to the intermediate speed, the limiter of bucket spool, and throttle oil path of spool.
of low pressure sensor to both the increase of actuator moves earlier than the movement As a result, P1 pump pressure increases, making
pump flow rate and unloading proportional equivalent to the control lever angle rate in light the simultaneous operation of boom up and bucket
valve is the same. Therefore the explanation is load operation. digging possible.
omitted. Even though the engine speed is low, similarly the
22.6.4 BUCKET DIGGING CONFLUENCE
3) The secondary pressure output by P1 pump cavitations can be prevented by actuating the
(CONFLUX) MAIN CIRCUIT
proportional valve (PSV-P1) and P2 pump stroke limiter.
(1) Operation :
proportional valve (PSV-P2) exerts on pump
1) The oil delivered through A1 port of P1 pump
regulator, actuating the pump onto the delivery
goes into P1 port of C/V (2), opens load check
flow increase side.
valve through parallel circuit and enters in
bucket spool.
2) On the other hand, the oil delivered through P2
port of P2 pump goes into P2 port of C/V (2),
and it flows to downstream via center bypass.
Because P2 center by-pass cut valve is
throttled or closed according to the bucket
operating pilot pressure. And the trapped oil
opens check valve, and then this oil confluxes
the P1 pump delivery oil at close to bucket
spool.
22-12
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P
3
P
4 5 6 7
P P
8
4pa2
5pb3 BUCKET 34.8MPa
DUMP 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Conflux), Auto-accelation and Standby flow rate constant control
22-13
22. HYDRAULIC SYSTEM
22-14
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P
3
P
4 5 6 7
P P
8
4pa2
5pb3 BUCKET 34.8MPa
DUMP 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
22-15
22. HYDRAULIC SYSTEM
This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION
(1) Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
(2) Prevention of natural fall by lock valve and (1) Purpose :
actuation at lowering Prevention of cavitation during boom
lowering motion.
(3) Constant recirculation function of boom down main
circuit (2) Principle :
The oil returning from the boom cylinder head (H) is
22.7.3 BOOM DOWN PILOT CIRCUIT recirculated to the rod (R).
(1) Operation : (3) Operation :
1) If the boom down operation is performed, the When the oil is supplied to the boom cylinder rod
secondary pilot proportional pressure comes (R) side during boom down operation, the boom
out of port 4 of the right pilot valve (10) and acts moves faster than it should do in some cases by the
upon the low pressure sensor (SE-4). self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod (R)
4pb3 port of C/V (2). side is on the negative side.
2) The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R) flows
(SE-4) enters the mechatro controller and into the A1 port of the P1 pump and the P1 port of
processed in it. C/V. The oil then passes through the boom spool
and goes out of the 4B3 port.
3) Then, the proportionl secondary pressure fed
On that occasion, the oil returning from the head
into C/V (2) 4pb3 port and branches off in three
(H) goes through the recirculation path in the boom
lines and switches boom 1-speed, boom 2-
spool, pushes the check valve in the spool open, is
speed spool and releases boom lock valve.
recirculated to the 4B3 port and is supplied to the
22.7.4 PREVENTION OF NATURAL FALL BY rod (R). When the (R) pressure is larger than the
LOCK VALVE AND ACTUATION AT head (H) pressure, the check valve in spool closes.
LOWERING Consequently, the recirculation is stopped.
(1) Purpose :
Prevention of natural fall when the lever is neutral
(2) Principle :
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation :
In the boom down action, the lock valve is changed
over by the secondary proportional pressure of
4pb3 port. Then the poppet spring chamber of the
lock valve gets through the drain line (Dr) and
makes the lock valve poppet open.
When the boom lever is at neutral, the drain line on
the lock valve poppet spring chamber is closed
which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from making a
natural fall.
22-16
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P
3
P
4 5 6 7
P P
8
4pa2
5pb3 BUCKET DUMP 34.8MPa 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.
22-17
22. HYDRAULIC SYSTEM
2) The voltage output by the low pressure sensor 3) The swing parking solenoid (SV-1) is excited
is input in the mechatro controller, and is signal- five seconds after the pressure of the swing low
processed. pressure sensors (SE-5) is reduced to zero.
In the case of arm in operation, the swing
3) Then, the secondary pressure led into 5pb2
parking solenoid (SV-1) is excited the moment
port of C/V (2) switches the swing spool.
the pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.
22-18
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P P
3 4 5 6 7
P
8
P
4pa2
5pb3 BUCKET 34.8MPa
DUMP 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL 3 6 4 1 5 2
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
22-19
22. HYDRAULIC SYSTEM
22.9 ARM CIRCUIT 22.9.2 ARM IN, LIGHT-LOAD VARIABLE controlled according to the load pressure and
NORMAL RECIRCULATION, INTERNAL the arm variable recirculation is cut.
This section describes the following operations.
CONFLUX MAIN CIRCUIT When the recirculation is cut, internal
(1) Arm in, light-load operating pilot circuit
(1) Operation : confluence is held similarly to that in light load
(2) Arm in, light-load variable normal recirculation main operation.
1) The P2 pump delivery is branched off in by-
circuit / internal conflux main circuit
pass circuit and parallel circuit, through P2 port 2) Left pilot valve actuation due to arm-in
(3) Arm in, heavy load operating pilot circuit operation is equivalent to that at light load
of C/V (2) and but because arm 1 spool is
(recirculation cut) operation.
switched, the delivery oil which goes through
(4) Arm in, heavy load operating sequence confluxed parallel circuit opens load check valve and is
22.9.4 ARM IN, HEAVY LOAD OPERATING
main circuit flowed into arm 1 spool.
RECIRCULATION CUT MAIN CIRCUIT
22.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT 2) On the other hand, P1 pump delivery oil flows in
(1) Purpose :
CIRCUIT P1 port of C/V (2), and the flows in by-pass
Speed up for arm in operation
circuit and parallel circuit. Then because arm 2
(1) Purpose : (2) Principle :
spool was switched, the delivery oil opens load
Speed-up and Anticavitation when the arm is at Cut the recirculation and reduce rod pressure.
check valve, goes through arm 2 spool, and
light loaded.
confluences with P2 pump delivery oil in the (3) Operation :
(2) Principle :
valve section, and then is flowed into arm 1) P2 pump delivery oil is branched off in by-pass
The oil returning from the arm cylinder rod (R) is
cylinder head (H) side through 5B5 port of C/V circuit and parallel circuit through P2 port of
recirculated variably to the head (H) at arm 2 spool
(2). C/V (2). Consequently the arm spool is
in C/V.
3) The return oil from arm cylinder (R) side flows switched and pushes and opens load check
(3) Operation : valve through parallel circuit, and flows in the
in 5A5 port of C/V (2) and passes through the
1) When the arm in operation is performed, the 5A5 port because the arm lock valve is open, arm spool.
secondary pilot proportional pressure gets out and is flowed into arm 2 spool. 2) On the other hand, P1 pump delivery oil flows in
of port 7 of the left pilot valve (10) and acts upon P1 port of C/V (2), and flow in by-pass circuit
4) Because arm 2 spool is switched to normal
the low pressure sensor (SE-7). and parallel circuit. Then because arm 2 spool
recirculation position, causing restriction of
At the same time, the pressure is branched off was switched, the delivery oil opens load check
passage to tank, the return oil from arm cylinder
in two flows, acts upon the 5pb5 port and the valve, and confluences with P2 pump delivery
(R) side flows into arm cylinder (H) side.
5pc1 port, changes over the arm spool and the oil in the valve section, and is flowed into arm
• Because, at light load, the pressure in
arm lock valve is released. cylinder head (H) side through 5B5 port of
cylinder rod (R) side is higher than that in
2) The output voltage by the low pressure sensor C/V(2).
the head (H) side, it opens the check valve
is input into mechatro controller, and is pilot 3) The return oil from arm cylinder (R) side flows
housed-in arm 2 spool and is recirculated in
signal-processed, and is output to P1, P2 pump in 5A5 port of C/V(2) and is flowed to arm lock
the head (H) side, resulting in the speed up
proportional valve (PSV-P1), (PSV-P2) and arm valve, but because the arm lock valve is open,
of arm-in operation at light load.
2 inverse proportional valve (PSV-A). the return oil flows in arm 2 spool.
5) Cavitations prevention control in arm-in
3) The secondary pressure from pilot proportional 4) The return oil returns directly into tank circuit
operation
valve, which is reduced by arm 2 inverse because arm 2 spool is switched to
Command current is output to arm 2 solenoid
proportional valve (PSV-A) switches arm 2 recirculation cut position.
proportional valve by signal processing of E/G
spool.
speed and arm-in pilot pressure, accordingly
the arm 2 spool is switched to neutral
(cavitations prevention) position, resulting in
cavitations prevention.
22-20
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P
3
P
4 5 6 7
P P
8
4pa2
5pb3 BUCKET 34.8MPa
DUMP 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
Fig. 22-7 ARM CIRCUIT : Arm in (Light & heavy load) operation, Arm variable recirculation
22-21
22. HYDRAULIC SYSTEM
This section describes the following operations. 22.9.7 NATURAL FALL PROTECTION WITH ARM
(5) Arm out pilot circuit LOCK VALVE
(6) Arm out 2 pumps conflux main circuit (1) Purpose :
To prevent the arm from falling naturally by the
(7) Natural fall protection with arm lock valve
weight of the arm & bucket.
22.9.5 ARM OUT PILOT CIRCUIT (2) Principle :
(1) Operation : Complete seat of the return circuit against the arm
1) When the arm out operation is performed, the spool of the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out (3) Operation :
of port 8 of the left pilot valve (10), and acts 1) When the secondary pressure for arm
upon the low pressure sensor (SE-8). At the operation disappears and the arm cylinder
same time, the oil is branched off in two flows stops, the pressure on the rod (R) side passes
and act upon the 5pa5 and 4pb4 ports of C/V through the selector of the lock valve from the
(2). 5A5 port of C/V, acts the back pressure on the
2) The operating proportional secondary pressure lock valve and seats the lock valve.
flowed in 5pa5 port of C/V (2) switches the arm 2) Since the oil flow into the arm spool from the
1 spool. lock valve is shut off completely, natural fall of
3) Then, the operating secondary pressure flowed the arm due to oil leaks through the arm spool
in 4pb4 port of C/V (2) switches the arm 2 spool is prevented.
valve.
22-22
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P P
3 4 5 6 7
P
8
P
4pa2
5pb3 BUCKET 34.8MPa
DUMP 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL 3 6 4 1 5 2
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
22-23
22. HYDRAULIC SYSTEM
22-24
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P P
3 4 5 6 7
P
8
P
4pa2
5pb3 BUCKET 34.8MPa
DUMP 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po 3 1 2 4
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL 3 6 4 1 5 2
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
Fig. 22-9 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.
22-25
22. HYDRAULIC SYSTEM
In this section, the independent operation is omitted 22.10.4 SWING / ARM IN, SWING PRIORITY MAIN
and describes difference in combined operation. CIRCUIT
(3) Swing / Arm in light load, pilot circuit (1) Purpose :
(4) Swing / Arm in, swing priority main circuit Stable swing speed.
(2) Principle :
22.10.3 SWING / ARM IN LIGHT LOAD, PILOT
Raise the oil pressure flowing to arm cylinder, and
CIRCUIT
give a priority of the delivery of P2 pump to swing
(1) Operation : operation.
1) In swing operation, swing pilot secondary (3) Operation :
pressure branches into two circuits and exerts
1) The swing main circuit operates with P2 pump
on 5pb2 port and 5pc3 port respectively.
flow. But on P2 pump circuit side, the flow goes
2) 5pb2 port pressure switches the swing spool to the swing circuit and arm circuit
and 5pc3 port pressure acts upon the swing simultaneously because the swing circuit and
priority valve and throttles the arm spool inlet. arm circuit make parallel circuit. But because
3) Swing pilot secondary pressure acts upon the the arm spool inlet is throttled by swing priority
low pressure sensor SE-5 and arm-in pilot valve, the pump pressure rises and
secondary pressure acts upon the low pressure consequently the oil is fed into swing circuit of
sensor SE-7. which the working pressure is higher, too.
The low pressure sensor voltage is processed 2) And simultaneously P1 pump also delivers oil to
by mechatro controller and transformed into arm through the arm 2-speed spool and
signal, and switches arm 2-speed spool to the prevents the movement of arm from slowing
combined operation position through PSV-A. down.
(4) Releasing swing priority
In the following operation, the swing priority is
released.
1) When boom-down is operated,
In the swing + arm-in + boom-down combining
operation, this function is used to prevent oil
from becoming shortage of oil for arm
operation.
2) When arm-out is operated,
In the swing + arm-out combining operation,
this function is used to prevent swing
movement from slowing down.
22-26
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P
3
P
4 5 6 7
P P
8
4pa2
5pb3 BUCKET DUMP 34.8MPa 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
Fig. 22-10 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function
22-27
22. HYDRAULIC SYSTEM
22-28
22. HYDRAULIC SYSTEM
P P
MB 5 MB
1 SE22
P
SE23
P
PSV-P1
MAIN PUMP
PSV1 a4 a1 A1 A2 a2 a5 PSV2 PSV-P2 4 R/G
3 R/G
(KDRDE5K) SWING SWING
VA VA
PG PG
VB VB
Av
REG
9 REG Av
BGD F E AC
D MA BGD E AC MA D
TRAVEL RIGHT TRAVEL LEFT
a6 a7
Dr Dr
25MPa 25MPa
a3 GB GB
GA GA
5.0MPa B Mv A B Mv A
Dr2 A3 R2 R1
247kw/
1850rpm M
MAIN CONTROL VALVE
P2 pc
B1 Dr
RIGHT TRAVEL SWING RIGHT
5pb1 FORWARD SWING LEFT
31.4MPa ARM OUT
5B1 FORWARD 34.3MPa(BOOST) pz1 ARM IN
P1 BOOM DOWN
5pa1 BACKWARD BOOM UP
5A1 BACKWARD pz2 BUCKET DUMP
BUCKET DIGGING
20 SWING
RIGHT
LEFT TRAVEL
FORWARD 4pa1
8
18 SE5
5pb2 LEFT
FORWARD 4A1
P 5B2 LEFT BACKWARD 4pb1
5pa2 BACKWARD 4B1 BUCKET
5A2 RIGHT SE1 SE2 SE3 SE4
24 SE7 SE8
14 15 16 OPTION 1
DUMP 4pc3
1
P
2
P P
3
P
4 5 6 7
P P
8
4pa2
5pb3 BUCKET 34.8MPa
DUMP 4A2
DIGGING 4pb2
5B3 DIGGING 4B2
HYD.TANK 13 5pa3
36.3MPa
5A3
17 5pb4 UP DOWN
UP 4pa3
1 2 3 4 5 6 7 8
DOWN 36.3MPa 4pb3
20 5pa4
BOOM-2
BOOM-1 12
UP 4A3 (OCEANIA)
DOWN 4B3
34.8MPa
ARM-1 BOOM LH
5pb5 IN OUT IN 4pa4
B
6
34.8MPa ARM-2
5b5 IN BOOM RH
5pa5 OUT 4pb4
SOL/V BLOCK
5A5 OUT Po
P1 LEVER
SV-4
A1 LOCK T A
P2 BYPASS P1 BYPASS 10
5pc1 36.3MPa CUT CUT
SWING
A2 P/B 22 dr3
SV-1
5pc2 5pc3 dr4 RS2 dr1 RS1 R3 4pc2
TRAVEL T P T P
1/2 SPEED 4pc1 BOOM & BUCKET ARM & SWING
SV-3
A3 CHANGEOVER
2 dr2 23 PILOT VALVE PILOT VALVE
11
SV-2
ATT
A4 BOOSTING 7 TRAVEL
PILOT VALVE P T
ARM
A5 P2 BY-PASS CUT
PSV-B
TRAVEL
A6 PRIORITY 3 6 4 1 5 2
PSV-C RIGHT TRAVEL FORWARD P SE9 P SE10
RIGHT TRAVEL BACKWARD
LEFT TRAVEL FORWARD
LEFT TRAVEL BACKWARD
A7 P1 BY-PASS CUT
PSV-D
A8 ARM 2
PSV-A
21 P T SV-31
T2 P2
19 A
UNLOAD LS01Z00065P1 01
22-29
22. HYDRAULIC SYSTEM
[MEMO]
22-30
23. ELECTRIC SYSTEM
TABLE OF CONTENTS
23-1
23. ELECTRIC SYSTEM
23-2
23. ELECTRIC SYSTEM
ENG. REVOLUTION
5 FUSE
E-12 : E-12 : SENSOR FOR ECU
BATTERY BATTERY
R-24 :
AUTO IDLE STOP RELAY 2 EGR VALVE
R-23 : 6 FUSE
AUTO IDLE STOP R-1 :
RELAY 1 BATTERY RELAY
R-39 : E-28 :
AIR HEATER RELAY INJECTOR 1
AIR HEATER
TO JC
E-15 : INJECTOR 2
E-2 :
FUSIBLE LINK
ALTERNATOR TO JC
M-1 :
STARTER MOTOR
6 FUSE INJECTOR 3
TO JC
D-13 : DIODE
INJECTOR 4
R-2 :
STARTER RELAY TO JC
7,8,9 FUSE
12 FUSE
INJECTOR 5
DIODE
R-4 :
D-9 :
SAFETY RELAY TO JC
INJECTOR 6
TO JC
ENG. HARNESS
E-22 : CYLINDER
DC-DCCONVERTER DISCRIMINATION G
SENSOR
ENG. CONTROLLER
CHECK CONNECTOR
BOOST SENSOR
E-44 : RESISTOR
E-27 :
ACCEL REDUNDANT VOLUME COMMON RAIL
SW-1 :
PRESS, SENSOR
KEY SW.
R-25 :
ENG. EMERGENCY FUEL TEMP SENSOR
STOP RELAY
R-4 : SAFETY RELAY
ENG. COOLANT
D-13 : DIODE THERMO SENSOR
E-3 : HOUR METER (FOR ECU)
D-14 : DIODE
C-6 :
AUTO GREASE CONTROLLER
CHARGE
R-28 : ALTERNATOR RELAY
R-25 :
KEY ON
ENG. EMERGENCY STOP RELAY
C-5 : SW-27 :
CONTROL : RADIATOR COOLANT
RADIATOR COOLANT
(SENSOR POWER SOURCE, CPU) 1 FUSE LEVEL SW.
LEVEL CONTROLLER
R-19 :
FLASHER RELAY
OUT SOURCE :
(PSV, SOL., MOTOR) 3 FUSE
CONTROL :
(SENSOR POWER SOURCE, CPU) 1 FUSE
WATCH IC 10 FUSE
TO
(2/8)
(1/8)
LS03Z00021P1 02
23-3
23. ELECTRIC SYSTEM
TERMINAL
NOMAL
RELEASE
E-16 :
SW-4 : ONE WAY CALL AMP
SE-16 : ACCEL POTENTIO
SWING PARKING RELEASE SW.
R-19 :
FLASHER RELAY
SE-1 : SV-1 :
PRESS SENSOR : BUCKET DIGGING SWING PARKING SOL.
SE-2 : E-17 :
PRESS SENSOR : BUCKET DUMP MIC ONE WAY CALL SPEAKER
SV-3 : TWO-SPEED SELECT SOL.
SE-3 :
PRESS SENSOR : BOOM RAISING
ONE WAY CALL
SE-4 : SV-2 : POWER BOOST SOL.
PRESS SENSOR : BOOM LOWRING
SE-7 :
PRESS SENSOR : ARM IN PSV-B
P2 BYPASS CUT
SE-8 : PROPORTIONAL VALVE
PRESS SENSOR : ARM OUT
SE-5 : PSV-C
PRESS SENSOR : SWING TRAVEL PRIORITY
PROPORTIONAL VALVE 27 FUSE
SE-9 :
PRESS SENSOR : TRAVEL RIGHT
POSITION
TERMINAL
PSV-D
SE-10 : P1 BYPASS CUT M-9 : ROOF WINDOW MOTOR
PRESS SENSOR : TRAVEL LEFT PROPORTIONAL VALVE
SE-22 :
PRESS SENSOR : PUMP P1 PSV-A 27 FUSE SW-17 : ROOF WINDOW SW.
19 FUSE
13 FUSE
SE-13 :
EU & KCMA OPT.
ENG. REVOLUTION SENSOR M-11 : FUEL SUPPLY PUMP
14 FUSE
C-1 : SE-28 :
MECHATRO C-2 : EXTRA PRESS SW-56 : FUEL SUPPLY AUTO STOP SW.
CONTROLLER GAUGE
(TCO-60-2) CLUSTER
EU OPT.
EXTRA DIS-PRESS EU
SV-31 :
TRAVEL PRIORITY UNLOAD RELAY TRAVEL PRIORITY
UNLOAD SOL.
TO
TRAVEL PRIORITY UNLOAD RELAY
(3/8) (2/8)
LS03Z00021P1 02
23-4
23. ELECTRIC SYSTEM
SW-12 : OPT.
OVER LOAD ALARM AUTO
SELECT SW. GREASE
SE-26 : SW-13 TRAVEL ALARM SW.
PRESS. SENSOR : BOOM HEAD R-8
TRAVEL ALARM RELAY E-13
EU(FOR OVER LOAD ALARM) TRAVEL ALARM
R-8 TRAVEL ALARM RELAY
EU OPT.
KCMA STD
R-52 :
TILT WARNING RELAY
L-6 : BOOM WORKING RESERVE CONNECTOR
LIGHT RIGHT 31 FUSE
EU
SV-14 : QUICK COUPLER OPERATION SOL. R-6 : R-6 :
WORKING WORKING L-1 : BOOM WORKING 31 FUSE
21 FUSE LIGHT RELAY LIGHT RELAY LIGHT LEFT R-52 : TILT SW-80 :
WARNING RELAY TILT SW.
L-2 : FRAME WORKING TO FUSE &
21 FUSE LIGHT RIGHT RELAY BOX
N
ITIO
POS SW-55 : BOOM, DECK WORKING LIGHT SW. R-52 :
TERMINAL
RELEASE
E-43 :
L-31 : TILT ALARM
EU OPT.
29 FUSE TILT ALARM LIGHT
TO FUSE &
SW-59 : QUICK COUPLER OPERATION SW. RELAY BOX
E-16 :
ONE WAY CALL AMP L-3 : SWING FLASHER LEFT & REAR WORKING LIGHT RESERVE CONNECTOR
C-5 : R-52 :
RADIATOR COOLANT TILT WARNING RELAY
PSV-M : LEVEL CONTROLLER
P1 INDEPENDENT TRAVEL TILT WARNING (LMN OPT.)
PROPORTIONAL VALVE
PSV-N :
P2 INDEPENDENT TRAVEL
PROPORTIONAL VALVE 31 FUSE RESERVE CONNECTOR
SW-66 :
KCMA STD
WATER SPRAY SW. SV-32 : WATER SPRAY SOL.
31 FUSE
R-12 : SV-6 : R-19 : FLASHER RELAY
REVOLUTION REVOLUTION RIGHT SOL.
RESERVE
RIGHT RELAY SW-33 : TO FUSE & CONNECTOR
REVOLUTION RIGHT SW. RELAY BOX
D-16/D-17 : TO FUSE &
DIODE RELAY BOX
SW-37 :
INDEPENDENT TRAVEL SW.
SV-9 : SW-35 :
R-15 : NIBBLER OPEN SOL. HEAVY LIFT SW.
NIBBLER OPEN
RELAY SW-18 :
LMN/BH SELECT SW.
SW-29 : KCMA
NIBBLER OPEN SW.
(CASE OF HAND CONTOROL NIBBLER CONNECT WITH 571)
23-5
23. ELECTRIC SYSTEM
OFF
LO
HI
SW-41 : E-6 : HORN LOW
R-5 : TO FUSE &
HIGH REACH CRANE HORN RELAY RELAY BOX
SW. SW-5 : HORN SW. RIGHT
RESERVE CONNECTOR
TO FUSE &
SW-10 : HORN SW. LEFT RELAY BOX
ENG. CONTROLLER
SW-32 : STROKE-END PROXIMILITY SW. CHECK CONNECTOR
30 FUSE
PSV-F :
JIB STRETCH REVERSE
ROPORTIONAL VALVE
C-4 : AIR CONDITIONER UNIT
R-6 : E-10 : C-4 :
WORKING RELAY RECEIVER DRIER AIR CONDITIONER
PSV-G : UNIT
JIB CONTRACT REVERSE 25 FUSE E-10 : RECEIVER DRIER E-11 : AIR COMPRESSOR CLUTCH
PROPORTIONAL VALVE
26 FUSE
18 FUSE
PSV-J :
ARM ONE-SPEED REVERSE
PROPORTIONAL VALVE
COOLING
UNIT
SW-43 : JIB PRESSURE SW.
OPT. SEPARATE
23-6
SW-30:
NIBBLER CLOSE SW.
SH6-E45 SPLICE
SV-9:
SW-39: NIBBLER OPEN SOL.
NIBBLER OPEN PRESSURE SW.
SV-10:
C-7: NIBBLER CLOSE SOL.
ITCONTROLLER (DoPa)
SV-6:
M-4:
REVOLUTION RIGHT SOL.
WASHER MOTOR
E-22: SV-7:
DC-D CCONVERTER REVOLUTION LEFT SOL.
SW-21: SV-16:
POWER BOOST SW. LEFT BACKET CONTROL SOL.
SW-10: SW-8:
HORN SW. LEFT AIR FILTER RESTRICTION SW.
SW-34: SW-27:
REVOLUTION LEFT SW. RADIATOR COOLANT LEVEL SW.
SW-43:
JIB PRESSURE SW. R-1:
BATTERY RELAY
SW-18:
LMN/BH SELECT SW. D-4:
DIODE
SW-5:
R-3:
HORN SW. RIGHT
GLOW RELAY
SW-20: SV-31:
POWER BOOST SW. RIGHT TRAVEL PRIORITY UNLOAD SOL.
SW-33:
REVOLUTION RIGHT SW.
SW-35:
HEAVY LIFT SW.
C-1:
SW-12:
MECHATRO CONTROLLER (TCO-60-2)
OVER LOAD ALARM SELECT SW.
C-1:
E-7: MECHATRO CONTROLLER (TCO-60-2)
TUNER AM & FM
C-1:
MECHATRO CONTROLLER (TCO-60-2)
C-1:
MECHATRO CONTROLLER (TCO-60-2)
R-19:
FLASHER RELAY
FRAME EARTH (GND)
L-8:
CAB WORKING LIGHT FRONT 2
M-11:
L-7:
FUEL SUPPLY PUMP
CAB WORKING LIGHT FRONT 1
L-20:
ROTARY LIGHT
SW-15: E-6:
CONFLUX/SINGLE SELECT SW. HORN LOW
E-5:
HORN HIGH
M-9:
ROOF WINDOW MOTOR
E-23: C-5:
12V SOCKET RADIATOR COOLANT LEVEL CONTROLLER
E-14:
CIGARETTE LIGHTER
M-3:
WIPER MOTOR
E-3:
HOUR METER
L-3:
SW-19:
SWING FLASHER LEFT & REAR WORKING LIGHT
WIPER INTERLOCK SW.
SW-55: L-2:
BOOM,DECK WORKING LIGHT SW. DECK WORKING LIGHT RIGHT
L-15:
CAB WORKING LIGHT FRONT 3
L-17:
BACK LIGHT E-13:
L-18: TRAVEL ALARM
CAB WORKING LIGHT BACK L-4:
L-16: SWING FLASHER RIGHT & REAR WORKING LIGHT
CAB WORKING LIGHT FRONT 4
C-4:
AIR CONDITIONER UNIT
SW-41:
HIGH REACH CRANE SW.
SW-26: SV-4:
CAB WORKING LIGHT SW. LEVER LOCK SOL.
C-2: SV-2:
GAUGE CLUSTER POWER BOOST SOL.
SV-3:
TWO-SPEED SELECT SOL.
E-16: SV-1:
ONE WAY CALL AMP SWING PARKING SOL.
SW-22:
SWITCHES TO JUDGE THE LENGTH OF INSERT BOOM 1
SW-32:
STROKE-END PROXIMILITY SW.
SV-13:
OPT SELECTOR SOL.
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
EGR VALVE
R-34:
PVC RELAY
SHIELD
SHIELD
SHIELD
SHIELD
SHIELD
SHIELD
(5/8)
LS03Z00021P1 02
23. ELECTRIC SYSTEM
23-7
R-1 :
BATTERY RELAY
23-8
(SECONDARY PRESSURE) C-1 :
MECHATRO CONTROLLER
(POWER SUPPLY FOR CONTROL)
C-1 :
MECHATRO CONTROLLER
R-1 :
23. ELECTRIC SYSTEM
C-1 :
MECHATRO CONTROLLER
C-1 : C-1 :
MECHATRO CONTROLLER MECHATRO CONTROLLER
E-3 :
HOUR METER
C-1 :
MECHATRO CONTROLLER FRAME EARTH (GND)
E-2 :
ALTERNATOR
R-29 (RL Y21) :
TILT WARNING
R-28 (RL Y28) : WIPER MOTOR RELAY
ALTERNATOR RELAY R-30 (RL Y11) :
WATER SPRAY EQUIPMENT
WIPER MOTOR REVERSING RELAY
R-41 (RL Y27) : THREE COLORS ROTARY LIGHT
TRAVEL PRIORITY
R-4 (RL Y4) : UNLOAD RELAY
SAFETY RELAY HYDRAULIC VLC
R-35 (RL Y35) :
OPT. RELAY 8 TILT WARNING
R-2 :
STARTER RELAY WATER SPRAY EQUIPMENT
HYDRAULIC VLC
C-6 :
AUTO GREASE CONTROLLER
C-1 :
MECHATRO CONTROLLER
SW-11 :
LEVER LOCK SW.
C-1 :
MECHATRO CONTROLLER
SV-4
LEVER LOCK SOL.
C-1 :
MECHATRO CONTROLLER
R-26 (RL Y26) :
LEVER LOCK RELAY
C-8 :
ENG. CONTROLLER
R-34
PCV RELAY
EGR VALVE
C-8 :
ENG. CONTROLLER
SW-1 :
KEY SW. E-14 :
CIGARETTE LIGHTER
E-5/6 :
HORN HIGH/LOW
SW-10/20 :
R-5 (RL Y5) : HORN SW. LEFT/RIGHT
HORN RELAY
E-7 :
TUNER AM & FM
R-1 : C-1 :
BATTERY RELAY MECHATRO CONTROLLER (BACK UP)
L-5 :
ROOM LIGHT
SW-16 :
ENG. ROOM LIGHT SW.
E-7 :
TUNER AM & FM
SW-1 :
KEY SW.
C-7 :
ITMECHATRO CONTROLLER (POWER SUPPLY)
C-2 :
GAUGE CLUSTER
M-11 :
FUEL SUPPLY PUMP
C-6 :
AUTO GREASE
SV-6 :
R-12 (RL Y12) : REVOLUTION RIGHT SOL.
REVOLUTION RIGHT RELAY
SW-33 :
REVOLUTION RIGHT SW.
C-1 :
R-13 (RL Y13) : MECHATRO CONTROLLER
REVOLUTION LEFT RELAY SV-7 :
REVOLUTION LEFT SOL.
SW-34 :
REVOLUTION LEFT SW.
C-1 :
MECHATRO CONTROLLER
R-16 (RL Y16) :
NIBBLER CLOSE RELAY SV-10 :
NIBBLER CLOSE SOL.
SW-30 :
NIBBLER CLOSE SW.
(5/8)
LS03Z00021P1 02
R-41 (RL Y27) :
TRAVEL PRIORITY UNLOAD RELAY
C-1 :
MECHATRO CONTROLLER
SV-31 :
TRAVEL PRIORITY UNLOAD SOL.
R-1 : R-35 (RL Y35) :
BATTERY RELAY OPT. RELAY 8
(SECONDARY PRESSURE)
C-4 :
AIR CONDITINER UNIT (AMP)
C-2 :
GAUGE CLUSTER
SV-8 :
ARM PUSH/PULL PORT SELECT SOL.
SV-5 :
BACKET DUMP CUT SOL.
C-1 :
MECHATRO CONTROLLER
SW-18 :
LMN/BH SELECT SW.
SW-41 :
HIGH REACH CRANE SW.
R-17 (RL Y17) :
EXTRA DIS-PRESS RELAY
SV-16 :
BACKET CONTROL SOL.
OPT. RELAY 2
R-36 : C-1 :
ROTARY LIGHT RELAY (RED) (OPT. RELAY 1) MECHATRO CONTROLLER
R-38 : C-1 :
ROTARY LIGHT RELAY (GREEN) (OPT. RELAY 4) MECHATRO CONTROLLER
L-1/2/6 :
WORK LIGHT
C-4 :
AIR CONDITIONER AMP
SW-40 :
ROTARY LIGHT SW.
R-9 (RL Y9) :
CAB WORK LIGHT RELAY 1 L-7/8/15 :
CAB WORKING LIGHT
SW-26 :
CAB WORKING LIGHT SW.
R-11 (RL Y11) :
CAB WORK LIGHT RELAY 2
L-16/17/18 :
CAB WORKING LIGHT/BACK LIGHT
C-4 :
AIR CONDITINER UNIT (MAIN)
C-4 :
AIR CONDITINER UNIT (COMPRESSOR)
SW-17 :
ROOF WIPER SW.
M-9 :
ROOF WIPER MOTOR
E-22 :
DC-DC CONVERTER
R-19 :
FLASHER RELAY
E-13 :
TRAVEL ALARM
C-1 :
R-8 (RL Y8) : MECHATRO CONTROLLER
TRAVEL ALARM RELAY
SW-32 :
STROKE-END PROXIMILITY SW.
TILT WARNING
HYDRAULIC VLC
TILT WARNING
WATER SPRAY EQUIPMENT
RESERVE
(7/8)
HYDRAULIC VLC
LS03Z00021P1 02
23. ELECTRIC SYSTEM
23-9
23-10
23. ELECTRIC SYSTEM
C-1 :
MECHATRO CONTROLLER 9P CONNECTOR
C-2 : C-1 :
GAUGE CLUSTER MECHATRO CONTROLLER
C-1 : SW-15 :
MECHATRO CONTROLLER CONFLUX/SINGLE SELECT SW.
M-3 : C-1 :
WIPER MOTOR MECHATRO CONTROLLER
C-4 : E-10 :
AIR CONDITINER UNIT RECEIVER DRIER
SW-19 : C-1 :
WIPER INTERLOCK MECHATRO CONTROLLER
SW.
E-22 : E-23 :
DC-DC CONVERTER 12V SOCKET
SW-40 : L-20 :
ROTARY LIGHT SW. ROTARY LIGHT
E-8 :
SPEAKER LEFT
E-7 :
TUNER AM & FM
E-9 :
SPEAKER RIGHT
OPT. RELAY 5
R-52 :
L-31 :
TILT WARNING RELAY
TILT ALARM LIGHT
RESERVE CONNECTOR
SW-80 :
TILT SW. L-31 :
TILT ALARM LIGHT
(8/8)
LS03Z00021P1 02
23. ELECTRIC SYSTEM
(SE) SENSOR
(P) PROPORTIONAL SOLENOID VALVE
(C) CONTROLLER
C-2 GAUGE CLUSTER YN59S00021F2 PSV-B P2 BYPASS CUT PROPO. VALVE SE-24 PRESSURE SENSOR ; BOOM HEAD
C-4 AIR-CON CONTROLLER AIR CON ACCESSORY PSV-C TRAVEL STRAIGHT PROPO. VALVE SE-26 PRESSURE SENSOR ; BOOM HEAD (FOR OVER LOAD ALARM)
C-5 ENGINE COOLANT LEVEL CONTROLLER ENGINE ACCESSORY PSV-D P1 BYPASS CUT PROPO. VALVE SE-29 OPT. SELECTOR PROXIMILITY SENSOR LC52S00019P1
C-6 AUTO GREASE CONTROLLER LC22E00081P1 PSV-E OPT. RELIEF ADJSTMENT PROPO. VALVE 1
C-7 IT CONTROLLER YN22E00230F1 PSV-F JIB STRETCH REVERSE PROPO. VALVE SV-1 SLEWING PARKING BRAKE SOL YN35V00047F1
C-8 ENGINE CONTROLLER ENGINE ACCESSORY PSV-G JIB CONTACT REVERSE PROPO. VALVE SV-2 POWER BOOST SOL
D-4 DIODE HARNESS ACCESSORY PSV-I OPT. RELIEF ADJSTMENT PROPO. VALVE 2 SV-3 TWO SPEED SOL
D-5 DIODE ACCESORY OF FUSE & RELAY BOX PSV-J ARM 1 SPEED REAR PROPO. VALVE SV-4 LEVER LOCK SOL
D-6 DIODE PSV-M P1 TRAVEL INDEPENDENT PROPO. VALVE SV-6 RIGHT ROTARY SOL LE35V00001F2
D-9 DIODE PSV-N P2 TRAVEL INDEPENDENT PROPO. VALVE SV-7 LEFT ROTARY SOL
(SV) SOLENOID
D-10 DIODE PSV-P1 P1 PUMP PROPO. VALVE YN35V00052F1 SV-8 ARM OUT / IN PORT TURNS REVERSE SOL 2436R1745F1
D-12 DIODE PSV-P2 P2 PUMP PROPO. VALVE SV-9 NIBBLER OPEN SOL
(D) DIODE
D-13 DIODE R-1 BATTERY RELAY YN24S00008F1 SV-10 NIBBLER CLOSE SOL
D-14 DIODE R-2 STARTER RELAY ENGINE ACCESSORY SV-13 OPT. SELECTOR SELECT SOL
D-15 DIODE R-4 SAFETY RELAY YN24S00010P1 SV-14 QUICK COUPLER OPERATION SOL
D-16 DIODE R-5 HORN RELAY SV-16 BUCKET REGULATION SOL LE35V00001F1
D-17 DIODE R-6 WORK LIGHT RELAY SV-31 TRAVEL STRAIGHT UNLOAD SOL
D-18 DIODE YN02D01001P1 R-8 TRAVEL ALARM RELAY SV-32 SPRINKLING SOL
D-19 DIODE R-10 BUCKET REGULATION RELAY SV-40 CRAWLER GROWTH SOL
D-20 DIODE R-12 RIGHT ROTARY RELAY SV-41 CRAWLER SHRINKAGE SOL
D-25 DIODE HARNESS ACCESSORY R-13 LEFT ROTARY RELAY SW-1 KEY SWITCH YN50S00029F1
E-1 FUSE & RELAY BOX YN24E00016F2 R-15 NIBBLER OPEN RELAY SW-4 SWING PARKING RELEASE SWITCH YN50S00047P1
E-2 ALTERNATOR ENGINE ACCESSORY R-16 NIBBLER CLOSE RELAY SW-5 HORN SWITCH RIGHT (OPT.) YN50E00017P1
E-3 HOUR METER YT58S00006P1 R-19 FLASHER RELAY YY24S00001P1 SW-7 ENGINE HYDRAULIC PRESSURE SWITCH ENGINE ACCESSORY
(R) RELAY
E-5 HORN HIGH LV53S00001F1 R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1 SW-8 AIR FILTER CLOGGING SWITCH YR11P00008S005
E-6 HORN LOW LV53S00001F2 R-24 AUTO IDLE STOP RELAY 2 SW-10 HORN SWITCH LEFT YN50E00017P1
E-7 TUNER AM&FM YN54S00044P1 R-25 EMERGENCY STOP RELAY SW-11 LEVER LOCK SWITCH YN50S00041F1
E-8 SPEAKER LEFT YN54S00050P1 R-26 LEVER LOCK RELAY SW-12 OVER LOAD ALARM SELECT SWITCH YN50S00040D6
E-9 SPEAKER RIGHT R-27 GREASING RELAY (NORMAL ROTATION) SW-13 TRAVEL ALARM SWITCH YN50S00040DF
(E) ELECTRIC FITTINGS
E-10 RECEIVER DRYER YN54S00041P1 R-28 ALTERNATOR RELAY SW-15 CONFLUX / SINGLE SELECT SWITCH YN50S00040D3
E-11 AIR-CON COMPRESSOR YX91V00001F1 R-29 WIPER MOTOR RELAY (NORMAL ROTATION) YN24S00012P2 SW-17 ROOF WINDOW WIPER SWITCH YN50S00040D9
E-12 BATTERY YN72S00016P1 R-30 WIPER MOTOR REVERSING RELAY (REVERSE ROTATION) SW-18 LMN/BH SELECT SWITCH YN50S00040D8
E-13 TRAVEL ALARM (OPT.) YN53S00004F1 R-31 WIPER MOTOR ARK PREVENTION RELAY SW-19 WIPER INTER LOCK SWITCH YT50S00004P1
E-14 CIGARETTE LIGHTER YN81S00003P1 R-32 WASHER MOTOR RELAY SW-20 POWER BOOST SWITCH RIGHT YN50E00017P1
E-15 FUSIBLE LINK LC13E01175S002 R-36 ROTARY LIGHT RELAY (RED) YN24S00010P1 SW-21 POWER BOOST SWITCH LEFT (OPT.)
E-16 ONEWAY CALL AMPLIFIER 2447R145 R-37 ROTARY LIGHT RELAY (YELLOW) SW-22 SWITCHES TO JUDGE THE LENGTH OF INSERT BOOM SW. 1
E-17 ONEWAY CALL SPEAKER LC54S00004P1 R-38 ROTARY LIGHT RELAY (GREEN) SW-26 CAB WORK LIGHT SWITCH YN50S00040D4
(SW) SWITCH
E-22 DC-DC COMVERTER YN77S00005F1 R-34 PCV RELAY ENGINE ACCESSORY SW-27 COOLANT LEVEL SWITCH ENGINE ACCESSORY
E-23 12V SOURCE SOCKET YN81S01002P1 R-39 AIR HEATER RELAY SW-29 NIBBLER OPEN SWITCH 2406P5872
E-24 GPS ANNTENA YN54S00047P1 SE-1 PRESSURE SENSOR ; BUCKET DIGGING LC52S00019P1 SW-30 NIBBLER CLOSE SWITCH
E-25 PDC ANNTENA & CONTROLLER YN22E00230F1 SE-2 PRESSURE SENSOR ; BUCKET DUMP SW-32 STROKE END PROXIMILITY SWITCH YN50S00019P1
E-27 ACCEL REDUNDANT VOLUME YN52S00052P1 SE-3 PRESSURE SENSOR ; BOOM UP SW-33 RIGHT ROTARY SWITCH (OPT.) YN03M01231P3
E-33 PCV FUSE HARNESS ACCESSORY SE-4 PRESSURE SENSOR ; BOOM DOWN SW-34 LEFT ROTARY SWITCH (OPT.)
E-44 RESISTER SE-5 PRESSURE SENSOR ; SLEWING SW-35 HEVY LIFT SWITCH YN50S00040D5
L-1 BOOM WORKING LIGHT LEFT YW80S00001F1 SE-7 PRESSURE SENSOR ; ARM IN SW-39 NIBBLER OPEN PRESSURE SWITCH GB50S00049F2
L-2 DECK WORKING LIGHT RIGHT YT80S00002F2 SE-8 PRESSURE SENSOR ; ARM OUT SW-40 ROTARY LIGHT SWITCH YN50S00040D2
(SE) SENSOR
L-3 SLEWING FLASHER LEFT & WORK LIGHT UNIT YM80S00001F1 SE-9 PRESSURE SENSOR ; TRAVEL RIGHT SW-41 HIGH REACH CRANE SWITCH PY50S00003P2
(L) LIGHT
L-4 SLEWING FLASHER RIGHT & WORK LIGHT UNIT YM80S00001F2 SE-10 PRESSURE SENSOR ; TRAVEL LEFT SW-43 JIB PRESSURE SWITCH GB50S00049F2
L-5 ROOM LIGHT YT80S00001P1 SE-11 PRESSURE SENSOR ; P2 SIDE OPT. SW-55 BOOM DECK WORK LIGHT SWITCH YN50S00040D1
L-6 BOOM WORKING LIGHT RIGHT YW80S00001F1 SE-13 ENGINE SPEED SENSOR ENGINE ACCESSORY SW-77 OIL FILTER CLOGGING SWITCH ENGINE ACCESSORY
L-10 HIGH REACH RATARY LIGHT 2456R457 SE-15 FUEL SENSOR YN52S00045F1
L-19 HIGH REACH THREE COLORS ROTARY LIGHT EZ53E00013F1 SE-16 ACCEL POTENTIO YN52S00032P1
M-1 STARTER MOTOR ENGINE ACCESSORY SE-17 BOOM POTENTIO YR52S00016P1
(M) MOTOR
23-11
23. ELECTRIC SYSTEM
23.3 HARNESS
23.3.1 HARNESS LIST
6 HARNESS YN14E01106P1
BOOM 3.10 BOOM HARNESS ASSY LS15E00001F1 1 HARNESS LS15E01001D1 BOOM LIGHT
LIGHT
The parts number may be changed due to the improvement of machine, so use the number for reference only.
23-12
23. ELECTRIC SYSTEM
TIGHTENING TORQUE :
YN17M00053F1 (12) SE. Asia 1.5N.m (1.1lbf.ft)
INSTRUMENT PANEL ASSY TIGHTENING TORQUE : SEMS BOLT TIGHTENING TORQUE :
YN17M00054F1 (12) Oceania
5.2N.m (3.8lbf.ft) 5.2N.m (3.8lbf.ft)
ITEM PART NAME PART No. Q'TY REMARKS 2 PLACES INSTALL TO CAB
TAPPING SCREW
3-2 POTENTIO METER YN52S00032P1 1 TAPPING
SEMS BOLT DUCT ASSY SCREW
3-10 KEY SWITCH YN50S00026F1 1 K250 2 PLACES
TIGHTENING TORQUE : TAPPING SCREW
4-2 CIGARETTE LIGHTER YN81S00003P1 1 2.8N.m (2.1lbf.ft) TIGHTENING TORQUE :
5.2N.m (3.8lbf.ft)
5-2 HOUR METER YT58S00006P1 1
SECTION BB SECTION DD SECTION EE
10 GAUGE CLUSTER YN59S00021F3 1
46-3 SPEAKER YN54S00050P1 2
TIGHTENING TORQUE : TIGHTENING TORQUE :
TIGHTENING TORQUE : 5.0N.m (3.7lbf.ft) 8.5N.m (6.3lbf.ft)
TIGHTENING TORQUE : 5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT
5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT TO CAB
INSTALL SEMS BOLT
INSTALL SEMS TO CAB
TIGHTENING TORQUE : TO CAB
4.1N.m (3.0lbf.ft) BOLT TO CAB
2 PLACES
SEMS BOLT
TIGHTENING TORQUE :
4.1N.m (3.0lbf.ft)
SECTION AA
VIEW
SEMS BOLT
TIGHTENING TORQUE :
5.0N.m (3.7lbf.ft)
TIGHTENING TORQUE :
TIGHTENING TORQUE : 0.43N.m (0.32lbf.ft) TIGHTENING TORQUE :
TIGHTENING TORQUE :
TIGHTENING TORQUE :
. .
8.5N m (6.3lbf ft) 8 PLACES 5.0N.m (3.7lbf.ft)
5.0N.m (3.7lbf.ft) TIGHTENING TORQUE :
4 PLACES
5.0N.m (3.7lbf.ft) 4.9N.m (3.6lbf.ft) SEMS BOLT TAPPING SCREW
SEMS BOLT TIGHTENING TORQUE : INSTALL SEMS BOLT
SEMS BOLT
12.0N.m (8.9lbf.ft) TO CAB
INSTALL
SEMS BOLT
TO CAB
SEMS BOLT
4 PLACES
TIGHTENING TORQUE :
5.0N.m (3.7lbf.ft)
SECTION CC
TIGHTENING TORQUE :
5.2N.m (3.8lbf.ft)
SEMS BOLT VIEW
INSTALL TAPPING SCREW TIGHTENING TORQUE :
TO A/C 5.0N.m (3.7lbf.ft)
23-13
23. ELECTRIC SYSTEM
UPPER
HEXAGON NUT
TOOTHED LOWER
HEXAGON NUT
LOCK WASHER
HORN WASHER
SECTION AA
SEMS BOLT SEMS BOLT
TIGHTENING TORQUE : TIGHTENING TORQUE :
2.8N.m (2.1lbf.ft) 2.8N.m (2.1lbf.ft)
VIEW VIEW
SEMS BOLT
TIGHTENING
TORQUE :
2.8N.m (2.1lbf.ft)
VIEW
TIGHTENING TORQUE :
5.0N.m (3.7lbf.ft)
SEMS BOLT
SEMS BOLT
TIGHTENING TORQUE :
5.0N.m (3.7lbf.ft)
CLIP CLIP
PUT SURPLUS
CABLE INTO CAB CLAMP CABLE WITH HARNESS
INSIDE TOGETHER
CONNECT CABLE WITH PASS CABLE THROUGH THE HOLE CABLE ARRANGEMENT
CAB SIDE ANTENNA FOR HARNESS
23-14
23. ELECTRIC SYSTEM
VIEW
AFTER INSTALLING GLOW RELAY AND STARTER RELAY
TO BRACKET (A), ASSEMBLE THIS BRACKET
TIGHTENING TORQUE :
23.5N.m (17.3lbf.ft)
SEMS BOLT
BRACKET
AIR HEATER RELAY
HORN (LOW)
HORN (HIGH)
SEMS BOLT
TIGHTENING TORQUE :
15.5N.m (11.4 lbf.ft)
2 PLACES
SEMS BOLT
TIGHTENING
STARTER RELAY TORQUE :
10.7N.m (7.9 lbf.ft)
B TERMINAL
NUT C TERMINAL
TIGHTENING TORQUE :
17.5N.m (12.9 lbf.ft)
GROUND
HORN (LOW)
GROUND
1
TIGHTENING TORQUE : TIGHTENING TORQUE :
10.7N.m (7.9lbf.ft) 10.7N.m (7.9lbf.ft) HORN (HIGH)
SEMS BOLT SEMS BOLT SEMS BOLT SEMS BOLT
TIGHTENING TORQUE : TIGHTENING TORQUE :
10.7N.m (7.9lbf.ft) 10.7N.m (7.9lbf.ft)
CONNECT SEMS BOLT CONNECT SEMS BOLT
AFTER CHECKING AFTER CHECKING
NO PAINT IS HERE NO PAINT IS HERE
3
CONNECT HARNESS AS SHOWN CONNECT HARNESS AS SHOWN
TO AVOID SHORT CIRCUIT ON TO AVOID SHORT CIRCUIT ON SECTION AA VIEW
POWER SOURCE WIRING POWER SOURCE WIRING
(BATTERY RELAY BOX) (COVER INSTALL)
VIEW
23-15
23. ELECTRIC SYSTEM
STARTER CABLE
4
TO FRAME WORKING
TO ATT HARNESS
LIGHT RIGHT
E-10 :
SECTION AA RECEIVER DRIER
TO ATT HARNESS
TO AIR FILTER CLOGGING SW.
8 5
7 BATTERY BATTERY RELAY FLOOR HARNESS GROUND P-31 GND TO RECEIVER DRIER
GROUND CABLE CABLE ECU HARNESS(GROUND)
CABLE TIGHTEN AFTER TO RADIATOR COOLANT LEVEL SW.
TUNER CHECKING NO PAINT
OVERLOAD ALARM SELECT SW. SEMS BOLT TO SWING FLASHER LEFT
NOTE 1 JIB PRESS. SW. TO ENG & REAR WOEKING LIGHT
DETAIL OF BATTERY HEAVY LIFT SW.
TRAVEL INDEPENDENT CHANGE SW. 3
SE-15 : FUEL SENSOR RIGHT ROTATING SW.(OPT) FLOOR
CONNECT A HARNESS WITH IN A CAP ATTACHMENT BOOST SW.(RH) GROUND
HORN SW.(RH) CABLE
LMN/BH CHANGE SW.
NIBBLER CLOSE SW.(OPT)
LEFT ROTATING SW.(OPT) CLIP
UPP HARNESS ECU HARNESS BATTERY RELAY CABLE STARTER CABLE
HORN SW.(LH) FIX WHITE TAPING
ATTACHMENT BOOST SW.(LH) POSITION
CLIP DC-DC CONVERTER TO BATTERY RELAY BOX
FIX WHITE TAPING POSITION TO DETAIL OF FUSE &
WASHER MOTOR
NIBBLER OPEN PRESS.SW.(OPT) RELAY BOX CONNECTION
SECTION aa NIBBLER OPEN SW.(OPT)
23-16
23. ELECTRIC SYSTEM
CLIP
GROMMET
UPPER
CLIP HARNESS CLIP CLIP
FIX WHITE TAPING POSITION
CLIP E-5 : HORN HIGH E-6 : HORN LOW
23-17
23. ELECTRIC SYSTEM
UPPER HARNESS
CLIP TO UPPER FRAME
CLIP
USE THE EXISTING NUT FIX WHITE TAPING POSITION
TIGHTENING TORQUE : CLIP
FIX WHITE TAPING POSITION CLIP
3.2~4.4N.m (2.4~3.2 lbf.ft)
CLIP CLIP
FIX A HARNESS PART OF
CORRUGATED TO
CONNECTOR WITH CLIP ECU HARNESS
FIX WHITE TAPING POSITION
TO FRAME WORKING CLIP
FIX THE CORRUGATED LIGHT RIGHT FIX WHITE TAPING POSITION
TUBE NOT CONTACT
TO SOL. BLOCK TO LOCKPART OF
CONNECTOR
SE-29 : VIEW X
TO SWING PRESS. SENSOR VIEW VII PRESS. SENSOR : SELECTOR DETECTION VIEW XI
23-18
23. ELECTRIC SYSTEM
E-10 :
RECEIVER
FIX A HARNESS TO
CLIP DRIER
AIR CONDITIONER HOSE
CLIP
VIEW XXVII
VIEW XV
TO BATTERY RELAY VIEW XVII VIEW XVII
23-19
23. ELECTRIC SYSTEM
VIEW XXIII
CONNECT A CONNECTOR
CLIP CLIP CAB SUB HARNESS WITH "CNT-2" TAG TO
FIX WHITE TAPING POSITION FLOOR HARNESS
TIGHTENING WITH BOLT FIX A HARNESS TO
TO INSTALL ECU FLOOR HARNESS
CONNECT A CONNECT OR WITH FIX WHITE TAPING POSITION(ECU)
"CNT-1" TAG TO FLOOR HARNESS CLIP
CONNECT A 1P-CONNECTOR WITH R-19 :
CONNECT A CONNECTOR WITH "CNT-3" TAG TO CAB SUB HARNESS FLASHER RELAY
"CNT-5" TAG TO ECU HARNESS
CLIP
FIX WHITE TAPING POSITION OF UPPER
HARNESS AND ECU HARNESS TO THE
VIEW XX FLOOR HARNESS WITH CLIP
23-20
23. ELECTRIC SYSTEM
NOTES :
(1) TIGHTENING TORQUE OF
BATTERY TERMINALS ARE 3.4N.m (2.5 lbf.ft).
(2) TIGHTENING TORQUE OF
GROUNDING CABLES ARE 10.7N.m (7.9 lbf.ft).
(3) UNLESS OTHERWISE SPECIFIED
TIGHTENING TORQUE IS SHOWN BELOW.
CLIP CLIP
M8 : 23.5N.m (17.3 lbf.ft)
M10 : 46.1N.m (34.0 lbf.ft)
M12 : 79.4N.m (58.6 lbf.ft)
(4) ATTACHMENT OF WELDING CLIP WIHOUT
TO SOL. BLOCK DIRECTIONS IS MADE INTO THE FOLLOWING.
CLIP CLIP
SECTION GG HARNESS
PSV-B :
P2 BYPASS CUT PROPORTIONAL VALVE
SV-3 : PSV-C :
SV-4 : PSV-D :
TRAVEL TWO-SPEED SELECT SOL. TRAVEL PRIORITY
LEVER LOCK SOL. P1 BYPASS CUT PROPORTIONAL VALVE
PROPORTIONAL VALVE
SV-2 :
SV-1 : ATTACHMENT
SWING PARKING BOOST SOL.
CLIP C-1 :
FIX A CONNECTOR AND REST MECHATRO
SOL. SIDE HARNESS TO THE CONTROLLER
HARNESS WITH CLIP E-1 :
FUSE & RELAY BOX
PSV-A :
ARM TWO-SPEED INVERSE PROPORTIONAL VALVE
CLIP
SV-31 : FIX A HARNESS TO THE HOSE MOUTHPIECE WITH CLIP CAB SUB HARNESS
TRAVEL PRIORITY UNLOAD SOL.
VIEW XX VI
CONNECT A CONNECTOR WITH "CNT-2"
FIX UPPER HARNESS AND ECU HARNESS TO TAG TO FLOOR HARNESS
THE FLOOR HARNESS WITH CLIP
ECU HARNESS
CLIP CLIP
FIX A CORRUGATED PART OF HARNESS TO FIX TO WELDNUT OF UPPER FRAME TO UNDER FLOOR
PRESS. SENSOR WITH CLIP FIX WHITE TAPING POSITION
FIX WHITE TAPING POSITION SECTION FF
FIX THE CORRUGATED TUBE NOT
CONTACT LOCK OF CONNECTOR SECTION EE
23-21
23. ELECTRIC SYSTEM
23-22
23. ELECTRIC SYSTEM
23-23
23. ELECTRIC SYSTEM
23-24
23. ELECTRIC SYSTEM
23-25
23. ELECTRIC SYSTEM
23-26
23. ELECTRIC SYSTEM
23.3.6-2 ECU HARNESS (2/2) : LS13E01097P1 23.3.6-3 FLOOR GROUNDING CABLE : LE13E01006P1
100 (3.94")
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010
3900
70 (12'9.5") 70
(2.76") (2.76")
2000
(6'6.7")
40
(1.59")
23-27
23. ELECTRIC SYSTEM
440 (17.3")
40
(1.57")
270 (10.6")
50 50
(1.97") (1.97")
23-28
23. ELECTRIC SYSTEM
NOTES :
1.UNLESS OTHERWISE SPECIFIED
TIGHTENING TORQUE IS SHOWN BELOW.
SEMS BOLT M12 : 79.4N.m (58.6 lbf.ft)
TIGHTENING TORQUE : M10 : 46.1N.m (34.0 lbf.ft)
25.5N.m (18.8 lbf.ft) M8 : 23.5N.m (17.3 lbf.ft)
FIX WHITE TAPING POSITION.
UPPER HARNESS
1
DETAIL aa
TO AIR-COMPRESSOR
SEMS BOLT
CLIP
TIGHTENING TORQUE : 25.5N.m (18.8 lbf.ft)
FIX WHITE TAPING POSITION.
CLIP
INSTALL WELD NUT OF ENGINE MOUNT.
CONNECT AIR-CON
ACCESSORY HARNESS CLIP
SW-7: ENGINE OIL PRESS SW. WITH ENGINE SUB HARNESS. TOGETHER INSTALL CLIP
BY BOLT OF AIR COMPRESSOR.
CONNECT TO UPPER HARNESS
CLIP DETAIL OF AIR COMPRESSOR
FIX A WOVEN BRAID PART OF HARNESS ON ENGINE OIL PRESS. SW. BY CLIP.
23-29
23. ELECTRIC SYSTEM
SW-7 :
ENGINE OIL PRESS. SW.
WHITE TAPING
23-30
23. ELECTRIC SYSTEM
TO WASHER MOTOR
SW-1 :
KEY SW. NOTE : 1. ATTACHMENT OF WELDING CLIP WITHOUT
DIRECTIONS IS MADE INTO THE FOLLOWING.
CLIP
SW-16 :
ACCEL POTENTIO HARNESS
CAB HARNESS
SE-3 :
SE-4 : PRESS SENSOR :
PRESS SENSOR : BOOM UP
BOOM DOWN
SE-1 :
TO WASHER MOTOR PRESS SENSOR :
BUCKET DIGGING
FIX A HARNESS TO CLIP OF
CAB SIDE COVER SE-2 : SE-7 :
VIEW I PRESS SENSOR : BUCKET DUMP PRESS SENSOR :
PUSH CONTROL LEVER MOST FRONTWARD ARM IN
AND FIX THIS SLACK HARNESS WITH CLIP
SE-8 :
PRESS SENSOR :
SW-35 : ARM OUT
HEAVY LIFT SW. CONNECT SWITCH
SW-13 :
TO TAGGED "HEAVY" CONNECTOR
SW-10 : TRAVEL ALARM SW.
SW-40 :
HORN SW. LEFT (OPT) (BLUE TAPING) IN CASE OF TRAVEL SW-12 : CLIP
ROTARY LIGHT SW.
SW-21 : ALARM SPEC., OVER LOAD ALARM SELECT SW. WHITE TAPING BUNDLE AFTER
CONNECT SWITCH TO TAGGED CLIP HARNESS DIVERGES
POWER BOOST SW. LEFT (OPT) CONNECT SWITCH TO CONNECT SWITCH TO TAGGED "ROTARY" CONNECTOR FASTEN HARNESS BY CLIP
(YELLOW TAPING) TAGGED "ALARM" "OVER L" CONNECTOR WITH BRACKET OF MULTI
SW-34 : CONNECTOR SW-18:
REVOLUTION LEFT SW. (OPT) LMN/BH SELECT SW. DETAIL A : A CASE OF MULTI
(RED TAPING) CONNECT SWITCH TO TAGGED
* IN CASE OF MULTI, USE TWO ITEM 2 : CLIP
CLIP "LMN/BH" CONNECTOR
(NOT USE ITEM 3 : CLIP)
FIX A CLIP ON HOLE
CLIP OF STAND SIDE
FIX A HARNESS
OF SW. SIDE SW-20 : FIX A HARNESS ON SENSOR
SW-11 :
LEVER LOCK SW. POWER BOOST SW. RIGHT BLOCK WITH CLIP
(YELLOW TAPING) CLIP
SW-33 : TO WASHER MOTOR
REVOLUTION RIGHT SW. (OPT)
(RED TAPING) CLIP
CLIP SW-5 :
FIX A CLIP ON HOLE HORN SW. RIGHT (OPT) (BLUE TAPING)
OF STAND SIDE CLIP
PUSH CONTROL LEVER
MOST FRONTWARD FASTEN FLOOR HARNESS FIX WHITE TAPING POSITION SE-2 :
AND FIX THIS SLACK WITH LEVER SW. THROUGH THE HARNESS PRESS SENSOR :
HARNESS WITH CLIP HARNESS AT SEAT SIDE OF BRACKET BUCKET DIGGING
CLIP TOGETHER E-7 : CLIP SE-8 : SE-2 :
TUNER FIX WHITE TAPING POSITION
CLIP PRESS SENSOR : PRESS SENSOR :
FIX A CLIP ON HOLE
ARM OUT BUCKET DUMP
OF SEAT SIDE SE-3 :
CLIP
FIX WHITE TAPING SE-7 : PRESS SENSOR :
POSITION PRESS SENSOR : SE-4 : BOOM UP
ARM IN PRESS SENSOR :
CLIP
BOOM DOWN
USE CLIP TO TIE UP WHITE VIEW II
TAPING PART OF HARNESS
VIEW III DETAIL A : A CASE OF SENSOR TOWER
WITH PILOT HOSE TOGETHER
23-31
23. ELECTRIC SYSTEM
E-1 :
SW-43: FUSE & RELAY BOX C-1 :
JIB PRESSURE SWITCH MECHATRO
CONNECT THE "CNT-2" TAGGED
CONTROLLER
SW-20: SW-20: CONNECTOR WITH "UPPER HARNESS"
PRESSURE SENSOR (P1 SIDE OPT.) PRESSURE SENSOR (P1 SIDE OPT.) C-8 : ENG. CONTROLLER
CONNECT TO SWING
PARKING RELEASE SW.
SW-43: 4
CLIP JIB PRESSURE SWITCH
FIX A HARNESS PART OF CORRUGATED E-22 :
AND REST SW. SIDE HARNESS DC-DC CONVERTER
TO THE HOSE WITH CLIP. CONNECT THE "CNT-4" TAGGED
CONNECTOR OF CAB HARNESS
ONLY SEPARATE BOOM SPEC. USES CLIP.
WITH "ITEM 1 HARNESS" CLIP
23-32
23. ELECTRIC SYSTEM
23-33
23. ELECTRIC SYSTEM
23-34
23. ELECTRIC SYSTEM
23-35
23. ELECTRIC SYSTEM
TO HARNESS (UPPER)
E-1 :
FUSE & RELAY BOX
TO CAB HARNESS
100 (3.94")
1PAF
YAZAKI 7123-3010
23-36
23. ELECTRIC SYSTEM
E-23 :
12V SOCKET
E-9 :
SPEAKER RIGHT
CONNECT TO
FLOOR HARNESS
CLIP
SW-41 :
HIGH REACH CRANE SW.
E-3 : CONNECT THE SWITCH
HOUR METER WITH "CRANE" TAGGED
BLACK CONNECTOR
SW-15 :
SW-17 : SW-26 :
M-3 : CONFLUX / SINGLE SELECT SW.
ROOF WIPER SW. CAB WORK LIGHT SW.
WIPER MOTOR CONNECT THE SWITCH WITH "CONFLUX"
CONNECT THE SWITCH CONNECT THE SWITCH WITH "CAB LIGHT"
TAGGED GREEN CONNECTOR
WITH "WIPER" TAGGED TAGGED NATURAL COLOR CONNECTOR
SW-55 :
BOOM , DECK WORKING LIGHT SW. NATURAL COLOR
E-4 :
CONNECTOR E-4 :
CONNECT THE SWITCH WITH "BOOM, DECK" CIGARETTE LIGHTER
CIGARETTE LIGHTER
TAGGED BLUE CONNECTOR
TO AIR
CONDITIONER UNIT FIX TO THE BRACKET
WR B
23-37
23. ELECTRIC SYSTEM
DOUBLE
SPLICE
WHITE TAPING
DOUBLE
TAPING AFTER SPLICE
BUNDLED
TO CAB WORKING LIGHT
TO CAB WORKING LIGHT
DOUBLE
DOUBLE E-9 :
SPLICE
SPLICE SPEAKER RIGHT
WHITE TAPING
TAPING TAPING
C-2 :
GAUGE CLUSTER
DOUBLE
SPLICE
SW-19 :
WIPER INTERLOCK SW. E-3 :
DOUBLE HOUR METER
TO CAB GND. SPLICE
SW-17 : SW-15 :
SW-41 :
ROOF WIPER SW. CONFLUX / SINGLE
HIGH REACH
CRANE SW. SELECT SW.
TO ROTALY LIGHT C-4 : E-14 :
TO HARNESS (FLOOR) AIR CONDITIONER UNIT CIGARETTE LIGHTER SW-55 :
WHITE TAPING
BOOM, DECK
TO HARNESS (UPP) DOUBLE
SW-26 : SPLICE WORKING LIGHT SW.
CAB WORK
LIGHT SW.
DOUBLE
SPLICE
WHITE TAPING
TAPING TAPING AFTER TAPING AFTER
BUNDLED BUNDLED
TAPING
TO CAB HARNESS
23-38
23. ELECTRIC SYSTEM
FIX WHITE
TAPING
POSITION
1
CLIP
CLAMP TO THE TUBE
FOR GREASE
TO UPPER
HARNESS
CB104
YAZAKI
CAP : 7120-1010
TERMINAL : 7115-1050-02
1300 (4'3.2")
1 PAM
WHITE TAPING 1300
(4'3.2")
1300 (4'3.2")
CB104
YAZAKI
CAP : 7120-1010 3900
YAZAKI
TERMINAL : 7115-1050-02 (12'9.5")
SEPARATE HOUSING : 7122-2215
AT SPLICE TERMINAL : 7114-2020
23-39
23. ELECTRIC SYSTEM
INSTALLING BOOM LIGHT LC80E00004F1 (04) INSTALLING UPPER LIGHT LS80E00004F1 (01)
ITEM NAME PARTS No. Q'TY REMARKS ITEM PART NAME PART No. Q'TY REMARKS
1 LIGHT YW80S00001F1 1 1 LIGHT YT80S00002F2 1
NOTE :
ITEM 1, TIGHTENING TORQUE 18.6N.m (13.7 lbf.ft)
SECTION AA
MAIN HARNESS
NUT
(SUPPLIED WITH LIGHT)
CLIP THE HARNESS PROTECTION
TUBE OF ITEM 1 IN CUTTING
HOLE PART OF BRACKET.
SECTION A-A
(HOW TO INSTALL LIGHT AT RIGHT SIDE DECK)
23-40
23. ELECTRIC SYSTEM
SEMS-BOLT
TIGHTENING TORQUE
23.5N.m (17.3lbf.ft)
1
E-13 :
TRAVEL ALARM
L-4 :
SWING FLASHER RIGHT
& REAR WORKING LIGHT
VIEW I
SW-13 :
TRAVEL ALARM SW.
CONNECT WITH NAME TUBE OF "ALARM"
3
4
TRAVEL ALARM RELAY
23-41
23. ELECTRIC SYSTEM
[MEMO]
23-42
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
24-1
24. COMPONENTS SYSTEM
24-2
24. COMPONENTS SYSTEM
24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port
a5 a5 4-M16
a2 PS2 EYE BOLT (M12) PS2 Depth 24
Dr1 Dr1
Z a2
D1 a3 Dr2 D1 a3
Dr2 B1
Z A3 A3
PSV2
A2 B1
a7
a7
A2
X X
A1 PB Do
A1
a6 PSV1
a6
SECTON X-X
(Water outlet)
PS1 a1
2 1-M10 Depth 18
a1 PS1 (For attaching bracket)
a4 EYE BOLT M12 a4
12- 11 Through
A1,A2
Hydraulic ports
3 Code Ports name Ports size-Depth
A1,2 Delivery port SAE 6000psi 1"
PS1(PS2)
a1(a2) B1 Suction port SAE 2500psi 3"
Dr1 Drain port PF3/4-20
a4(a5)
PB
Ps1,Ps2 Side branch port PF1 1/4-24
Do B1 PSV1,PSV2 Serve assist port PF1/4-13
1
a4,a5 Sensor port PF3/8-17
No. Parts Q'ty a1,a2,a6,a7 Gauge port PF1/4-15
1 Main pump assy 1 D1,Do Oil filling port, Outlet port PF3/4-20
2 Regulator assy 2 PB Gauge port Rc1/8
3 Gear pump assy (for pilot) 1 A3 Gear pump delivery port PF1/2-19
4 Solenoid proportional reducing valve 2 a3 Gear pump gauge port PF1/4-14
5 PTO unit (For Oceania) 1 Dr2 Gear pump drain port PF3/8-15
24-3
24. COMPONENTS SYSTEM
Regulator
a6 a7
PB
PTO Gear case Regulator
(For Oceania) PS2
D1
Dr1
Main pump
PS1 Do B1 Dr2
24-4
24. COMPONENTS SYSTEM
24-5
24. COMPONENTS SYSTEM
24.1.1.2.1 CONSTRUCTION
(1) Main pump
536
889
405
A A
724 262
888 409
156
886 153 709
251 491
491 490 212 211 152 728 469 151 141 752 410
492
Tightening torque
Tightening torque
Item number Thread size
N m (lbf
405 M8 34 (25) 543 545
406,408 M12 98 (72)
410,411,412 M22 630 (465)
409 M10 57 (42) 725 724
466 PF 1 1/4 270 (199) 541
467 PF 1/4 36 (27)
468 M18X1.5 64 (47)
469 PF 3/4 170 (125) 887
490,492 NPTF1/16 8.8 (6.5) 726
491 Rc 1/8 12 (8.9)
493 Rc 1/4 22 (16)
531,532 M30X2 480 (354)
806,807 M20 240 (177) SECTION X-X SECTION B-B
24-6
24. COMPONENTS SYSTEM
127
823
192
191
711
827 B B
774 04
Apply (sealub L101)
to the oil seal surface
circumferential.
130
111
830
124,125
261
312
825
313 Valve plate for clockwise rotation.
126
752 122 824 411
129
889 468,731 467,725
128
733
SECTION A-A
05
ITEM PARTS Q'ty ITEM PARTS Q'ty ITEM PARTS Q'ty ITEM PARTS Q'ty
111 Drive shaft 1 214 Tilting bushing 2 493 Plug 2 774 Oil seal 1
113 Driven shaft 1 251 Swash plate support 2 531 Tilting pin ; M30X2 2 789 Backup ring ; P21 2
122 Roller bearing 1 261 Front cover 1 532 Servo piston ; M30X2 2 792 Backup ring ; G40 2
123 Roller bearing 1 262 Cover 1 534 Stopper (L) 2 806 Nut : M20 2
124 Needle bearing 2 271 Pump casing 1 535 Stopper (S) 2 807 Nut ; M20 2
125 Inner ring 1 312 Valve cover 1 536 Servo cover 2 823 Snap ring 1
126 Spacer 2 313 Valve plate (R) 1 541 Seat 2 824 Snap ring 3
127 Spacer 1 314 Valve plate (L) 1 543 Stopper 1 2 825 Snap ring 2
128 Bearing spacer 3 405 Socket bolt 8 545 Steel ball 2 827 Snap ring 1
129 Bearing spacer 2 406 Socket bolt ; M12X35 8 548 Feed back pin 2 828 Snap ring 2
130 Booster 7 408 Socket bolt ; M12X55 11 702 O-ring ; 1B G40 2 830 Snap ring 1
141 Cylinder block 2 409 Socket bolt ; M10X16 2 709 O-ring ; 1B G85 1 885 Valve plate pin 2
151 Piston 18 410 Socket bolt ; M22X60 9 711 O-ring ; 1B G95 1 886 Spring pin 4
152 Shoe 18 411 Socket bolt ; M22X95 2 724 O-ring ; 1B P8 9 887 Pin 1
153 Retainer plate 2 412 Socket bolt ; M22X180 1 725 O-ring ; 1B P11 2 888 Pin 2
156 Spherical bushing 2 466 RO Plug ; PF1 1/4 2 726 O-ring ; 1B P10 2 889 Pin 4
157 Cylinder spring 18 467 ROH Plug ; PF1/4 2 728 O-ring ; 1B P24 3 901 Eye bolt ; M12 2
171 Front casing 1 468 Adapter 2 729 O-ring ; 1B P38 2 953 Set screw 2
191 Drive gear 1 469 ROH Plug ; PF3/4 3 731 O-ring ; 1B P16 2 954 Set screw 2
192 Driven gear 1 490 Plug 20 732 O-ring; 1B P21 2 04 Gear pump 1
211 Shoe plate 2 491 Plug 12 733 O-ring; 1B G170 1 05 PTO unit 1
212 Swash plate 2 492 Restrictor 4 752 Seat packing 2
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3
24-7
24. COMPONENTS SYSTEM
728
434
311
312
361
732 Delivery port
PF1/2
Drain port PF3/8 307 310 308 309 434 466 355 850 Tightening
709 435 Tightening torque; 887
725 torque ; 53N.m
34N.m (25.1lbf.ft) (39.1lbf.ft)
SECTION Y-Y
Tightening torque
Tightening torque
Item number Thread size
N m (lbf ft)
312 M14X1.5 29 (21)
433,434 M8 17 (12.5)
435 M10 33 (24)
466 PF 1/4 16 (12)
468 PF 3/4 74 (55)
24-8
24. COMPONENTS SYSTEM
117
128 Z
126
825
128
886
416
711
826
115
118
710
409 901
125
316
Tightening torque Z
709 Tightening torque
SECTIONZ-Z Item number Thread size
N m (lbf
409 M10 57 (42)
326 284 414
414 M16 240 (177)
416 M12 98 (72)
24-9
24. COMPONENTS SYSTEM
24.1.1.2.2 OPERATION
(See the sectional drawings of pump on 24-6, 24-7)
The pump assembly is constructed with two pumps
which are arranged parallel, and the two pumps are
connected via drive gear (191) and driven gear
(192). The rotating power of engine is transmitted to
the driven shaft (113) via drive shaft (111), drive
gear (191) and driven gear (192) and the two
pumps are driven by this rotating power.
Furthermore this pump has the construction that
can attach pilot gear pump to rear end of driven
gear (113), 4th pump to rear end of drive gear (111),
and 5th pump to PTO gear casing via drive gear
(191).
The pump assy consists largely of the rotary group,
the main part of the pump that makes rotary on; the
swash plate group that changes the delivery rate;
the valve cover group that selects between oil
suction and delivery; and the PTO group that
transmits the drive power to 5th pump.
(1) Rotary group
The rotary group consists of drive shaft (111),
cylinder block (141), piston shoe (151, 152),
retainer plate (153), spherical bearing (156),
bearing spacer (126, 127, 128, and 129), drive gear
(191), driven gear (192) and cylinder spring (157),
etc. The shaft is supported by bearings (123) and
(124) at its both ends. The shoe (152), which is
caulked to the piston (151), forms a spherical joint
and relieves it of thrust force that is generated by
load pressure. Further, the piston is provided with a
pocket so it moves lightly on shoe plate (211),
taking hydraulic balance.
The sub group of the piston shoe (151, 152) is
pressed against the shoe plate (211) by the cylinder
spring (157), via the retainer plate (153) and the
spherical bushing (156), so that it moves smoothly
over the shoe plate (211). The cylinder block (141)
is also pressed against valve plate (313, 314) by
the action of cylinder spring (157).
24-10
24. COMPONENTS SYSTEM
24-11
24. COMPONENTS SYSTEM
24.1.1.3 REGULATOR
24.1.1.3.1 CONSTRUCTION
24-12
24. COMPONENTS SYSTEM
24-13
24. COMPONENTS SYSTEM
24.1.1.3.2 OPERATION
(1) Control function
Control function …… Electric flow control.
•Positive flow control.
•Total horsepower control.
Emergency mode control.
•Hydraulic positive control.
•Hydraulic total horsepower control
(2) Summary
The regulator KR3D-YTOK for the in-line type axial piston pump K5V series is composed of the control
mechanism as mentioned below:
1) Electric flow control: At normal operation
The tilting angle of the pump (delivery rate) is controlled by controlling the current command value (I) of the
solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate (Q) as the current command value (I) rises. When inputting
the current according to required flow rate for work, by this function, the pump delivers only the necessary oil
flow, the machine does not consume excessive power.
2) Horse power control (+power shift control) : at emergency mode (at current fail)
In emergency mode, the power shift command pressure Pf shifts the power set value. The power shift
pressure Pf (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power
control section of regulator on each pump through pump inside passage and shifts respective control to the
same power set value.
In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle (delivery rate) is
automatically reduced; consequently the input torque is controlled to the constant value or less. (When the
rotation is constant, the input power is also constant.)
This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is
controlled, the regulator of each pump is controlled to the different tilt angle (delivery rate). Consequently in
the condition where the power is controlled, the overloading of engine is automatically prevented regardless
of the loading of pump 2. And in normal condition, because the power shift pressure is 0MPa, the power
control is not worked.
With this mechanism, it is possible to obtain proper power for the working condition.
This regulator is made up of the above two kinds of control system, but when both controls are actuated
together, the low tilt angle (low flow rate) command precede on mechanical operation described later.
Command current I
Fig. 24-5
24-14
24. COMPONENTS SYSTEM
feed back lever rotates at (F) fulcrums with the Hydraulic circuit diagram
movement of the servo piston towards (E), B
24-15
24. COMPONENTS SYSTEM
24-16
24. COMPONENTS SYSTEM
consequently the flow rate is also reduced. Since !() )
0
the feed back lever is connected with servo
piston and spool, the feed back lever rotates at Fig. 24-9
(R) fulcrum with the movement of the servo
piston towards (Q), consequently the spool is
returned to the original position. With this
movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
24-17
24. COMPONENTS SYSTEM
rate is raised. Since the feed back lever is Hydraulic circuit daigram
connected to servo piston and spool, the feed B
24-18
24. COMPONENTS SYSTEM
24-19
24. COMPONENTS SYSTEM
24-20
24. COMPONENTS SYSTEM
24-21
24. COMPONENTS SYSTEM
500
[1] 247kW E/G horse power
[2] 198kW : At emergency mode Reference value in ( )
Input revolution ; 1850 min-1 Two pumps are loaded at the same time
Input horse power ; 247 kW Pf:Power shift pressure (Reference value)
Input torque ; 1275 N.m
12.2MPa 700mA
400 367L 370L
Q 1850min-1 Pd=7.8MPa at Qmax
[a]
Delivery flow rate Q [ L/min ]
[2] [1]
349L
[b]
300 2942
200 1961
22.9MPa
186L 34.3MPa
122L
100 981
400mA
Input torque
50L
Tin N m
Min.Flow(at 1850min-1)
Tin
0 5 10 15 20 25 30 35 40[MPa]
Delivery pressure Pd
0 1 2 3 4 [MPa]
Pilot pressure Pi
24-22
24. COMPONENTS SYSTEM
24.1.2.1 SPECIFICATIONS
(1) Outside view and hydraulic ports
3-M16X2 DEPTH 29
TAP FOR LIFTING BOLT ( MARK)
4-M20X2.5 DEPTH 26
FOR ATTACHING MACHINE ( MARK)
VIEW A
Fig. 24-17 Control valve outside view and hydraulic port
24-23
24. COMPONENTS SYSTEM
(2) Specifications
ITEM SPECIFICATIONS
Part no. LS30V00009F1
Model UY36-114
Rated flow 370×2 L/min (98×2 gal/min)
31.4 MPa at 380L/min (4550 psi at 100gal/min)
Main relief valve set pressure
When power boost
34.3 MPa at 340L/min (4980 psi at 90gal/min)
Overload relief valve set pressure
Boom H, Bucket H, Arm R 36.3 MPa at 30L/min (5260 psi at 7.9gal/min)
Boom R, Bucket R, Arm H 34.8 MPa at 30L/min (5050 psi at 7.9gal/min)
24-24
24. COMPONENTS SYSTEM
24.1.2.2 CONSTRUCTION
(1) Control valve
87
14 75
76
88
89
Plug
52 81
24-25
24. COMPONENTS SYSTEM
Main plunger 1
65,66 66 Housing
5 4 14
83
15
Cover [BKT] Cover [BM-1] Plug
65,66
16
17
21 16 Cover
Cover
20
111
112
18
Socket bolt 18
Socket bolt
16
Socket bolt O-ring O-ring
Washer
19 70
O-ring Cover
49 85 8 7 6 79,92
Socket bolt
47 51,52 Washer
86
Check valve
[BM-],BKT]
Check valve
[AM-2]
24-26
24. COMPONENTS SYSTEM
59 59
O-ring 61 Flange O-ring
(1 place) (1 place) 61
60 60
O-ring O-ring
(6 places) (6 places)
O-ring
(4 places) O-ring
(4 places)
19 19
O-ring O-ring
(2 places) (3 places)
(SW side mating surface) (BKT side mating surface)
24-27
24. COMPONENTS SYSTEM
62,63
(9 Places)
Socket bolt 63,64
(5 Places) 56
Washer 3 65,66
Socket bolt 55
Washer
57
BM Boost check
Manifold
24-28
24. COMPONENTS SYSTEM
121,122
123,124
125
126
127
137,138 128,129
136 130
135 131
134 132
133
71,72 63,67
Plug
102
98
95 97 Poppet
99
Spring
24-29
24. COMPONENTS SYSTEM
Main plunger
2
15 11 10 Housing
plug
17
Cover 21
Cover
18 18
Socket bolt Socket bolt
16 16
O-ring O-ring
53,54
7 13 12
37
44,46
Plug for over load relief hole
[SW, OPT, BM-2]
24-30
24. COMPONENTS SYSTEM
Tightening Tightening
torque No. NAME Q’ty REMARK torque No. NAME Q’ty REMARK
N•m (lbf•ft) N•m (lbf•ft)
1 HOUSING 1 36 SPRING 1
OVERLOAD
2 HOUSING 1 37 PLUG 2 RELIEF HOLE
3 MANIFOLD 1 38 CHECK 1
4 PLUNGER ; AM-2 1 Include 22,32~35 39 SPRING 3
5 PLUNGER ; BM-1 1 Include 23,32~35,38~43 40 SPACER 3
6 PLUNGER ; BUCKET 1 Include 32~35 41 O-RING 7 1B P18
7 PLUNGER ; TRAVEL L&R 2 Include 32~35 42 BACKUP RING 3
8 PLUNGER ; TRAVEL STRAIGHT 1 Include 26,32~34,36 78.4 (58) 43 CAP 3
9 — 44 BACKUP RING 2
10 PLUNGER ; AM-1 1 Include 28,32~35,39~43,45 45 CHECK 2
11 PLUNGER ; BM-2 Include 29,32~35 46 O-RING 2 1B P20
12 PLUNGER ; OPT-1 1 47 CHECK 10
13 PLUNGER ; SWING 1 48 SPRING 2
14 O-RING 4 1B P36 49 SPRING 10
245 (180) 15 CAP 2 343 (250) 50 CAP 7
16 O-RING 20 51 BACKUP RING 9
17 COVER 10 52 O-RING 13 1B P31
98.1 (72) 18 SOCKET BOLT 40 M12×30 53 O-RING 2 1B P29
19 O-RING 8 54 CAP 2
20 COVER 1 55 O-RING 2
21 COVER 8 56 FLANGE 2
22 PLUNGER ; AM-2 1 98.1 (72) 57 SOCKET BOLT 8 M12×25
23 PLUNGER ; BM-1 1 58 —
24 PLUNGER ; BUCKET 1 59 O-RING 2 1B P10
25 PLUNGER ; TRAVEL L&R 2 60 O-RING 18 1B P29
26 PLUNGER ; TRAVEL STRAIGHT 1 61 O-RING 8 1B G45
27 — 245 (180) 62 SOCKET BOLT 9 M16×90
28 PLUNGER ; AM-1 1 63 WASHER CD 26 M16
29 PLUNGER ; BM-2 1 245 (180) 64 SOCKET BOLT 5 M16×45
30 PLUNGER ; OPT-1 1 29.4 (22) 65 CAP 5
31 PLUNGER ; SWING 1 66 O-RING 8 1B P11
98.1 (72) 32 CAP 10 245 (180) 67 SOCKET BOLT 12 M16×100
33 SPRING GUIDE 20 147 (110) 68 CAP 1 Include 69
34 SLEEVE 10 69 O-RING 1 1B P24
35 SPRING 1 70 COVER 1
24-31
24. COMPONENTS SYSTEM
Tightening Tightening
torque No. NAME Q’ty REMARK torque No. NAME Q’ty REMARK
N•m (lbf•ft) N•m (lbf•ft)
147 (110) 71 CAP 2 107 FLANGE 1
72 O-RING 3 1B P22.4 98.1 (72) 108 SOCKET BOLT 4 M12×40
73 — 109 WASHER CD 4 M12
74 — 110 O-RING 1
78.5 (58) 75 OVERLOAD RELIEF ASSY 3 Include 60,139,140 111 COVER 1
78.5 (58) 76 OVERLOAD RELIEF ASSY 3 Include 60,139,140 112 PISTON 1
77 — 113 BACKUP RING 3
78 FLANGE 2 114 O-RING 2 1B P25
147 (110) 79 SOCKET BOLT 12 M14×45 115 SLEEVE 1
80 O-RING 2 78.5 (58) 116 CAP 1
98.1 (72) 81 MAIN RELIEF ASSY 1 Include 52 117 POPPET 1
343 (250) 82 CAP 1 118 SPRING 1
78.5 (58) 83 PLUG 1 119 —
84 — 24.5 (18) 120 CAP 1
343 (250) 85 CAP 1 121 CAP 1
86 CAP 1 122 O-RING 1 1B P8
245 (180) 87 CAP 2 123 COVER 1
88 SPRING 2 177 (130) 124 SOCKET BOLT 4 M14×80
89 CENTER BYPASS SPOOL 2 125 PISTON 1
90 COVER 2 LOAD HOLDING VALVE 126 SPRING 1
177 (130) 91 SOCKET BOLT 8 M14×40 127 PLATE 1
92 WASHER 12 M14 128 BACKUP RING 1
93 CAP 4 129 O-RING 1 1B G30
94 — 130 SPRING 1
95 O-RING 2 1B P10 131 SPRING GUIDE 1
96 — 132 SLEEVE 1
97 O-RING 2 1B G45 133 POPPET 1
98 POPPET 2 LOAD HOLDING VALVE 134 CHECK 1
99 SPRING 2 135 SPRING 1
100 SLEEVE 2 34.3 (25) 136 CAP 1
101 POPPET 2 LOAD HOLDING VALVE 137 O-RING 1
102 SPRING 2 138 BACKUP RING 1
103 BACKUP RING 2 139 BACKUP RING 6
104 O-RING 2 1B P12.5 140 O-RING 6 1B P20
105 BACKUP RING 2 141 SPRING 6
106 PISTON 2 LOAD HOLDING VALVE 142 POPPET 2
24-32
24. COMPONENTS SYSTEM
Plunger
Plunger
Plunger
Travel straight
1. BM-1, Travel switch spool : The overall lengths of spools differ from other spools.
2. Only the plungers AM-1, 2 and BM-1 equip check valve on one side end.
3. The return springs differ by the type of plunger.
24-33
24. COMPONENTS SYSTEM
24-34
24. COMPONENTS SYSTEM
VIEW Z
24-35
24. COMPONENTS SYSTEM
24-36
24. COMPONENTS SYSTEM
24-37
24. COMPONENTS SYSTEM
24-38
24. COMPONENTS SYSTEM
24-39
24. COMPONENTS SYSTEM
24.1.2.3 OPERATION
(1) Travel straight circuit
This circuit is provided to retain the straightness on traveling even if several actuators (Arm, Boom, Bucket,
Swing, Opt.) other than traveling are operated simultaneously with traveling straight.
1) Where traveling straight while operating travel plunger on right and left sides.
When only travel plunger is operated, pilot pressure of travel straight selector valve does not actuate on Pz1
port. Consequently oil from P1 port is fed to left travel and oil from P2 port is fed to right travel to allow driving
them individually for traveling straight.
24-40
24. COMPONENTS SYSTEM
Parallel passage
Parallel passage
24-41
24. COMPONENTS SYSTEM
2) When swing motion is operated under the above travel straight conditions.
Operate swing plunger, and pilot pressure of travel straight selector valve actuates on Pz1 port.
Consequently the travel straight spool is switched, P1 port is connected to right and left parallel passages,
and P2 port is connected to oil supply passage of plunger for right and left traveling.
Therefore oil from P1 port flows through parallel passage and drives swing motor, and oil from P2 port drives
right and left travel motors to hold it traveling straight.
COMBINED OPERATION
OF TRAVEL AND SWING
24-42
24. COMPONENTS SYSTEM
Parallel passage
Parallel passage
24-43
24. COMPONENTS SYSTEM
24-44
24. COMPONENTS SYSTEM
Parallel passage
Parallel
passage
Bucket conflux
check valve
24-45
24. COMPONENTS SYSTEM
Option cunflux
check valve
24-46
24. COMPONENTS SYSTEM
Parallel passage
Center
bypass
valve
Parallel
passage
24-47
24. COMPONENTS SYSTEM
Tank passage
a-2. When the pressure oil reaches to the pressure set by spring C, pilot poppet B opens, consequently oil
passes through side hole (4) and flows into tank passage.
Pilot poppet B
Spring C
Tank passage
a-3. Oil starts flowing to allow to reduce the pressure before and after orifice (2), and when the pressure of
chamber (1) pressure x d2 becomes higher than that of chamber (3) x d1 (chamber (1) pressure x
d2>chamber (3) pressure x d1), main poppet A opens and oil flows into tank passage to control the circuit
pressure to constant value.
Main poppet A
Tank passage
24-48
24. COMPONENTS SYSTEM
Spring C
Piston D
Piston A Spring C
Circular
passage
Tank passage
a-2. When the pressure oil reaches to the pressure set by spring C, pilot poppet D opens. Consequently oil
passes through side hole (4) and circular passage, and the oil flows into tank oil passage.
Pilot poppet D
Spring C
Circular
passage
Tank passage
24-49
24. COMPONENTS SYSTEM
a-3. Oil starts flowing to allow reducing the pressure before and after orifice (2), and piston A moves
rightward to allow seating it to top end of pilot poppet D.
The oil in chamber (1) passes through orifice (5) of pilot poppet D, side hole (4) and circular passage,
and flows into tank passage.
Pilot poppet D
Piston A
Circular
passage
Tank passage
a-4. The pressure before and after orifice (5) of pilot poppet D is reduced, and when the pressure of chamber
(1) pressure x d2 becomes higher than that of chamber (3) x d1 (Chamber (1) pressure x d2>Chamber
(3) pressure x d1), main poppet B opens and pressure oil in cylinder port flows into tank passage to
protect actuator.
Tank passage
b. Make up operation
Since main poppet B is retained in d1>d2 conditions, cylinder port pressure is generally higher than that
of tank pressure to allow securely seating.
When the pressure of cylinder port lowers to the pressure less than tank pressure (Cylinder port
pressure<tank pressure) (comes closer to negative pressure), main poppet B is opened by receiving the
pressure corresponding to difference of areas of d1 and d2, and oil flows into cylinder port through tank
passage to prevent cavitations.
Main poppet B
To cylinder port
Tank passage
24-50
24. COMPONENTS SYSTEM
3) Holding valve
Boom holding valve is taken as example for explanation.
a. Where plunger at neutral position, (4pc1 pilot signal: OFF)
Piston A and poppet B are retained at positions shown in figure, and passage (5) and drain port (dr2) are
blocked by poppet B. And since chamber (1) is connected to chamber (2) through orifice (4), the pressure
is equivalent to pressure Pc.
Consequently since d1 is larger than d2 (d1>d2), poppet C is seated to allow completely blocking
chambers (2) and (3).
Drain port Poppet B
Piston A
Poppet C
Boom 1 PL
Poppet C
Boom 1 PL
24-51
24. COMPONENTS SYSTEM
Drain port
Poppet B
Piston A
Poppet C
Boom 1 PL
24-52
24. COMPONENTS SYSTEM
4) Priority valve
Swing priority valve provided on arm section
a. Where swing plunger is not operated,
a-1. Where parallel passage pressure Oil supply passage pressure,
Piston (1), poppet (2), and check valve (3) are positioned as shown in the figure and securely seated.
Piston
Spring A
Spring B
Spring C
Poppet
Check valve
Supply passage
parallel passage
Spring C Spring B
Poppet
Check valve
Supply passage
parallel passage
24-53
24. COMPONENTS SYSTEM
Piston
Spring A
Spring guide
Spring B
Spring C
Poppet
Check valve
Supply passage
parallel passage
Spring guide
Poppet
Check valve
Supply passage
parallel passage
Orifice
24-54
24. COMPONENTS SYSTEM
5) Arm recirculation
Arm digging operation
a. AM-1
Plunger moves leftward and center bypass passage is blocked, consequently oil from pump passes
through parallel passage and opens poppet valve A, and is fed to head side of cylinder through high-
pressure oil supply passage.
The return oil from rod side opens the poppet of load holding valve and continues to flow. But all flow opens
the check valve C in plunger and is recirculated into head side because the tank passage is blocked by
sleeve B in manifold.
b. AM-2
Plunger moves leftward and center bypass passage is blocked, consequently oil from pump passes
through center passage and opens check valve D, and is fed to head side of cylinder through high-
pressure oil supply passage.
The return oil from rod side flows to tank passage. But the flow opens the check valve E in plunger and
recirculated into head side because the opening is restricted by plunger and the pressure increases.
Poppet A
Parallel passage
Sleeve B
Check valve C
Tank passage
Check valve D
Check valve E
24-55
24. COMPONENTS SYSTEM
6) Boom recirculation
Boom down operation
Plunger moves leftward and center bypass passage is blocked, consequently oil from pump opens check
valve A through parallel passage, and is fed to rod side of cylinder through high-pressure oil supply passage.
The return oil from head side opens the poppet of load holding valve and flows to tank passage through boost
check valve in manifold. But the flow opens the check valve B and recirculated into rod side because the
pressure is increased by boost check valve.
Check valve A
Parallel passage
Check valve B
Tank passage
24-56
24. COMPONENTS SYSTEM
24.1.3.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
PORT 1, 3 PORT 2, 4
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDLAULIC SYMBOL
24-57
24. COMPONENTS SYSTEM
24.1.3.2 CONSTRUCTION
302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
Tightening Tightening
torque No. Name Q’ty torque No. Name Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.
24-58
24. COMPONENTS SYSTEM
24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-26)
The action of spring (509) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201).
Therefore, spool (201) (for return) is pushed up by
spring (221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is that the
output pressure is equal to the tank pressure.
216
509
221
201
Fig. 24-27 When the lever is tilted
(3) Lever held (See Fig. 24-28)
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (509) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2,4)
rises above a set value, ports (2,4) and the P port
close while ports (2,4) and the T port open. When
the pressure at ports (2,4) falls below a set value, 509
ports (2,4) and the P port open while ports (2,4) and
the T port close. Thus the secondary pressure is
T PORT
kept constant.
P PORT
24-59
24. COMPONENTS SYSTEM
24-60
24. COMPONENTS SYSTEM
24.1.4.1 OUTLINE
(1) Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
(2) Specifications
P T
Item Specifications
Part No. YN30V00105F1
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
24-61
24. COMPONENTS SYSTEM
5
3
8 10
3
11 12
4
10
9
9
7 6
2
24-62
24. COMPONENTS SYSTEM
24.1.5.1 SPECIFICATION
(1) General view
Au
P
Mu
Au Mu GA(GB)
A(B)
AIR BREATHER P
PORT
Au
Dr
GB GA
B Mu A
HYDRAULIC DIAGRAM
24-63
24. COMPONENTS SYSTEM
(2) Specifications
Displacement cm (in )
3 3 151 (9.2)
Working pressure MPa (psi) 25.0 (3,625)
Max. flow L/min (gal/min) 253 (66.8)
Braking torque N•m (lbf•ft) 685~891 (505~657)
Release pressure MPa (psi) 3.1 (450)
Relief set pressure MPa (psi) 25.2 (3,654)
Weight kg (lbs) 53 (117)
Part No. LS32W00012F1
Speed reduction type Planetary 2-stage
Reduction unit
Swing unit
Mechanical brake
Relife valve
Make-up valve
By-pass valve
24-64
24. COMPONENTS SYSTEM
24.1.5.2 CONSTRUCTION
(1) Swing motor
17
41
42
SECTION A-A
15,16
32 33
A PORT SIDE
RELIEF VALVE
A PORT
b 34
g
TOP DEAD POINT h BOTTOM DEAD POINT
i
B PORT
B PORT SIDE
31 RELIEF VALVE
30 a DRAIN PORT
29
28 34 39 38 37 36 35
MAKEUP PORT
16 15
17 18
14 19
13 20
43 b
c 21
12
MECHANICAL BRAKE
11
RELEASE CHAMBER
10 d 22
9 e 23
8 f 24
7 25
6 26
5 40
4
3 2 1 27
24-65
24. COMPONENTS SYSTEM
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 INNER RING 1 23 SNAP RING 1
2 OIL SEAL 1 24 CYLINDER 1
TAPERED ROLLER
3 1 25 HOUSING 1
BEARING
4 BACKING SPRING 1 26 COLLAR 1
5 CAM PLATE 1 27 SNAP RING 1
6 RETURN PLATE 1 78 (58) 28 BYPASS VALVE ASSY 2
7 PISTON ASSY 9 29 BACK-UP RING 2
8 LINING PLATE 3 30 O-RING ; 1B P18 2
9 PLATE 3 31 O-RING ; 1B P12 2
10 O-RING 1 32 COVER 1
11 PISTON 1 78 (58) 33 RELIFE VALVE ASSY 2
12 O-RING 1 34 O-RING ; 1B P26 4
13 SPRING 19 284 (209) 35 SOCKET BOLT ; M16×60 4
14 PISTON 2 36 CHECK VALVE 2
29 (22) 15 CAP 3 37 SPRING 2
16 O-RING ; 1B P11 3 137 (101) 38 CAP 2
17 PARALLEL PIN 2 39 BACK-UP RING ; T2 P26 2
18 SCROWAVE 4 40 PLUG 1
19 TEFLON RING 4 41 PISTON 2
20 BUSH 4 42 TEFLON RING 2
21 BALANCE PLATE 1 43 O-RING 1
22 NEEDLE BEARING 1
24-66
24. COMPONENTS SYSTEM
SECTION A-A
24-67
24. COMPONENTS SYSTEM
24.1.5.3 OPERATION
16 15 MAKEUP PORT
17 18
14 19
13
20
43 b
c
21
12
11 MECHANICAL BRAKE
RELEASE CHAMBER
10 d 22
9 e 23
8 f 24
7 25
6 26
5 40
4
3 2 1 27
24-68
24. COMPONENTS SYSTEM
43 44 45 46 47 48 49
j
Piston chamber "L"
53 52 51 50
Fig. 24-30 Detail of relief valve (34)
(4) Make-up valve
1) Operation in half lever position
(When cushion relief valve does not function.)
After accelerating slewing of the upper structure, when the speed is being reduced by half-lever with the
function of control valve, the supply flow rate from pump to port A is lowered. But if the upper structure is
slewed at a comparatively high speed, the pressure in the (C) section is lowered to negative pressure making
lubrication necessary. However, when the pressure of port B is equal to or lower than the working pressure
of cushion relief valve the all oil of (C) section led through port B is discharged to the control valve. As a
result, the flow rate from the control valve (Since the valve is in the half-lever position, the flow rate from
pump is limited.) does not satisfy the specified oil quantity. To prevent this, the make-up check valve (42) is
installed to supply necessary oil into the (C) section.
2) Braking
(When cushion relief valve is functioned)
When the lever is moved to neutral position rapidly as described in item 1), the pump does not supply oil to
port A, but the upper structure is slewed by the force of inertia. In this case, the cushion relief valve on port
B side functions, and the oil from relief valve goes through the passage (i) (h) and opens make-up check
(37) valve on the port A side to flow into passage (b) (c). But the oil quantity is insufficient due to the leakage.
Therefore oil opens make-up check valve (37) through the make-up port, and flows into passage (b) (c) to
prevent cavitation.
24-69
24. COMPONENTS SYSTEM
24-70
24. COMPONENTS SYSTEM
24.1.6.1 SPECIFICATION
(1) Appearance
BEARING CENTER
VALVE PORT
2-G (PF) 1
(VA,VB)
DRAIN PORT
27-M24 2-G (PF)1/2
(D1,D2)
G (PF) 3/4
FILL PORT
LEVEL PORT OIL LEVEL
G (PF) 3/4
DRAIN PORT VIEW Y
Rotation direction
Tightening
Oil inlet Oil outlet Rotation direction Port
Port size torque Function
port port (Viewed from valve port side) name
N•m (lbf•ft)
VA VB Right (Clockwise) P PF1/4 36 (26.6) Pilot (2 speed changeover) port
VB VA Left (counter clockwise) D1, D2 PF1/2 98.1 (72.4) Drain port
VA, VB PF1 255 (188) Motor drive port
MA, MB PF1/4 29.4 (21.7) Pressure measurement
24-71
24. COMPONENTS SYSTEM
(2) SPECIFICATIONS
24-72
24. COMPONENTS SYSTEM
24.1.6.2 CONSTRUCTION
24-73
24. COMPONENTS SYSTEM
24-74
24. COMPONENTS SYSTEM
24-75
24. COMPONENTS SYSTEM
59 60 28 29 27 26 25 39 40 42 41
24-76
24. COMPONENTS SYSTEM
Fig. 24-38
(2) Parking Brake
Parking brake is released when high pressure oil, selected by the brake valve portion that is connected directly
to the rear cover (23), is applied to the brake piston (20). Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separating plates (18), inserted into the casing (1),
and friction plates (19), coupled to cylinder block (12) by the outer splines.
When no pressure is activated on the brake piston (20), it is pushed by the brake springs (54) and it pushes
friction plates (19) and separating plates (18) towards casing (1) and generates the friction force which brakes
the rotation of cylinder block (12) and hence the shaft (8).
24-77
24. COMPONENTS SYSTEM
TO COUNTERBALANCE VALVE
(BRAKE VALVE)
43 43 43
9 5 1-1 17
30
LOAD
APPLICATION POINT
10 10 11 45 33 31
24-78
24. COMPONENTS SYSTEM
CAP
CONNECTING PISTON (56-5)
PORT B (56-4)
VALVE SEAT
(56-3)
PORT A
24-79
24. COMPONENTS SYSTEM
SPRING SPRING
24-80
24. COMPONENTS SYSTEM
24-81
24. COMPONENTS SYSTEM
24-82
24. COMPONENTS SYSTEM
SPRING
SPRING
24-83
24. COMPONENTS SYSTEM
24-84
24. COMPONENTS SYSTEM
(M24X2)
VIEW Y PLUG
Do not leak oil
Tighting torque
: 36.3N.m (26.8 lbf.ft)
VIEW Z
24.1.7.2 SPECIFICATIONS
Item Specifications
Assy parts No. LS55V00008F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 370 L/min (98 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
E, F Rated flow 40 L/min (11 gal/min)
Low pressure ports Working pressure 490 kPa (71 psi)
G Rated flow 12 L/min (3.2 gal/min)
Revolution speed 12 min-1 (12 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF1
Ports size
E, F PF1/4
G PF3/4
Length : L 405.5 mm (16.0")
Weight 53 kg (117 lbs)
24-85
24. COMPONENTS SYSTEM
24.1.7.3 CONSTRUCTION
16,17
5 (0.197")
Apply Three Bond
6 #1805 to stem
2 places
5
6 places
7 8 9
10,14
4 places 3 4 2 places 4 places
24.1.7.4 OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (4) preventing both
components from falling off, cover (3) closing one side of body (1), seal (5) that partitions off the circuits and O-ring
(6), (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to stem
(2) or body (1) past the circumferential groove between body (1) and stem (2) ; the oil flow is never shut off because
of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the
body (1) from seizure with the stem (2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
24-86
24. COMPONENTS SYSTEM
24.1.8 CYLINDER
24.1.8.1 SPECIFICATIONS
(1) General view
B A
ngth ngth
e d le d le
nd cte
exte r e tra
lly lly
Fu Fu
24-87
24. COMPONENTS SYSTEM
24.1.8.2.1 CONSTRUCTION
(1) Boom cylinder
)
)
( 5.51"-0.020"
( 5.91"-0.020"
0
2
0
26
-0.5
-0.5
140 0
150 0
25 4
27
PT1/8
P/No LS01V00055F1
No. PARTS Q’ty No. PARTS Q’ty No. PARTS Q’ty
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 2
2 PIN BUSHING 1 11 DUST WIPER 1 20 O-RING: 1B G100 1
3 PISTON ROD 1 12 O-RING: 1B G160 2 21 BACKUP RING 2
4 PIN BUSHING 1 13 BACKUP RING 3 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING 1 23 SETSCREW 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M18 16
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 2
8 BUFFER SEAL 1 17 SLIPPER SEAL 1 26 WIPER PIN 2
9 U-PACKING 1 18 WEAR RING 2 27 PLUG: PT1/8 1
24-88
24. COMPONENTS SYSTEM
)
160 0 ( 6.30"-0.039"
( 6.30"-0.039"
2
0
Z
0
4
-1.0
-1.0
160 0
32 32
BORING
8-M14XP2 DP20 MIN 27
T=49 (36)
28
VIEW Z 29
31
30
DETAIL A T=353~382 (260~282)
T=14.7 (10.8) Apply Loctite #242
Apply Loctite #242 T=1860 (1370) T=981 (724)
12,13
PT1/4 24,25 23 22 19 18 17 16 20,21 15 1 3 5 7 14 6 8 26 9,10 11
PT1/8
A
ORIFICE
Fig. 24-52 Construction of arm cylinder
P/No LS01V00056F1
No. PARTS Q’ty No. PARTS Q’ty No. PARTS Q’ty
1 CYLINDER TUBE 1 12 O-RING : 1B G180 2 23 SETSCREW : M8 1
2 PIN BUSHING 1 13 BACKUP RING 2 24 CUSHION PLUNGER 1
3 PISTON ROD 1 14 O-RING 1 25 STOP RING 1
4 PIN BUSHING 1 15 CUSHION RING 1 26 SOCKET BOLT : M18 20
5 ROD COVER 1 16 PISTON 1 27 CHECK VALVE 1
6 BUSHING 1 17 SLIPPER SEAL 1 28 SPRING 1
7 RETAINING RING 1 18 WEAR RING 3 29 SPRING SUPPORT 1
8 BUFFER SEAL 1 19 DUST RING 2 30 O-RING : 1B P14 1
9 U-PACKING 1 20 O-RING : 1B G115 1 31 PLUG : PT3/8 1
10 BACKUP RING 1 21 BACKUP RING 2 32 WIPER PIN 4
11 DUST WIPER 1 22 PISTON NUT 1
24-89
24. COMPONENTS SYSTEM
)
160 0 ( 6.30"-0.039"
160 0 ( 6.30"-0.039"
4 2X4-M12XP1.75 DP18 MIN
0
0
-1.0
-1.0
2
25 25
T=255~275 (188~203)
T=14.7 (10.8)
Apply Loctite #242
T=981 (724) T=1860 (1370) Apply Loctite #242
PT1/8
P/No LS01V00057F1
No. PARTS Q’ty No. PARTS Q’ty No. PARTS Q’ty
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 2
2 PIN BUSHING 2 11 DUST WIPER 1 20 O-RING: 1B G95 1
3 PISTON ROD 1 12 O-RING: 1B G150 2 21 BACKUP RING 2
4 PIN BUSHING 2 13 BACKUP RING 2 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING 1 23 SETSCREW: M8 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M18 16
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 4
8 BUFFER SEAL 1 17 SLIPPER SEAL 1
9 U-PACKING 1 18 WEAR RING 2
24-90
24. COMPONENTS SYSTEM
Hydraulic cylinder construction (See Fig. 24-51, Fig. 24-52, Fig. 24-53)
By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (3) that takes out the
motion of pistons reciprocating in the cylinder tube assy, and rod cover (5) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a piston mount (clevis) that connects piston rod assy (3) with other parts.
In addition to these main components, slipper seal (17) and ware ring (18) are located between, cylinder tube assy
(1) and piston rod assy (3) ; buffer seal (8), rod packing (9) and dust seal (11) are located between piston rod assy
(3) and rod cover (5) ; and an O-ring and a back-up ring are placed between cylinder tube assy (1) and rod cover (5).
24.1.8.2.2 OPERATION
If pressurized oil is fed alternatively to the oil inlet and
CUSHION RING (15) CHAMBER "A" PATH "B"
outlet provided in the cylinder, force acts on the piston TANK
which in turn causes the piston rod (3) to extend and PISTON (16)
retract. ROD (3)
ROD SIDE
HEAD
(1) Operation of cylinder with cushion
SIDE
1) Cushion on rod side
The cushion mechanism is provided to prevent (5)
CUSHION STROKE ROD COVER
the generation of shock when the moving speed
of piston (16) is not reduced and strikes rod Fig. 24-54 Cushion mechanism on the rod side
cover (5).
An oil in chamber "A" returns to the tank by RESTRICTED PATH "C"
passing through paths "B" and "C" at a fixed flow CLEARANCE "D" TANK
24-91
24. COMPONENTS SYSTEM
SPRING
SPRING SEAT
PLUG
O-RING
DETAIL E
24-92
24. COMPONENTS SYSTEM
D - 10 Diode ↑
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 16 Diode ↑
D - 17 Diode ↑
E - 1 Fuse and Relay box YN24E00016F2
E - 2 Alternator VH27060E0190
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LV53S00001F1
E - 6 Horn low LV53S00001F2
(E) Electric fittings
24-93
24. COMPONENTS SYSTEM
valve
solenoid valve
(YN35V00047F1)
PSV - B P2 unload propo. valve YN35V00048F1
Solenoid valve assy
PSV - C Travel straight propo. valve ↑
PSV - D P1 unload propo. valve ↑
PSV - P1 P1 pump propo. valve (LS10V00016F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump ↑
R - 1 Battery relay YN24S00008F1
R - 2 Starter relay VHS283001271A
R - 4 Safety relay YN24S00010P1
R - 5 Horn relay ↑
R - 6 Working light relay ↑
R - 8 Travel alarm relay ↑
R - 9 Cab working light relay (For SE. Asia) ↑
R - 19 Flasher relay YY24S00001P1
(R) Reray
24-94
24. COMPONENTS SYSTEM
24-95
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
YN22E00214F1
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
YN59S00021F3
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
C-4
Controller
YN20M01468P1
Air-con Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-96
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-5
Rated voltage DC24V
Controller
Maker's (Hino) P/No. S8347-01230A
VHS834701230A
Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
Hino P/No. : 82580-8050A
YS10 - 01501 ~ (YAZAKI : 7382-1680)
Hino P/No. : 82580-8870A
(YAZAKI : 7283-1080)
C-8
Controller Maker's P/No. 89661-E0010
VH89661E0010 Rated voltage 24V (DC)
Engine controller Working voltage 16~32V (DC)
YN11 - 45001 ~ Operating voltage
(at starter ON) 9~32V (DC)
YQ11 - 06001 ~ Back-up source
(reference value) 5mA MAX (BAT=24V)
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-97
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E-1
Fuse capacity and circuit
Fuse & Relay box
YN24E00016F2
Fuse & Relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~ Front side of machine
E-2
Alternator
VH27060E0190
Generator
LS10 - 02001 ~
YS10 - 01501 ~
E-3
Hour meter Movement Quarts
Operating voltage 10~80VC
YT58S00006P1 GM terminal : 2962447
GM connector : 2962448
Service meter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-98
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 5, 6
Type ULM-24V
Horn
Rated voltage DC24V 2-o 8.5
LV53S00001F1 (High)
Operating voltage range DC26V
LV53S00001F2 (Low)
Sound level 113~118dB(A)/2m
Warning sound T2
330+20Hz high sound
LY01 - 00101 ~ Basic frequency 280+20Hz low sound
LS10 - 02001 ~ Insulation resistance More than 3M /DC500V
T1
YS10 - 01501 ~
NAME PLATE
Hi : BLUE
Lo : RED
E-7
Maker SOKEN Co,.Ltd.
Tuner
Part name AM/FM radio
YN54S00046P1
Radio (AM & FM)
(Oceania)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
E - 8, 9
Maker SOKEN Co., Ltd.
Speaker
Maker parts No. SOK104A004
YN54S00050P1
Rated input 10W
Radio
Impedance 8
LY01 - 00101 ~
Frequency 33.3Hz
LS10 - 02001 ~
YS10 - 01501 ~
E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
YN54S00041P1
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
YN11 - 45001 ~
Desiccant moisture 17% or over than the
YQ11 - 06001 ~ adsorption capability weight of desiccant
(Include initial absorption 2%)
LC10 - 07001 ~
Refrigerant HFC-134a
YC10 - 03501 ~
LQ12 - 06001 ~ Inner volume/Desiccant 578cm3/300g Inlet (From condenser)
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-99
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 11
Air-con compressor
!"#!"""
YX91V00001F1
$%&
Air-con
&"""'
YX03 - 01601 ~
() *
YX04 - 01773 ~
#+ &
YX05 - 02001 ~ ,-#%".+ /
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
E - 12
Type 145F51
Battery
Voltage 12V
YN72S00016P1
Capacity (5HR) 112Ah
Power
Weight (Incl. fluid) Approx. 33kg (72.8 lbs)
LS10 - 02001 ~
Electrolyte Approx. 9.0 L (2.38 gal)
YS10 - 01501 ~
Negative Positive
terminal terminal
(0.67")
(0.67")
Taper
Taper
17
17
17.9 19.5
(0.705") (0.768")
504 (19.84")
182 (7.17")
257 (10.1")
212 (8.35")
24-100
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 13 GND AV 0.5 Black
Model BA3111A
Alarm
Rated voltage DC 12V~36V
YN53S00004F1 Power AV 0.5 Red / Green
LC10 - 07001 ~ )
*'+#%
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~ /
0
*
LS10 - 02001 ~
YS10 - 01501 ~
E - 15
Fusible link
LC13E01175S002
Fuse
LS10 - 02001 ~
YS10 - 01501 ~
E - 27
Resistance 2
Rated voltage DC 5V
Accel redundant volume
Resistance 2 TOCOS
YN52S00052P1 Parts E-27 RA30YME20FB202
Accel redundant volume
YN11 - 45001 ~ After soldering,
insulate this part
YQ11 - 06001 ~ with heat shrinkable tube
LC10 - 07001 ~ Clip
LQ12 - 06001 ~
LL12 - 05001 ~
Fix this resistance with tape HOUSING : 172131-5
LS10 - 02001 ~ PVC tube (Black) TERMINAL : 170340-1
Dial
YS10 - 01501 ~ VIEW I
24-101
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L - 1, 6
Light (Halogen)
YW80S00001F1
Boom work light (LH, RH)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
L - 2,7
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effective area of lens 71cm2
Deck work light
Cab working light front
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
L-3
Meker Knight beam (Imasen)
Light
Type BL46-146
YM80S00001F1
Bulb DC 24V, 25W
Flasher lamp (LH)
Lighting cycle 90 times / min
Rear work light
YN11 - 45001 ~
AV0.85 W
YQ11 - 06001 ~
AV0.85 Y REAR WORKING
LC10 - 07001 ~ SWING LIGHT LIGHT
YC10 - 03501 ~
AMP PART NO.
LQ12 - 06001 ~
HOUSING : 174259-2
LL12 - 05001 ~ TERMINAL : 171661-1
LS10 - 02001 ~ AV0.85 R
HARNESS SEAL : 176886-2 AV0.85 B SWING LIGHT
YS10 - 01501 ~ LOCK PLATE : 1-174260-1 GND
VIEW I
L-4
Light
YM80S00001F2
Flasher lamp (RH)
Rear work light
YN11 - 45001 ~
YQ11 - 06001 ~ SECTION A-A
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-102
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens
YT80S00001P1
Room light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Bulb
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~ SECTION A-A Door
Switch
YS10 - 01501 ~
M-1
Motor
VHS28100E0010
Starter motor
LS10 - 02001 ~
YS10 - 01501 ~
M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
YN11 - 45001 ~ Controller
YQ11 - 06001 ~
Wiper motor 24V
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
Wiper sw
LL12 - 05001 ~ OFF-Stop
Stop signal ON-Start
LS10 - 02001 ~
Reverse signal
YS10 - 01501 ~ Electric diagram
M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 600cc (0.16 gal) / min or more
YN54C00001F1
Capacity 1.5L (0.4 gal)
Window washer
Injection pressure 88.3 kPa (12.8 psi) or more
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-103
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A
YN24S00008F1 Exciting current 0.4A or less / 24V
Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
YN11 - 45001 ~ Closed circuit voltage 16V or less VIEW I
Terminal B
YQ11 - 06001 ~ Open circuit voltage 7V or less GND terminal
HOUSING AMP
LC10 - 07001 ~ 174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
YC10 - 03501 ~ 1-174360-7
TERMINAL AMP
LQ12 - 06001 ~ 171661-1
WIRE PROOF PLUG AMP
LL12 - 05001 ~ 172888-2
Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)
Tape
M6
24-104
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R - 4,5,6,8,9,23,24,25,
26,28,45 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
YN24S00010P1
Rated voltage DC 24V
Safety relay
Horn realy Contact 1C
Work light relay * Accessory of relay box
Travel alarm relay
Cab working light relay
Auto idle stop relay 1, 2
Engine emergency stop relay Pin assignment
Lever lock relay
Alternator relay
Boom cyl. working light relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~ Terminal arrangement
YS10 - 01501 ~
R - 19
Relay
YY24S00001P1 UPPER
Flasher relay
YN11 - 45001 ~
YQ11 - 06001 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
TERMINAL NUMBER
R - 29,30,31,32
Maker's P/No. V23134-A0053-C643
Relay
Parts name Relay
YN24S00012P2
Rated voltage DV 24V
Wiper motor relay
Contact 1C
Washer motor relay
YN11 - 45001 ~ * Accessory of relay box
YQ11 - 06001 ~
Pin assignment
LC10 - 07001 ~
YC10 - 03501 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-105
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R - 39
Relay
VH286201430A
Air heater relay
LS10 - 02001 ~
YS10 - 01501 ~
SE - 1 ~ 5, 7 ~ 11,20
Pressure sensor
(Low pressure)
!
LC52S00019P1
Bucket dig and dump,
( )* +, - "$$-+"
Boom up and down, ' +, -
" "*+- "$$-+" .-(/-
Swing, +- $(/ $
"$$-+"$ 0"1*$% 2 3#45653#&
+- $(/ 2 4545#
Arm in and out, & " 0-7 &4 %"/ /(+-
Travel RH and LH and other 3 "1+ 1+ 0( $-** *-(/ 2 45656#&
YN11 - 45001 ~ "8-
YQ11 - 06001 ~
"# $% .&!
LC10 - 07001 ~ &' &&
YC10 - 03501 ~
LS10 - 02001 ~
YS10 - 01501 ~
SE - 13
Output voltage 2.8V or more
Speed sensor
Clearance 1.0mm
VHS894101290A Sumitomo : 090-II (4P : B)
E/G speed sensor P/No. : 6188-0265
Hino. P/No.
YN11 - 45001 ~ Sensor side : 82580-6120A (B)
YQ11 - 06001 ~ Harness side : 82580-6130A (B)
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~ M16 x 1 Hex. : 17
LS10 - 02001 ~
Hex. : 22
YS10 - 01501 ~ Tightening torque : 47N.m (34.7 lbf.ft)
24-106
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SE - 15
Float operation
Fuel sending unit
Float Resistance
YN52S00045F1 +0.1
FULL 10 -0.6
Fuel level
3/4 (19)
YN11 - 45001 ~
YQ11 - 06001 ~ 1/2 32+5
LC10 - 07001 ~ 1/4 (49.5)
YC10 - 03501 ~ EMPTY 85 +10
0
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
Float
SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage
YN11 - 45001 ~
YQ11 - 06001 ~ Notch part
LC10 - 07001 ~
YC10 - 03501 ~ Potentio
LQ12 - 06001 ~ 3MA JM II + AMP
Bracket
HOUSING : 174359-2
LL12 - 05001 ~ TERMINAL : 171661-1
LS10 - 02001 ~
YS10 - 01501 ~ Dial
24-107
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
PSV - A, B, C, D
Proportional solenoid valve
Hydraulic solenoid valve
Hydraulic symbol A5 to A8
(YN35V00047F1)
YN35V00048F1
YN35V00049F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
HYDRAULIC SYMBOL
Arm 2 speed
P1 unload
Travel straight
P2 unload
Attachment boost
Swing parking
Lever lock
PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
YN35V00052F1 TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
Pump P1, P2 HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
YN11 - 45001 ~
YQ11 - 06001 ~ Rated voltage DC 24V
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~ Sleeve O-ring Solenoid Seal nut
LL12 - 05001 ~ 1B P20
LS10 - 02001 ~
YS10 - 01501 ~
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
Rated voltage DC 24V
valve (8 spool) assy pressure
Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A4 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YN35V00047F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-108
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 1 Auto return
Switch
Connection
YN50S00026F1 Terminal
Position
Starter switch
Auto return
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
VIEW A Terminal
YC10 - 03501 ~
arrangement
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
YN50S00047P1 Rated DC30V, 10A
Swing parking brake Insulation resistance
release
YN11 - 45001 ~ Vinyl tube
T No. YAZAKI
YQ11 - 06001 ~ Contact construction : Position 7122-2237
Red (2)
LC10 - 07001 ~ 7114-2020
Swing parking release
YC10 - 03501 ~
Normal
LQ12 - 06001 ~
LL12 - 05001 ~
White (3) Blue (1)
LS10 - 02001 ~
YS10 - 01501 ~
SW - 5, 10, 20, 21
)* +,
Switch ,
(-
YN03M01861F1
(Right grip)
! "# #$
% % &
YN03M01862F1 '$! (
(Left grip)
Horn, ATT Power boost
LC10 - 07001 ~
YC10 - 03501 ~
(( (, ./01,+ 23*" 4 (5
LQ12 - 06001 ~ (( (,
%#6,+ 7 "*8 7
LL12 - 05001 ~ 6 4(( (
9 '"5
LS10 - 02001 ~
YS10 - 01501 ~
SW - 7
Type Normal close
Switch
Working pressure 39.258.8kPa (5.7~8.5psi)
VHS83530E0220
Rating DC24V / 12W
E/G oil pressure switch More than 100M /
Insuration resistance DC500V megger
LS10 - 02001 ~
YS10 - 01501 ~
24-109
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 8
Switch
YR11P00008S005
Air cleaner
Clogging switch
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 11
Switch
YN50S00041F1
Lock lever
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ !
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
!
"#
SW - 13
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040DF Type (alternate)
Travel alarm (Australia) More than 1M /
Insulation resistance DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~
Terminal connector
LC10 - 07001 ~ Connector
YC10 - 03501 ~ Position
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 15
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040DD Type (alternate)
Conflux / single flow More than 1M /
Insulation resistance DC500V megger UP
switching (OPT)
YN11 - 45001 ~
Terminal connector
YQ11 - 06001 ~ Connector
Position
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-110
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 17
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040D9 Type (alternate)
Roof window wiper More than 1M /
Insulation resistance DC500V megger UP
switch (OPT)
YN11 - 45001 ~
Terminal connector
YQ11 - 06001 ~ Connector
Position
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 19
Switch
Rated voltage DC 12V
YT50S00004P1
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
YN11 - 45001 ~
Insulation resistance 5M or more
YQ11 - 06001 ~
Operation force Initial motion 0.8+0.3
0 kg
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~ Max. stroke
SW - 26
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040D4 Type (alternate)
Cab work light switch More than 1M /
Insulation resistance DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~
Terminal connector
LC10 - 07001 ~ Connector
YC10 - 03501 ~ Position
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 27
Purpose Coolant level detection
Switch
Working temperature -40 ~130
VHS834601510A
Coolant level switch Hino P/No. : 82580-71708
Sumitomo P/No. : 6188-0110
YN11 - 45001 ~
YQ11 - 06001 ~ Electrode side
LC10 - 07001 ~
YC10 - 03501 ~ CONNECTOR
LQ12 - 06001 ~
Housing side
LL12 - 05001 ~ (To ground) Mating connector
LS10 - 02001 ~ M18, P=1.5 Hino P/No. : 82580-71808
YS10 - 01501 ~ Sumitomo P/No. : 6189-0189
24-111
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 55
Switch
YN50S00040D1
Boom work light switch
!"" %$
#
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
#
YC10 - 03501 ~ $
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-112
25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
25.8 TROUBLESHOOTING.....................................................................................................25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.3 EXPLANATION OF MONITOR MODE...................................................................25-46
25-1
25. AIR-CONDITIONER SYSTEM
25-2
25. AIR-CONDITIONER SYSTEM
• Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air
blows off from grille through duct.
• Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows
in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.
25-3
25. AIR-CONDITIONER SYSTEM
COMPRESSOR
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
25-4
25. AIR-CONDITIONER SYSTEM
27
33 30
27-1
40
32
39
27-3 27-4
27-2
35
35-8 35-6
35-1
34 35-7
35-10 35-9
25-5
25. AIR-CONDITIONER SYSTEM
25.2.2 CONSTRUCTION
(1) Air conditioner unit
49
47
48
46 44
31
42 31
41
50
3 1
45 1
A
1 32 43
39
37
38
36
40
B
2
33
25-6
25. AIR-CONDITIONER SYSTEM
14 16
6 1 1 31
1
5
15
1
31
62
1 3
1 1
D
E 4
7
28 1
A 1 1
27
1
20
26
13
C 60
11
29
23
21 22
24 82
24
83
51 54 79
9 63
78 23 C 84 61
17
E
18
31
D
B
10
19
12
1 25
3
31
77
25-7
25. AIR-CONDITIONER SYSTEM
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1
25-8
25. AIR-CONDITIONER SYSTEM
25.3 PIPING
25.3.1 AIR CONDITIONER
30
NOTE
40 1. Apply oil for refrigerant R134a to the
O-rings of all air-conditioner hose fittings.
2. Refrigerant volume : 1010 50g
3. T : Tightening torque N.m(lbf.ft)
27
C 2
B
A
15
17 6
1
12
25
2
13 59
25
39
58 25
25
24 25 25
D 1
49
24
17
6
6
8
15
A 8
55 17
1
2
24
5
8
8
6
8 54
B 63
62 25
JAM NUT FOR 49
TENSION PULLEY 14
T=46.5 (34.3) 61
32 6
60 34
21 9
L 10
33 18
13
4 2 25
INITIAL BELT
TENSION 22 5
When the belt is 15
pushed by the 35
force of 27N,
adjust the 25 7
deflection of 14 8
L part to be 56
2mm (0.079in). 57
12 3
1
5 25
17
61
C D
Fig. 25-5
25-9
25. AIR-CONDITIONER SYSTEM
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Hose : L = 3200 1 27 Air conditioner assy 1
2 Hose : L = 4300 1 30 Panel 1
3 Bracket 1 32 Compressor assy 1
4 V-belt : B-42 1 33 Pulley assy 1
3.92~4.9 (2.9~3.6) 5 Clip 4 34 Condenser 1
46.5 (34.3) 6 Sems bolt : M10×25 6 35 Air dryer assy 1
4.9 (3.6) 7 Sems bolt : M6×20 2 39 Filter 1
8 Sems bolt : M8×20 7 40 Solar radiation sensor 1
23.0 (17.0) 9 Capscrew : M8×100 4 49 Clip 3
10 Washer 4 54 Grommet 1
12 Tube for heater : L = 2300 1 55 Grommet 1
13 Tube for heater : L = 3300 1 4.4 (3.2) 56 Capscrew : M6×50 4
14 Tube for D hose : L = 3000 1 57 Washer 4
15 Tube for S hose : L = 2300 1 58 Tube for L hose : L=100 1
17 Tube for L hose : L = 2700 1 59 Clip 1
18 Tube for L hose : L = 1200 1 60 Clip 1
21 Bracket 1 46.5 (34.3) 61 Sems bolt : M10×30 2
46.5 (34.3) 22 Sems bolt : M10×35 3 62 Plate 1
24 Clip 4 23.0 (17.0) 63 Sems bolt : M8×25 2
25 Clip 19
32 COMPRESSOR ASSY
L TUBE (10)
25-10
25. AIR-CONDITIONER SYSTEM
C
6
A 7 5
12
6
5
8
8 B
8
5
A
4
7 9
3
10
2 5
1
6
8
B C
Fig. 25-6
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
3 Capscrew 2 9 S tube 1
4 Capscrew 2 10 L tube 1
5 S hose 1 12 L tube 1
6 D hose 1
25-11
25. AIR-CONDITIONER SYSTEM
25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows
Chemical formula CH2FCF3
through the cooling circuit changes its phases from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
(compartment) to the high temperature part
Critical density 511 kg/m3 (31.9lb/ft3)
(outside of the vehicle). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Many kinds of refrigerants that change in that Specific volume of saturated
0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient 0
• It is easy to liquefy (condense). (It dose not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)
• It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
• It has small specific heat. (Since the
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held
down to a minimum.)
• It has a high critical temperature and a low
solidification point.
• It is stable chemically and does not corrode
and permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-
mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used,
sufficient refrigeration will not be performed
or the equipment in which the refrigerant is
used may be broken. Therefore, always use
a designated refrigerant for the cooling unit.
Table shows the principal characteristics of
the R134a refrigerant that is used in this
machine.
25-12
25. AIR-CONDITIONER SYSTEM
25-13
25. AIR-CONDITIONER SYSTEM
effect is attained.
For instance, in order to cool the air to 15°C (59°F), the
refrigerant can not absorb evaporation heat from the air RECEIVER
DRYER
unless it evaporates at a temperature lower that 15°C
(59°F). For that purpose, it can be seen from Fig. 25-7 CONDENSER
that the pressure of the refrigerant in the evaporator
must be less than 0.51 MPa (74psi). Fig. 25-8 Construction of cooling circuit
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and
turns into dry vapor.
Consequently, the cooling circuit is so constructed that
the evaporator can cool down an object (air in this case)
sufficiently (i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of refrigerant
can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The
compressor acts as a pump that allows the refrigerant
to circulate. The compressive action of the compressor
and the heat exchange (heat radiation) action of the
condenser transform the refrigerant in a dry vapor state
back to a liquid state.
25-14
25. AIR-CONDITIONER SYSTEM
25-15
25. AIR-CONDITIONER SYSTEM
25-16
25. AIR-CONDITIONER SYSTEM
25-17
25. AIR-CONDITIONER SYSTEM
25-18
25. AIR-CONDITIONER SYSTEM
1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)
25-19
25. AIR-CONDITIONER SYSTEM
Fig. 25-15
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.
CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-16
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING
AIR MIX
ROD SUB
AIR MIX
ROD SUB
Fig. 25-17
25-20
25. AIR-CONDITIONER SYSTEM
Fig. 25-18
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.
EVAPORATION SENSOR
Fig. 25-20
25-21
25. AIR-CONDITIONER SYSTEM
Fig. 25-23
25-22
25. AIR-CONDITIONER SYSTEM
Fig. 25-24
25-23
25. AIR-CONDITIONER SYSTEM
• Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it
with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
25-24
25. AIR-CONDITIONER SYSTEM
(3) Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side
Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter
25-25
25. AIR-CONDITIONER SYSTEM
Fig. 25-25
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when BLUE
sound is heard.
CHARGING
3) Connect the center valve of the gauge manifold
HOSE
with the charging hose of the vacuum pump. (GAS VALVE)
25-26
25. AIR-CONDITIONER SYSTEM
25-27
25. AIR-CONDITIONER SYSTEM
• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)
25-28
25. AIR-CONDITIONER SYSTEM
25-29
25. AIR-CONDITIONER SYSTEM
25-30
25. AIR-CONDITIONER SYSTEM
25-31
25. AIR-CONDITIONER SYSTEM
NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)
MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING
FUSE 5A
COMPRESSOR
JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111
25-32
25. AIR-CONDITIONER SYSTEM
EVA SENSOR
SUN SENSOR
MOTOR ACTUATER
(FOR AIR MIX)
MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)
BLOWER MOTOR
BLOWER AMP
MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY
25-33
25. AIR-CONDITIONER SYSTEM
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
(1) Control panel and control unit
The control unit is integrated into control panel, and
processes the signal input by each sensor, etc. and
the signal input by each switch through control
panel with the function of the built-in micro
Fig. 25-34
computer, and comprehensively controls each
actuator (Inner and outer air flow select, air mix),
fan motor and compressor on the output side.
And the self-diagnosis performance is provided to
facilitate the trouble shooting.
TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)
In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-35
* The installing position is provided on the left side
of air-con unit.
25-34
25. AIR-CONDITIONER SYSTEM
(3) Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control. Fig. 25-36
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
this relay has polarity.
5. Inspection: Inspect the continuity between 3
and 4 according to the conditions mentioned
below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2: Not
continued
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.
When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR
25-35
25. AIR-CONDITIONER SYSTEM
0.02MPa(2.9psi) 0.59MPa(86psi)
ON
OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
25-36
25. AIR-CONDITIONER SYSTEM
25.8 TROUBLESHOOTING
"HL.*" is shown on the set temp. . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
A snow mark ( ) on A snow mark ( )
the panel is flashing. on panel is flashing. Inspect and correct or replace parts.
NO YES
. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.
A
NO YES
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch
eliminate cause, correct on and off. Inspect and
correct electric circuits. Controller is faulty Inspect duct or
and measure operating or inner air sensor eliminate cause for
force. (less than 14.7N : OK) is faulty. cool air intrusion.
Refer to Troubleshooting
for refrigeration cycle.
Inspect and replace.
NO YES
25-37
25. AIR-CONDITIONER SYSTEM
NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES
NO YES
Inspect and replace.
25-38
25. AIR-CONDITIONER SYSTEM
NO YES
Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES
Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES
25-39
25. AIR-CONDITIONER SYSTEM
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 ~ 9.
NO YES
CASE (2)
YES NO
25-40
25. AIR-CONDITIONER SYSTEM
Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.
No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes
Replace
25-41
25. AIR-CONDITIONER SYSTEM
25-42
25. AIR-CONDITIONER SYSTEM
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES
High pressure
is lower.
NO YES
Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.
25-43
25. AIR-CONDITIONER SYSTEM
2) MODE is flickering.
3) R/F is flickering.
Check harness or connector to motor actuator for the inner and outer
air damper for disconnection.
Note) The above indication and flickering does not function if the
harness and connector were disconnected under the condition
the panel ON/OFF switch is ON.
After the failure was occured, if the panel ON/OFF switch is
turned ON, it functions.
After correction of failure, if the main switch is not switched from
OFF to ON the error indication and flickering are not released.
25-44
25. AIR-CONDITIONER SYSTEM
Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the
condition the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.
25-45
25. AIR-CONDITIONER SYSTEM
ON/OFF SW
1) Press inner and outer air flow select switch and ON/OFF switch simultaneously for 1 second.
2) Press AUTO switch.
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3) Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd
digit of segment in three digits. The 1st digit is indicated by "H".
4) Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing
UP or DOWN of blower switch, and the required sensor is selected from the list below.
1 EVAPORATOR SENSOR
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF
switch for 1 second again, or turning off the main switch of excavator.
Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.
25-46
25. AIR-CONDITIONER SYSTEM
THIRD SEGMENT
SECOND SEGMENT
When the segment exclusively used for monitor indicates 0
(displays the inner air sensor condition),
since the segment indicates 3F, the sensor is in normal
operating condition according to the list of 3 segments.
--> The inner air sensor is in normal operating condition.
2) Example 2
3) Example 3
4) List of 3 segments
SECOND SEGMENT
25-47
25. AIR-CONDITIONER SYSTEM
[MEMO]
25-48
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
31
31-1
31. DISASSEMBLING AND ASSEMBLING
31-2
31. DISASSEMBLING AND ASSEMBLING
31-3
31. DISASSEMBLING AND ASSEMBLING
[MEMO]
31-4
32. ATTACHMENT
TABLE OF CONTENTS
32
32-1
32. ATTACHMENT
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
32-2
32. ATTACHMENT
(D) ARM CYLINDER HEAD PIN (C) BOOM CYLINDER ROD PIN
(A) BOOM FOOT PIN
4. BOOM
ARM CYLINDER
(E) ARM CYLINDER
ROD PIN
3. ARM
32.1.2 BUCKET
32-3
32. ATTACHMENT
32-4
32. ATTACHMENT
(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0mm (0.04in).
32-5
32. ATTACHMENT
32.1.3 ARM
: 30mm 9
: 30mm
3
32-6
32. ATTACHMENT
: 30mm
B
B
F
SECTION B-B
32-7
32. ATTACHMENT
CLEARANCE
: 32 mm
Tightening torque
Classification Size
N.m (lbf.ft)
Metric Boom top pin use M20 539 (398)
threads Double nut use M20 181 (134)
PF,PT threads 1/8" 16.7 (12.3)
32-8
32. ATTACHMENT
32.1.4 BOOM
BLOCK
STAND
32-9
32. ATTACHMENT
:8, 12, 14 mm A4
A3
After disconnection of pipe, plug every pipe.
A1
Half clamp plug : See Tools 11.5.2-(5) O-RING
A2 A17
A7
O-RING ARM (H)
A9 ARM (R)
A8
BUCKET (H)
BUCKET (R)
A A
: 36 mm
32-10
32. ATTACHMENT
D
D
:12, 14 mm
SHIM
After adjustment
of shim, the total
gap should be
3) Removing arm cylinder head pin (D) Apply grease
with in 0.6~1.0mm
(0.02~0.04in).
Loosen nut (3), remove capscrew M20×200 (2) to inner wall
of bushing D
and pull out pin (D). SECTION D-D
Fig. 32-21 Removing arm cylinder
: 30mm
32-11
32. ATTACHMENT
: 36,41mm C2
C2
C2
Fig. 32-22 Removing and installing boom cylinder
4) Removing boom cylinder foot pin (B)
After adjustment of shim,
(See Fig. 32-23,Fig. 32-24) the total gap should be within
0.6~2.0mm (0.02~0.08in).
Loosen nut (5), remove capscrews M20×200 (4) SHIM
and pull out pin (B).
4
B B
: 30mm
5
5) Remove boom cylinder (2). Apply grease to
inner wall of bushing
Weight of boom cylinder : 396 kg (873 lbs)
6) Remove another boom cylinder the same way. SHIM
SECTION B-B Install plastic shim
to cylinder side.
Fig. 32-23 Removing and installing boom cylinder
head pin (B)
32-12
32. ATTACHMENT
32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in its
most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head
and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent
damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak
tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
32-13
32. ATTACHMENT
• For the details of special tools and jigs, refer to the back pages of this manual.
AIR
OIL PAN
Fig. 32-26 Preparation
32-14
32. ATTACHMENT
)
160 0 ( 6.30"-0.039"
( 6.30"-0.039"
2
0
Z
0
4
-1.0
-1.0
160 0
32 32
BORING
8-M14XP2 DP20 MIN 27
T=49 (36)
28
VIEW Z 29
31
30
DETAIL A T=353~382 (260~282)
T=14.7 (10.8) Apply Loctite #242
Apply Loctite #242 T=1860 (1370) T=981 (724)
12,13
PT1/4 24,25 23 22 19 18 17 16 20,21 15 1 3 5 7 14 6 8 26 9,10 11
PT1/8
A
ORIFICE
Fig. 32-27 Construction of arm cylinder
P/No LS01V00056F1
No. PARTS Q’ty No. PARTS Q’ty No. PARTS Q’ty
1 CYLINDER TUBE 1 12 O-RING : 1B G180 2 23 SETSCREW : M8 1
2 PIN BUSHING 1 13 BACKUP RING 2 24 CUSHION PLUNGER 1
3 PISTON ROD 1 14 O-RING 1 25 STOP RING 1
4 PIN BUSHING 1 15 CUSHION RING 1 26 SOCKET BOLT : M18 20
5 ROD COVER 1 16 PISTON 1 27 CHECK VALVE 1
6 BUSHING 1 17 SLIPPER SEAL 1 28 SPRING 1
7 RETAINING RING 1 18 WEAR RING 3 29 SPRING SUPPORT 1
8 BUFFER SEAL 1 19 DUST RING 2 30 O-RING : 1B P14 1
9 U-PACKING 1 20 O-RING : 1B G115 1 31 PLUG : PT3/8 1
10 BACKUP RING 1 21 BACKUP RING 2 32 WIPER PIN 4
11 DUST WIPER 1 22 PISTON NUT 1
32-15
32. ATTACHMENT
32.2.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder,
check the construction and the availability of
service parts as well as necessary tools and jigs
on separate Parts Manual.
• The figures in parentheses after part names
correspond to those in .
• The following explanation and quantities are for
a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined,
the construction differs from separated type,
refer to the sentence in parenthesis.
(2) Pull out piston rod (3) about 200mm (8in). Because
the piston rod is heavy, finish extending it with air
200mm
pressure after the above-mentioned oil draining (8")
operation.
(3) Loosen and remove socket bolts (26) of the rod
cover in sequence.
Fig. 32-28
Cover the extended piston rod (3) with cloths to prevent
it from being accidentally damaged during operation. ALLEN WRENCH 26
Turn counterclockwise
5
Cover here with cloths
3
Fig. 32-29
32-16
32. ATTACHMENT
• At this time, the weight of piston rod (3) is loaded KNOCK THIS EDGE
on rod cover (5). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the
rod weight may be held.
5
3
Fig. 32-30 Drawing out piston rod assy (3).
(5) Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
Since the piston rod assy is heavy in this case, lift the HORIZONTALLY
tip of the piston rod (3) with a hoist and draw it out.
However, when piston rod (3) has been drawing out to
approximately two thirds of its length, lift it in its center OIL PAN
to draw it completely. However, since the plated surface
Fig. 32-31 Method of drawing out the piston rod
of piston rod (3) is lifted, do not use a wire rope which
assy
may score the surface, but use a strong cloth belt or a
rope.
19
18
Fig. 32-33 Remove wear ring (18) and dust ring (19)
32-17
32. ATTACHMENT
22
23
TURN COUNTER
Since piston nut (22) is tightened to a high torque, use
CLOCKWISE.
a hook wrench suitable for the outside diameter of 16
piston nut (22) . Use care so the hook of the wrench is EYE WRENCH
22
positively fixed in the groove of the piston nut perimeter.
Fig. 32-36 How to loosen piston nut (22)
32-18
32. ATTACHMENT
Cut the seal ring (17-1) by tapping it with a screwdriver SCREWDRIVER (OR CHISEL)
or a chisel. Take care not to strike it too hard, otherwise
SEAL
the groove may be damaged. BACK-UP RING RING
(NYLON) 17-3 (TEFLON)
17-1
20
32-19
32. ATTACHMENT
11
WOOD PIECE
WOOD PIECE
VISE
32-20
32. ATTACHMENT
4 BASE
32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with
commercial detergent.
(2) Do not use the used oil seal, O-ring, back-up ring,
etc. even if they are not damaged after inspection.
(3) After cleaning, dry all parts by compressed air, and
put them on the working bench taking care not to
damage them.
32-21
32. ATTACHMENT
Since it is hard to deform seal ring (17-1) in room
temperature, immerse and soften it in hydraulic oil
heated about 150 to 180 C degrees. Therefore slip it in
piston seal groove quickly with fitting jig so as not to be
cooled. Fig. 32-47 Attaching seal ring (17-1)
To avoid burn, wear gloves when fitting the heated seal
ring (17-1), and fit it quickly. And the hydraulic oil must
be heated with electric heater. (Do not use fire. There is
a danger.)
(3) Shrink the seal ring (17-1) to the original size using
correcting jig.
(4) Fit back-up rings (17-3) to both sides of seal ring.
Make sure about the fitting direction of back-up ring.
(5) Fit O-ring and back-up ring (2 places) to the bore
side. Fig. 32-49 Direction of components
(2) Apply grease to dust seal (11), or the hole of rod PRESS HERE. (STRAIGHT DOWN)
cover (5), and fit dust seal (11) to the bottom of the
PRESSING JIG Press metal
hole. At this moment, press the metal ring of dust
ring.
seal (11) with a jig.
11
RUBBER
CLIP
METAL RING
32-22
32. ATTACHMENT
(3) Fit buffer seal (8), back-up ring (10) and rod- INSERT U-RING INTO GROOVE FROM THIS SIDE.
packing (9) in their grooves in that order. Before
setting packings, coat them with hydraulic oil (or
vaseline if not available). If you forget the coating,
the packings may be scored. When attaching seals,
deform them in a heart shape as illustrated.
9
10
11
Fig. 32-52 How to fit rod-packing (9)
(2) Install rod cover (5) on piston rod (3) with inserting
guide jig as shown in Fig. 32-53 paying attention for
3
the lip section of dust seal not to be caught on the
stepped section.
Fig. 32-53 Inserting rod cover (5)
32-23
32. ATTACHMENT
22 V-BLOCK
32-24
32. ATTACHMENT
: 14 mm
ALLEN WRENCH
TURN CLOCKWISE
Fig. 32-59 Tightening socket bolts (26)
32-25
32. ATTACHMENT
port and store the cylinder. (Fig. 32-62)
32-26
32. ATTACHMENT
1) Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep as
may be caught by your nail.
2) In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone.
If the score or the indention is excessive, replace or replate the damaged part.
• Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.
32-27
32. ATTACHMENT
32-28
32. ATTACHMENT
32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause Remedy
1. Oil leak through sliding 1. Rod-packing 1. Foreign matter is trapped in the 1.Remove foreign matter.
surface of piston rod. Oil bore of rod packing.
ring is formed on piston 2. Score is present on the bore of rod 2. Replace rod packing.
rod, and the ring grows up packing.
to oil drops, and they drip. 3. Other rod packings are failed. 3. Replace rod packing.
2. Buffer seal 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of buffer seal.
OIL LEAKS FROM HERE 2. Score is present on the bore of 2. Replace buffer seal.
buffer seal.
3. Other buffer seal are failed. 3. Replace buffer seal.
3. Dust seal 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of dust seal.
2. Lip on the bore of dust seal is 2. Replace dust seal.
scored.
3. Another dust seal is failed. 3. Replace dust seal.
4. Piston rod 1. Score is present on the sliding 1.Smooth out the sliding surface with
surface of piston rod. an oilstone. If leakage occurs even
if the sliding surface is finished
below 1.6S, rod packings may be
scored. Disassemble and inspect it
and replace rod packings as
required.
If leak will not stop by that
treatment, replace piston rod.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged. 1. Replace O-ring.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube. 1. Replace cylinder tube.
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is trapped in the 1. Remove foreign matter
[When the rod is loaded with sliding surface of slipper seal.
a static load equal to the 2. Score is present on the sliding 2. Replace slipper seal.
maximum working pressure surface of slipper seal.
multiplied by the area of the 3. Other back-up ring are failed. 3. Replace back-up ring.
cylinder bore, the maximum 1. Sliding surface of wear rings is
movement of the piston is 2. Wear ring scored.
1. Replace wear ring.
more than 0.5mm (0.02") in
3. O-ring 1. O-ring is damaged. 1. Replace O-ring.
ten minutes.]
32-29
32. ATTACHMENT
Fig. 32-64
B
A
MATERIAL : SNCM6 OR SCM3
SURFACE TREATMENT : PARKERIZING
C
Fig. 32-65
Table32-5
Unit : mm (inch)
CYLINDER USED A B C SOCKET BOLT
BOOM, ARM, BUCKET 140 (5.51) 56 (2.20) 14 (0.551) M16
A
B
C
D
32-30
32. ATTACHMENT
E
Plate thickness :
Plate thickness :
32-31
32. ATTACHMENT
R10
(0.39")
D
C
B
Fig. 32-69 Rod cover inserting jig
Table32-9
Unit : mm (inch)
CYLINDER USED A B C D E F G
About 12 F
R10
(0.39") G
A
B
32-32
32. ATTACHMENT
R10
F (0.39")
E
HANDLE
D
G
A About 5~ 10
B
D
C
A
B
32-33
32. ATTACHMENT
32-34
33. UPPER STRUCTURE
TABLE OF CONTENTS
33-1
33. UPPER STRUCTURE
PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding
the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize
the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component
and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in
specification.
33-2
33. UPPER STRUCTURE
33.1.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
A1-1
seat (A1) to ease handling.
2) Move the whole control stand to its foremost A1
position.
3) Move the operator’s seat to its forward end. C1
4) Incline the reclining seat as forward as possible.
C2
(2) Remove operator’s seat. (Include upper rail.) B2
C1
1) With the above-mentioned condition, remove C2
two cap screws (B2) M8×20 from the upper rail.
Then move the control stand to its rearmost end
and remove two capscrews (B2) M8×20.
1
: 6 mm
2) Remove the operator’s seat. [about 20kg (44 8
lbs).]
Carry out the following operations as required.
3) Remove seat belt (C1).
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (8).
33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to
the tightening torque table.
A4 A5
Allen Tightening torque
Tightening position wrench
HEX N·m (lbf·ft)
A2
Capscrew (B2) 6 23.5 (17.3)
Sems bolt (C2) 17 46.1 (34) A6
33-3
33. UPPER STRUCTURE
33.1.2 CAB
33.1.2.1 REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7)
Lift cover (A7) upwards and remove it. (Fixed with
2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6×16 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1). A22
(4) Remove the harness connector (See Chapter 23) A1
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71) (CN-72) and (CN-500)
at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 33-3 Disassembly and assembly of cover (A7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
(6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6×25 and 1 sems bolt (A39) M6×16. And right A3
A14
panels (A4) and (A4-1B) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed
A22
with 3 clows and 2 clips)
B2
3) Unfix 3 harness clips (A4-1H) of inside on right A40
A4-1H
panel (A4-1B). And free the harnesses A29
A4
connected to key switch.
A4-1H A39
4) With harnesses are connected condition, install A40
key switch cover (A3) to bracket (A1) of rear cab A4-1H
temporally. (See Fig. 33-5)
5) Disconnect harness connectors of work light A29 A4-1B
switch on right panel (A4), air conditioner panel
and cigarette lighter, and remove right panel (A4) A22
and (A4-1B). (See Chapter 23)
6) Loosen sems bolts (A22) M6×16 and (A23)
M6×40 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver
A5-2
A23
Fig. 33-4 Disassembly and assembly of right panels
(A4-1B), (A3) and (A5-2)
33-4
33. UPPER STRUCTURE
RELAY BOX
ASSY
33.1.2.2 INSTALLATION
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 79.4 (60
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)
33-5
33. UPPER STRUCTURE
33.1.3 BATTERY
33.1.3.1 REMOVING
(1) Open left panel assy (71), (73).
1) Open it with starter key.
2) Open left panel assy (71), (73).
3) Fix it with stay.
: 17 mm
(3) Remove battery cable
1) Remove cable (A7) [between the earth and 73
battery (–)]. 71
(Always remove (-) terminal first and install it at
Fig. 33-8
last.)
2) Cable (A8) [between battery (+) and (-)] 2 7
3) Cable (A5) [between battery (+) and battery
relay]
: 13 mm
3
A8 4
: 17 mm
2) Remove plate (3).
3) Remove battery (B1). B1
33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (3) against battery (B1), and
tighten capscrew (4).
: 17 mm,
Tightening torque : 10.8N•m (8.0 lbf•ft)
(2) Installing grounding cable
Install grounding cable (A7) last. Especially care
must be taken that the grounding face is free from
painting, rust, etc.
: 13 mm
33-6
33. UPPER STRUCTURE
33.1.4 GUARD
5
73 2
6 1
71
: 19 mm
8
Weight : 74kg (163 lbs) 8
4) Remove 6 sems bolts (6) M12×30. A B
5) Remove bonnet (2). Fig. 33-11 Removing bonnet assy (1), (2)
: 19 mm
Weight : 24kg (53 lbs)
(2) Remove guard (7)
38 7
38
1) Remove 6 sems bolts (38) M12×25.
2) Remove guard (7)
: 19 mm
Weight : 15kg (33 lbs)
33-7
33. UPPER STRUCTURE
: 19 mm 34
Weight : 10kg (22 lbs)
3) Remove 3 sems bolts (38) M12×25. 38
4) Remove guard assy (44). 38
: 19 mm
44
: 19 mm
Weight : 15kg (33 lbs)
6 38
: 19 mm
Weight : 16kg (35 lbs) 52 51
38
(6) Remove cover assy (61)
1) Unlock and open cover assy (61).
Fig. 33-15 Removing stay (63) and cover assy (61)
2) Remove connector for right side deck light.
3) Remove 4 sems bolts (38) M12×25.
4) Remove cover assy (61).
: 19 mm
Weight : 33kg (73 lbs)
33-8
33. UPPER STRUCTURE
: 17 mm
74
Weight : 16kg (35 lbs)
71
: 17 mm 74
Weight : 19kg (42 lbs)
73
Fig. 33-17 Removing panel assy (73)
(9) Remove panel assy (72). 72
1) Unlock and open panel assy (72).
2) Remove 4 nuts (74) M10.
3) Remove panel assy (72).
: 17 mm
Weight : 19kg (42 lbs)
74
: 19 mm
Weight : 10kg (22 lbs) 62
33-9
33. UPPER STRUCTURE
: 19 mm
: 19 mm
38
16
15
38
Fig. 33-21 Removing guard (15),(16)
(13)Remove panel (4), beam (11), bracket (9) and pillar
(12) 38
39
1) Loosen 3 sems bolts (38) M12×25, and remove
panel (4).
2) Remove 2 sems bolts (39) M12×30.
11
3) Remove beam (11).
Weight : 10kg (22 lbs)
4) Loosen 4 sems bolts (39) M12×30, and remove 38
12
bracket (9). 9
Weight : 19kg (42 lbs) 4
38 39
5) Loosen 2 sems bolts (38) M12×25, and remove
Fig. 33-22 Removing panel (4), beam (11),
pillar (12).
bracket (9) and pillar (12)
: 19 mm
(14)Remove panel (4), pillar (10) and (14)
14
1) Remove 3 sems bolts (38) M12×25. 38
2) Remove panel (4).
3) Loosen 4 sems bolts (39) M12×30, and remove
pillar (10). 10 4
Weight : 14kg (31 lbs)
4) Loosen 4 sems bolts (38) M12×25, and remove 38
pillar (14).
: 19 mm
39
Weight : 13kg (29 lbs) 38
Fig. 33-23 Removing panel (4), pillar (10), (14)
33-10
33. UPPER STRUCTURE
: 19 mm
Weight : 10kg (22 lbs) : guard assy (83) 85
84 85
85
86
(17)Remove guard assy (81), (82) 83
1) Loosen 2 sems bolts (85) M12×25, 4 sems bolts 85
(86) M12×30 and remove guard assy (81).
2) Loosen 6 sems bolts (85) M12×25, and remove
guard assy (82).
: 19 mm 85
Weight : 21kg (46 lbs) : guard assy (81)
13kg (29 lbs) : guard assy (82) Fig. 33-25 Removing guard assy (84), (83), (81) and
(82)
33.1.4.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
33-11
33. UPPER STRUCTURE
33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,8,9,10,11,12,13)
1) Remove attaching sems bolts (14) M12×30 and sems bolts (15) M12×25.
2) Remove covers.
: 19 mm
12
11
10
1 9
8
7
5
13
4
33.1.5.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7,8,9,10,11,12,13)
: 19 mm
Tightening torque : 80.0 N•m (59.0 lbf•ft)
33-12
33. UPPER STRUCTURE
33.1.6.2 REMOVAL
(1) Remove 10 capscrews (A1) M16×45.
B2
B1
: 24 mm
(2) Hook the wire to the lifting eye on the fuel tank assy C1
A5
A7
A3
A1
A1
A1 A1
Fig. 33-28 Removing fuel tank
33-13
33. UPPER STRUCTURE
33.1.6.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A1) M16×45
Tightening torque
No. Name Q'ty N.m (lbf.ft)
A1 Capscrew 10 191 (140)
A6 Machine screw 5 1.96 (1.4)
A8 Cock 2 34 (25)
33-14
33. UPPER STRUCTURE
33-15
33. UPPER STRUCTURE
33.1.7.2 REMOVAL
(1) Draw out the suction hose (A3)
1) Remove 2 sems bolts (A19) M12×35 for tube
(A8) installation.
A34
A8
: 19 mm
2) Remove 2 clips (A34) of the tank side and pull
out hose (A3).
2 : Flat-blade screwdriver
A3
A19
: 19 mm
: 22 mm
2) Remove pilot hose (A3).
: 22 mm
3) Remove pilot hose (A17). A3
A9 S/V
C/V T
: 22 mm C1 A4 A17 Dr2
PT S/V
4) Remove pilot hose (A4). H/V T
T
Dr
: 22 mm
: 22 mm
33-16
33. UPPER STRUCTURE
: 30 mm
A3
A1 A1
33-17
33. UPPER STRUCTURE
33.1.7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M20×45 with
Loctite #262. (See Fig. 33-36.)
D
B2 SUCTION
1. Three elements (D) are used as one set. STRAINER
LS50V00007F1
2. Replace O-ring (C) and packing (F) with new ones
respectively.
33-18
33. UPPER STRUCTURE
Hyd.tank
38 7
38
39
16
15
38
Fig. 33-40 Removing guards
33-19
33. UPPER STRUCTURE
33.1.8.2 REMOVAL
(1) Loosen capscrews (A21) M12×40, (A42) M12×110 A5 A42
A6
and remove half clamp (A36). And disconnect 2 A36
hoses (A5), (A6) from the delivery side. A21
A36
: 19 mm a5
A1
(2) Remove side branch hose (A1), (A2). Ps2
a2
Dr1
: 41 mm a1 Ps1
: 14 mm A2
2) Remove elbow (A7) of suction hose (A4) from
pump.
A25
3) Remove drain hose (1) (Dr).
(See Fig. 33-42)
A7
: 22 mm
A4
Fig. 33-41 Removing hoses
(4) Removing other hoses
Psv1- A16
1) Disconnect hoses of the following ports. FILTER- Psv2 S/V P1-
Psv2 3 PUMP A3
2
Hose
Port No. Tool Remarks
1 TANK-
PUMP Dr2
Remove the parts marked * only if necessary.
Fig. 33-42 Removing other hoses
2) Attach tags to hoses to identify.
3) Put a plug in the hoses and the pump.
33-20
33. UPPER STRUCTURE
SE-23:
Pressure sensor :
P2 pump
SEMS BOLT Using Zip-tie,
Using Zip-tie,
clamp the corrugated Tightening torque SE-22: clamp the corrugated part of
part of harness to the 38.2N.m (28 lbf.ft) Pressure sensor : harness to the pressure sensor.
P1 pump
pressure sensor. Pressure sensor: Pressure sensor:
Installing part of P2 pump Installing part of P1 pump
: 17 mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the tension of
the wire rope.
1-4 1-5
On that occasion, the assembly is drawn out with
the insert NA (1-3) remaining on the flywheel
side.
3) Remove element (1-1) from the tip of the spline 1-6 1-5
shaft. 1-2 1-3
: 10 mm
6) Remove 4 capscrews (1-5) M20×65 that fasten
the insert NA (1-3) with the engine side flywheel,
as necessary. Then remove and spring pin (1-7)
from insert NA (1-3).
: 17 mm
33-21
33. UPPER STRUCTURE
33.1.8.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Installing hub (1-2)
Put hub (1-2) into the pump spline till it enters
16.5mm (0.65in) from the end face of the spline
(See Fig. 33-45 Detail aa). Then install two set
screws (1-6) and fix them together.
: 10 mm
Tightening torque : 210 N•m (155 lbf•ft)
(2) Installing insert R (1-4)
Install insert R (1-4) into hub (1-2) by means of
capscrews (1-5).
: 17 mm
Tightening torque : 465 N•m (343 lbf•ft)
(3) Installing element (1-1)
Put element (1-1) into hub (1-2) and insert R (1-4).
(4) Installing insert NA (1-3)
Put spring pin (1-7) into insert NA (1-3) and install it
to the engine flywheel by means of capscrews (1-
5).
: 17 mm
Tightening torque : 465 N•m (343 lbf•ft)
33-22
33. UPPER STRUCTURE
: 14 mm
Tightening torque : 143 N•m (105 lbf•ft) 16.5 0.5
(0.65" 0.02")
(9) Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM".
4
(10)Installing the hose (See Fig. 33-42) 3
T=68.6N.m (51 lbf.ft)
Apply Loctite #262
DETAIL aa VIEW I
Tool Tightening torque
Port
mm N m (lbf ft)
Fig. 33-45 Installing hydraulic pump
Cap nut Dr3 22 34.3 (25.3)
Cap nut Psv1,2 19 29 (22)
33-23
33. UPPER STRUCTURE
33.1.9.2 REMOVAL
(1) Pulling out hose (3).
35 (1.38")
5
1) Loosen clips (5), (6) on both sides of hose (3). Insert width
of hose
2) Pulling out hose (3)
: Flat-blade screw driver
(2) Remove air cleaner assy (1) 7
1) Remove 4 sems bolts (7) M10×30 DETAIL aa
Insert width of hose
: 17 mm 45 45
6 (1.77") (1.77") cc
2) Remove air cleaner assy (1) from plate (4).
bb
3
6
DETAIL bb
40 8")
5
(1.
33.1.9.3 INSTALLATION
(1) Installing is the reverse order of removing with Replacing parts
attention paid to the following items:
1) Put in air hoses to the end as shown in Fig. 33-
48.
2) Tightening torque :
O RING (1-6)
No. Name Tightening torque N.m (lbf.ft) (LS11P00014S006)
33-24
33. UPPER STRUCTURE
33.1.10 MUFFLER
33.1.10.2 REMOVAL
(1) Remove U bolt (6).
6
11
1) Remove 4 nuts (11) M8. 1
6
: 13 mm
2) Remove 2 U bolts (6). 10
11
(2) Remove clamp assy (7)
1) Remove 2 capscrews (10) M10×35
7
: 17 mm 2
2) Separate clamp assy (7) from muffler (1).
(3) Removing other parts
Remove brackets (2) and (3) as necessary.
: 19 mm, 22 mm
3
B
C
A
Procedure of
fastening U bolt Installing clamp side (7)
33-25
33. UPPER STRUCTURE
33.1.10.3 INSTALLATION
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (6) (See Fig. 33-50)
1) Tighten 4 nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm
the C dimensions on the right and left once
again.
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
4) Tightening torque
Nut A : 8.8 N•m (6.5 lbf•ft)
Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (7)
1) Place the end of clamp (7) 10mm (0.40in) away
from the tip of the muffler slit so the joint of clamp
does not extend over the slit in the muffler. (See
Fig. 33-50)
2) Install the clamp assy (7) in the illustrated
direction.
(3) Tightening torque :
33-26
33. UPPER STRUCTURE
33.1.11 COUNTERWEIGHT
33.1.11.1 REMOVAL
(1) Lifting up counterweight temporarily
Hook wire rope to slinging jig, and lift it and stretch
wire rope to the degree where it is providing no
slack temporarily.
Weight of counterweight ;
Approx. 9,700kg (21,390 lb)
Wire more than ø24 (0.95 inch) ;
2.0m (6ft)×2 pcs.
(2) Removing counterweight
1) Remove 4 capscrews (A1) M42×400.
Fig. 33-51 Lifting up counterweight
: 65 mm
2) Remove shim (A4), (A5), (A6). (Select)
3) Remove counterweight (C1).
A4
A5
A6
C1
A1
A2
Fig. 33-52 Removing counterweight
33.1.11.2 INSTALLATION
(1) Install counterweight in the reverse order of
removing.
Using shims of less than 2
(2) Install shim (A4), (A5), (A6) as it was. (select)
sheets, and adjust clearance
(3) Slinging counterweight to 10mm (0.39") between
counterweight and guard.
Check that the attaching bolts can be screwed in by
A6,A5,A4
hand.
(4) Apply Loctite #262 on capscrews (A1), and tighten
them with washers (A2).
: 65 mm
Tightening torque : 4150 N•m (3060 lbf•ft)
(5) Remove slinging tools.
A2,A1
33-27
33. UPPER STRUCTURE
: 19 mm
(7) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose
for draining water. Clip
10
[Water capacity of radiator : 16.4L (4.3gal)]
1
(8) Remove hose from radiator sub tank (1)
Remove clip of radiator cap side and disconnect
hose (10).
33-28
33. UPPER STRUCTURE
33.1.12.2 REMOVAL
(1) Remove radiator stay (A1), (A2).
1) Remove 4 sems bolts (A3) M12×35.
: 19 mm
2) Remove 2 stays (A1), (A2). B1 B2
B A2 B4-2
(2) Remove water hose (2),(3) A3
A4
Fig. 33-57 Removing radiator assy
(3) Remove hoses (6), (8) for inter-cooler
1) Remove a fixing U-bolt (20) from tube (13). 17
31
: 13 mm
24
2) Loosen sems bolt (30) M12×20. 2 39
16 5
: 19 mm
31 36
3) Loosen hose bands (21) and remove hose (6). 33 21
3 31
: Flat-blade screwdriver 23 20
23 13
4) Loosen hose bands (21), (39) and remove hose 32
(5). 34
35 21
29
: Flat-blade screwdriver 7
32
5) Remove a fixing U-bolt (20) from tube (11). 23 30
8 21
: 13 mm
21
6) Loosen sems bolt (30) M12×20. 21
6
: 19 mm 11
33-29
33. UPPER STRUCTURE
: 13 mm
(5) Disconnecting hydraulic oil tube (29), (30) 29
19
1) Loosen 2 capscrews (23) M12×60 for attaching 13 23
clamp (13). (2-places)
2) Place an oil pan under the hose joint. Loosen 4
sems bolts (19) M12×35, and remove tubes (29)
30
and (30).
23
(6) Remove radiator assy. (See Fig. 33-57) 13
1) Remove 4 sems bolts (A4) M20×50.
: 30 mm 19
: 30 mm
2) When lifting the engine fan, shift the radiator so
it does not interfere with the engine fan.
3) Plug up pipe ends with clean cloth, etc.
4) Removing radiator A4
Place a wire sling in the lifting eyes of the radiator Fig. 33-59 Removing hydraulic oil tube (29), (30)
assy and remove the assy by crane.
Weight : 192kg (423 lbs)
33-30
33. UPPER STRUCTURE
33.1.12.3 INSTALLATION
(1) Installing is done in the reverse order of removing. Insert width CLIP Tightening torque
of hose 11N.m (8 lbf.ft)
And removed clips of hose should be clamped at
50(1.97")
original position.
Insert Insert width
(2) Install radiator assy width of hose
of hose 50
Place a wire sling in the lifting eyes of the radiator 25
(1.
97
") CLIP
(0.98")
and move it to original position temporally. And Tightening torque
11N.m (8 lbf.ft)
install hydraulic hose, radiator hose and hose of Insert width
of hose
inter-cooler. Regarding Inserting width of hose.
50(
(See Fig. 33-60)
1 .9
7")
(3) Radiator attaching bolt
Apply Loctite #262 on 4 semsbolts (A4) M20×56.
: 30 mm
Tightening torque : 500 N•m (369 lbf•ft)
(4) Adjust the clearance between the fan and the
(1.57") 40
radiator shroud all around the circumference, as Insert
width of hose CLIP Tightening torque
5.9N.m (4.4 lbf.ft)
below :
Insert width
Circumferential direction: of hose
18±3mm (0.7in±0.1in)
50(1.97")
(1.57") 40
44±5mm (1.7in±0.2in)
(5) Clean the plastering area of the insulation
thoroughly before plastering it.
50(1.97")
(6) Making up hydraulic oil and LLC (Long Life
(1.57")
40
Coolant)
After completion of other installation, make up Insert width
of hose
(1.97")(1.97")
50
(1.97")50 (1.97") CLIP Tightening torque
Insert width of hose 11N.m (8 lbf.ft)
33-31
33. UPPER STRUCTURE
29
Tightening torque
88N.m (64.9 lbf.ft)
INTER-COOLER
(w/FUEL COOLER)
30
VIEW A
Fig. 33-62 Removing radiator and inter-cooler
33-32
33. UPPER STRUCTURE
(3) Installing
Installing is done in the reverse order of removing.
33-33
33. UPPER STRUCTURE
33.1.13 ENGINE
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to Tools)
STARTER
OIL FILTER
ELEMENT
THERMOSTAT
ALTERNATOR
33-34
33. UPPER STRUCTURE
33.1.13.2 REMOVAL
24
23
18
19
14
11 5 15 13
6
25 26
32 39 33
14
16 15
28
52 * 35
17
51 3
2
52 7 29
8 1
33
26
24
12
19
32 15
10 15
23 37
25
14 17
18
16 14 38
29
36
28
Fig. 33-64 Dismantling and mounting engine
(1) Remove hose of engine oil filter
Place oil pan under the connection of filter (1), and disconnect hoses (6), (7), (8) at positions.
: 17 mm, 41 mm
(2) Plug connector of filter side and hose.
(3) Loosen engine mounting bolt of frame
1) Loosen 2 nuts (28) M18 and 2 nuts (29) M27.
: 27 mm, 41 mm
2) Loosen 2 capscrews (23) M18×150 and 2 capscrews (24) M27×170.
3) Remove 2 plates (18) and 2 plates (19).
4) Remove upper rubber mounts (14) and (15) 2 each.
(4) Slinging engine body
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to "Tool".)
1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 1,150 kg (2,536 lbs)
Wire: ø10 (0.394")×1m (3ft 3in) - 2pcs.
(5) Position engine on the stand stably.
33-35
33. UPPER STRUCTURE
33.1.13.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Tightening torque
Tightening torque
No. Name Remarks
N.m (lbf.ft)
5 Bolt 26.5 (20)
Apply Loctite
23 Capscrew 226 (167) #262
Apply Loctite
24 Capscrew 765 (564) #262
Apply Loctite
25 Capscrew 115 (85) #262
Apply Loctite
26 Capscrew 172 (127) #262
35 Sems bolt 46.1 (34)
36 Sems bolt 46.1 (34)
37 Sems bolt 46.1 (34)
! "
!"
#$ $" &' #"
% ($ #"
33-36
33. UPPER STRUCTURE
33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1) During pushing 4 locked claws of boot retaining
plate (4) with flat-blade screw driver, lift the plate
(4) and remove it.
: Flat-blade screwdriver
2) Loosen 3 sems bolts (10D) M6×16.
: Plus screw driver
3) During lifting right upper console cover (9D) up;
disconnect connector of tuner and antenna.
Move boot (3) upwards and remove console
cover (9D).
• Removing of boot and lever is unnecessary. Fig. 33-65 Removing plate (4)
4) Loosen 3 sems bolts (16A) M6×16 and remove 10D
lower console (4). 9D
: Plus screw driver 10D
(2) Removing left-hand console cover 16A
16B
1) Remove the boot retaining plate (4) in the same
way as right-hand console cover. (See Fig. 33- 5 16B 4 16A
65) 16B
: Flat-blade screwdriver
16C
2) Loosen 2 sems bolts (A6) M8×20 and remove left
armrest assy.
6
: 13 mm
3) Loosen 4 sems bolts (16B) M6×16.
: Plus screw driver
4) Remove the left upper console cover (5) in the
same way as right-hand console cover.
5) Loosen 2 sems bolts (16C) M6×16 while lifting
left under console cover (6) up, and remove left Fig. 33-66 Removing console covers
lower console cover.
33.1.14.2 INSTALLATION
Install it in reverse order of removing according to the
tightening torque table.
A6
Item Bolts Tightening torque N.m (lbf.ft)
33-37
33. UPPER STRUCTURE
33.1.15.2 REMOVAL
(1) Attach tag on which hose name is entered to the
2
remote control hoses between multi control valve 8 P/V 5
and pilot V, and write numbers P1 to P8 on it. P/V P/V 1
See Tools 11.5 PLUG (3) P/V
4 P2 P5
: 19 mm, 22 mm P/V
P8 0 P1
(2) Attach tag on which hose name is entered to the 7 6
remote control hoses between multi control valve P/V P4 P6 P/V
and main control valve, and write numbers C1 to C8
P7
on it. 3
See Tools 11.5 PLUG (3) P/V P3
: 19 mm, 22 mm
(3) Remove 4 sems bolts (B18) M8×20, and remove Fig. 33-69 Removing hoses between P/V
multi control valve (0) with bracket (B10) from and multi C/V
machine.
33.1.15.3 INSTALLATION
(1) Installing is done in the reverse order of removing 4Pc1
4Pa2 B3
(2) Relations between pilot valve and multi control C/V C/V 5Pb2
valve hose C4 C/V
C2
C5 C1
P/V Hose ISO Multi Mark-
Port Size Color Control pattern port ing C6
1 3/8 Red Bucket digging P1 1 0 5Pa5
2 3/8 Blue
Right side
Bucket dump P2 2
C / V C / V C4Pb2
/V
3 3/8 Green Boom up P3 3 5Pa2
4 3/8 Gray Boom down P4 4 C8
P 1/4 Black Pilot primary - -
T 3/8 Black Drain - - C3
C/V
5 3/8 Gray Swing left P5 5 4Pa3
C7
6 3/8 Red Swing right P6 6 C/V
Left side
5Pb5
7 3/8 Blue Arm in P7 7
8 3/8 Green Arm out P8 8
P 1/4 Black Pilot primary - -
T 3/8 Black Drain - -
B7
B18
(3) Tightening torque
Fig. 33-70 Connection between multi control valve
Tool Tightening torque
Tightening position and main C/V
mm N.m (lbf.ft)
Sems bolt (B18) 13 35.3 (26.0)
33-38
33. UPPER STRUCTURE
7
6
33.1.16.2 REMOVAL
(1) Remove 4 capscrews (7) M20×40, and remove
control valve (3) by hoist.
: 30 mm
Weight :Approx. 385kg (849 lbs)
33.1.16.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 4 capscrews (7) M20×40.
: 30 mm
Tightening torque : 431 N•m (318 lbf•ft)
2)
Connector / Bolt Hose nut
Tread Tightening Tightening
Opposing torque Opposing torque Remarks
Name
size Ports flats N.m (lbf.ft) flats N.m (lbf.ft)
4pc1,4pc2,4pc3,4pf1,5pc1 36.3 2
PF1/4
5pc2,5pc3,5pf1,dr1,dr4,pc 19 (26.8 1.5) 19 29 (21)
4pa1~4,4pb1~4,pz1,dr2 73.5 5
PF3/8 ORS Joint
pz2,5pa1~5,5pb1~5,dr3 22 (54.2 3.7) 22 49 (36)
Rs,Rs2
PF1
41 255 (188) 41 137 (101)
M12 4A1,4B1,5A1,5B1,5A2,5B2 10 98.1 (72.4)
Capscrew
M14 P1,P2,4A2,4B2,4A3,4B3,5A5,5B5 12 147 (108)
R1,R2
M12 Sems bolt
19 98.1 (72.4)
33-39
33. UPPER STRUCTURE
R1 Tank return
R2 Tank return
P2 P2 pump
33-40
33. UPPER STRUCTURE
P1 pump P1
Drain dr1
Tank return R3
33-41
33. UPPER STRUCTURE
33.1.17.2 REMOVAL
(1) Remove hoses from your side to far side in order.
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See Fig. 33-74)
: 22 mm
(3) Turn and loosen lever (2-1) tightened in pilot valve,
and remove lever assy in a set. (See Fig. 33-74) )*+ ) *
$%
& '
!!&
(4) Remove 4 capscrews (A14) M6×25. (See Fig. 33- $& !!&
33.1.17.3 INSTALLATION
Install it in the reverse order of removal and tighten it. Front of machine
T Arm (R) Boom (R)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew (Green) T (Gray)
(A14) Bucket (R)
Swing (R) (Blue)
(Red)
Swing (L)
(Gray)
33-42
33. UPPER STRUCTURE
A6
A7
A5
B1
A8
33.1.18.2 REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and
SE-10 (A9) at the connector.
$
3 '( !45(
: 24 mm 16 %71) /$
(2) Attach tag, and discount connectors and hoses -
(A2), (A3), (A4), (A5) 0-12 %)
$ , 0. %)
: 19 mm (P port)
: 22 mm (T port, 1~4 port) /.
,
(3) Plug hose ends
0. %)
Plug PF1/4, PF3/8
!
(4) Remove 4 sems bolts (A8) M8×25, and remove
*+
*.
right and left pedals (A5), (A6).
*+
: 13 mm *
(5) Remove 4 sems bolts (A7) M10×20 and remove
right and left lever (A1), (A2).
: 17 mm
(6) Remove 4 sems bolts (A11) M10×30.
: 17 mm
$ !" ##
(7) Remove pilot valve lifting it upward.
(8) Stop up holes with plugs PF1/4.
%&' (!)
Fig. 33-78 Installing and Removing pilot valve
33-43
33. UPPER STRUCTURE
33.1.18.3 INSTALLATION
Install it in the reverse order of removal and tighten it.
Sems bolt (A11)
33-44
33. UPPER STRUCTURE
33.1.19.2 REMOVAL
(1) Remove hose.
A24
1) Remove hose (A7) from the connector in the
makeup port M.
A24
: 41 mm A16
A53 B
2) Remove 2 hoses (A8), (A10) from the Tee in the A
drain port Dr.
: 36 mm A15
A14 B
3) Remove hose (A40) from the elbow of the PG A
: 19 mm
4) Remove 2 hoses (A16), (A53) from the
connectors of the A, B port.
: 36 mm
Put in plugs PF3/4, PF1/2, and PF1/4 into the
removed ports.
C/V
A6 DR Rs1
A40
M
A88 DR
A2
A77
33-45
33. UPPER STRUCTURE
: 30 mm
1) Remove two plastic caps (7) M12 at the top of
the swing motor and install eye bolts.
: Flat-blade screwdriver
2) Put a wire sling in the eye bolts and remove the
swing motor unit.
Weight of swing motor unit ;
Approx. 286kg (631 lbs) (Include reduction assy)
33.1.19.4 INSTALLATION
Install the swing motor unit in the reverse order of 11
Coat all the mounting surface of
disassembly, confirming the orientation of the swing the swing motor with Loctite #515
equivalent.
motor unit.
(1) Tighten 14 capscrews (11) M20×65.
LEVEL GAUGE
Put sealing tape
on the thread
portion of tube for
level gauge. Fix the plug at the
7
Tightening torque 10 drain hose edge on
69.1 N.m (51 lbf.ft) Tightening torquethe hole of the upper
46.1N.m (34 lbf.ft) frame bottom plate.
33-46
33. UPPER STRUCTURE
33.1.20.2 REMOVAL
(1) Remove travel motor hose
1) Remove 2 hoses (A4). (G port : PF3/4)
T : Tightening torque
of connector
T=255 N.m (lbf.ft)
T=36.3 (26.8) A5
B1 (188)
SWIVEL JOINT
A15
F
B
B1 D
T=36.3 (26.8) E
T=255 (188)
C
A4
A2 A
G
A1
A5
T=162 (119)
A4
Fig. 33-82 Removing piping (lower side)
33-47
33. UPPER STRUCTURE
: 36 mm A
C/V
Tightening torque : 177 N•m (130 lbf•ft) D
5B1
: 19 mm S/V 3
A3
Tightening torque : 29 N•m (21 lbf•ft)
: 36 mm
mm
3.5At assembling,
this distance
should be 3.5mm (0.138in).
33-48
33. UPPER STRUCTURE
: 24 mm EYE BOLT
(See 11.7 SPECIAL TOOLS No.9 Plug)
LOWER FRAME
C2
CAPSCREW
M16 40
Loctite #262
T=279N.m C1
(206 lbf.ft) SWIVEL JOINT
33.1.20.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Piping tightening torque
(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.
33-49
33. UPPER STRUCTURE
C1
Fig. 33-87 Temporarily lift upper frame
33.1.21.2 REMOVAL
(1) Lifting up upper frame temporarily
Insert two upper swing body lifting jigs and two
counterweight mounting capscrews (C1) M42×410
into the upper frame center section from above.
Then lift it tentatively at four points by using a
special fixture or by installing two chain blocks to
the boom foot.
Wire rope; ø16 (0.630")×4m(13ft-1in), 2pcs.
ø16 (0.630")×2.5m(8ft-2in), 2pcs.
Chain block; For 3,200kg (7,050 lb) 2pcs.
Fig. 33-88 Matching mark on swing bearing and
(2) Marking match marks on swing bearing
upper frame
Put match marks on upper frame and swing
bearing.
(3) Removing upper frame attaching bolts
Remove 35 capscrews (10) M27×143 and a reamer
bolt (11) used to install swing bearing and upper
frame.
: 41 mm
(4) Slinging upper frame
Sling according to Fig. 33-87, and remove upper
frame and put it on a stand.
Weight : Approx. 6ton (13,200lbs)
33-50
33. UPPER STRUCTURE
33.1.21.3 INSTALLATION
(1) Installing is done in the reverse order of removing. Apply Loctite #515 to the race surface
(2) Cleaning mating surfaces of upper frame and swing over the whole circumference (shaded area)
on the inside of capscrew.
bearing.
(3) Apply Loctite #515 to the inside of the capscrews
on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (11)
temporarily.
: 41 mm
Tightening torque : 1180 N•m (870 lbf•ft)
33-51
33. UPPER STRUCTURE
536
889
405
A A
724 262
888 409
156
886 153 709
251 491
491 490 212 211 152 728 469 151 141 752 410
492
Tightening torque
Tightening torque
Item number Thread size
N m (lbf
405 M8 34 (25) 543 545
406,408 M12 98 (72)
410,411,412 M22 630 (465)
409 M10 57 (42) 725 724
466 PF 1 1/4 270 (199) 541
467 PF 1/4 36 (27)
468 M18X1.5 64 (47)
469 PF 3/4 170 (125) 887
490,492 NPTF1/16 8.8 (6.5) 726
491 Rc 1/8 12 (8.9)
493 Rc 1/4 22 (16)
531,532 M30X2 480 (354)
806,807 M20 240 (177) SECTION X-X SECTION B-B
33-52
33. UPPER STRUCTURE
127
823
192
191
711
827 B B
774 04
Apply (sealub L101)
to the oil seal surface
circumferential.
130
111
830
124,125
261
312
825
313 Valve plate for clockwise rotation.
126
752 122 824 411
129
889 468,731 467,725
128
733
SECTION A-A
05
ITEM PARTS Q'ty ITEM PARTS Q'ty ITEM PARTS Q'ty ITEM PARTS Q'ty
111 Drive shaft 1 214 Tilting bushing 2 493 Plug 2 774 Oil seal 1
113 Driven shaft 1 251 Swash plate support 2 531 Tilting pin ; M30X2 2 789 Backup ring ; P21 2
122 Roller bearing 1 261 Front cover 1 532 Servo piston ; M30X2 2 792 Backup ring ; G40 2
123 Roller bearing 1 262 Cover 1 534 Stopper (L) 2 806 Nut : M20 2
124 Needle bearing 2 271 Pump casing 1 535 Stopper (S) 2 807 Nut ; M20 2
125 Inner ring 1 312 Valve cover 1 536 Servo cover 2 823 Snap ring 1
126 Spacer 2 313 Valve plate (R) 1 541 Seat 2 824 Snap ring 3
127 Spacer 1 314 Valve plate (L) 1 543 Stopper 1 2 825 Snap ring 2
128 Bearing spacer 3 405 Socket bolt 8 545 Steel ball 2 827 Snap ring 1
129 Bearing spacer 2 406 Socket bolt ; M12X35 8 548 Feed back pin 2 828 Snap ring 2
130 Booster 7 408 Socket bolt ; M12X55 11 702 O-ring ; 1B G40 2 830 Snap ring 1
141 Cylinder block 2 409 Socket bolt ; M10X16 2 709 O-ring ; 1B G85 1 885 Valve plate pin 2
151 Piston 18 410 Socket bolt ; M22X60 9 711 O-ring ; 1B G95 1 886 Spring pin 4
152 Shoe 18 411 Socket bolt ; M22X95 2 724 O-ring ; 1B P8 9 887 Pin 1
153 Retainer plate 2 412 Socket bolt ; M22X180 1 725 O-ring ; 1B P11 2 888 Pin 2
156 Spherical bushing 2 466 RO Plug ; PF1 1/4 2 726 O-ring ; 1B P10 2 889 Pin 4
157 Cylinder spring 18 467 ROH Plug ; PF1/4 2 728 O-ring ; 1B P24 3 901 Eye bolt ; M12 2
171 Front casing 1 468 Adapter 2 729 O-ring ; 1B P38 2 953 Set screw 2
191 Drive gear 1 469 ROH Plug ; PF3/4 3 731 O-ring ; 1B P16 2 954 Set screw 2
192 Driven gear 1 490 Plug 20 732 O-ring; 1B P21 2 04 Gear pump 1
211 Shoe plate 2 491 Plug 12 733 O-ring; 1B G170 1 05 PTO unit 1
212 Swash plate 2 492 Restrictor 4 752 Seat packing 2
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 33-92
33-53
33. UPPER STRUCTURE
728
434
311
312
361
732 Delivery port
PF1/2
Drain port PF3/8 307 310 308 309 434 466 355 850 Tightening
709 435 Tightening torque; 887
725 torque ; 53N.m
34N.m (25.1lbf.ft) (39.1lbf.ft)
SECTION Y-Y
Tightening torque
Tightening torque
Item number Thread size
N m (lbf ft)
312 M14X1.5 29 (21)
433,434 M8 17 (12.5)
435 M10 33 (24)
466 PF 1/4 16 (12)
468 PF 3/4 74 (55)
33-54
33. UPPER STRUCTURE
3) Drain oil
REGULATOR
Drain out the oil in the pump casing by removing
drain port plug (469).
: 12 mm
: 6 mm, 8 mm, 10 mm
33-55
33. UPPER STRUCTURE
: 17 mm
Fig. 33-94
33-56
33. UPPER STRUCTURE
Fig. 33-95
9) If necessary, remove stopper (L: 534), stopper
(S: 535), servo piston (532), tilting pin (531), and
servo cover (536) from pump casing (271).
• Using suitable jig to prevent damage tilting
pin head, and remove tilting pin (531).
• Fitted part of tilting pin (531) and servo piston
(532) was applied adhesive (Three Bond
#1305N). Do not damage servo piston at
removal, because it is hard to remove due to
interference of adherence.
• Do not loosen hex nut (806) located on servo
cover (536) to keep the correct set of flow
rate.
10) Remove snap ring (827) and remove front
cover (261).
• Always fix the front cover for this operation.
When fixing it, do not damage mating face of
front cover.
• A groove is provided on the periphery of front
cover (261). Apply flat-bladed screw driver to
groove and pry the front cover (261) to
remove it along drive shaft (111) straightly.
• Front cover (261) has oil seal (774), do not
damage lip of oil seal (774) when removing.
Fig. 33-96
11) Loosen socket bolts (408) that are fastening
front casing (171).
• Always fix the front cover for this operation.
When fixing it, do not damage mating face of
front cover.
33-57
33. UPPER STRUCTURE
Fig. 33-98
33-58
33. UPPER STRUCTURE
33-59
33. UPPER STRUCTURE
Fig. 33-101
5) Install front casing (171) to pump casing (271)
and fasten them with socket bolts (408).
: 17mm
Tightening torque : 630 N•m (465 lbf•ft)
33-60
33. UPPER STRUCTURE
Fig. 33-105
33-61
33. UPPER STRUCTURE
Fig. 33-106
11) Insert check valve sub (541, 543, 545) and
needle bearing (124) into valve cover (312).
• Insert check valve sub (541, 543, 545) into
valve cover (312) in the correct order.
• Since check valve sub (541, 543, 545) tend
to fall, apply grease to inserting part of valve
cover (312) to prevent from falling.
Consequently it makes assembly easier.
Fig. 33-107
12) Put O-rings (724, 726, 735) and seat packing
(752) on the mating face of pump casing (271)
and valve cover (312).
• Since O-rings (724, 726, 735) and seat
packing (752) tend to fall, apply grease to
attaching surface to prevent from falling.
Consequently it makes assembly easier.
Fig. 33-108
33-62
33. UPPER STRUCTURE
: 6mm
Tightening torque : 29 N•m (22 lbf•ft)
33-63
33. UPPER STRUCTURE
Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
Clearance between piston and cylinder
0.0375 0.078
bore Replace piston or cylinder.
(0.0015") (0.0031")
(D-d)
Gap between piston and caulked part of
shoe 0 ~ 0.1 0.35
Replace piston shoe assy.
(0.004") (0.014")
( )
Thickness of shoe 5.4 5.0
Replace piston shoe assy.
(t) (0.213") (0.197")
Free height of cylinder spring 40.9 40.1
Replace cylinder spring.
(L) (1.610") (1.579")
Combined height of retainer plate and
23.8 22.8 Replace a set of spherical bushing or
spherical bushing
(0.937") (0.898") retainer plate.
(H-h)
Cylinder over pin dia. (spline in cylinder) 35.17 35.57
Replace cylinder, spherical bushing.
spline in spherical bushing (1.385") (1.400")
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
33-64
33. UPPER STRUCTURE
33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on
it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements
may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valveÅfs relief valve are of regular frequency. In
case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This
will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes
by measuring pressures.
(2) Troubleshooting
1) Overloading to engine
2) Pump’s oil flow rate is extremely low and delivery pressure is not available.
33-65
33. UPPER STRUCTURE
33-66
33. UPPER STRUCTURE
33-67
33. UPPER STRUCTURE
33.2.1.2 REGULATOR
626
625
624
753
627
623
621 D 728
B 645
611
622 F
874 646
733 613
732 875 644
631 612
898
652 875
A 643
651
836 G E
897 C
655
654
653
814
630
438
629
763
802
628
756
801
924
412
656 413
438 735
Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722
466 496 734
755 G
887
F
708
A 876
662 B 724 614
436 C
642 730 725 8-724 755
041 755
755 467
467 755
641
33-68
33. UPPER STRUCTURE
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
33-69
33. UPPER STRUCTURE
Hammer Plastic
2) Cleaning Torque wrench
Remove dust and rust, etc. on regulator surface Plier Snap ring
with wash oil. Steel bar 4X100
Pin set
Bolt M4X50
: 5 mm
630 924
Fig. 33-113 Removing cover (C) (629)
33-70
33. UPPER STRUCTURE
: 5 mm
436
641
615
• Fulcrum plug (614) and adjust plug (615)
come off easily if a M6 bolt is used. 614
33-71
33. UPPER STRUCTURE
$"
$!&%#
$
Fig. 33-121 Removing feedback lever (611) [2]
33-72
33. UPPER STRUCTURE
467
641
Fig. 33-123 Part of exploded view of regulator
33-73
33. UPPER STRUCTURE
• Make sure that the spool and the sleeve (652) SPOOL FEEDBACKLEVER(611
move smoothly in the casing.
• Beware of the direction of the spool. Fig. 33-125 Direction of the spool (652)
33-74
33. UPPER STRUCTURE
33-75
33. UPPER STRUCTURE
: 5 mm
Tightening torque : 12 N•m (8.9 lbf•ft) $ $
Fig. 33-131 Assembling compensating parts
11) Installing spool and spring
466
Assemble spool (642) and spring (662) into pilot
cover (641), and tighten VP plugs (467).
662
642
467
641
Fig. 33-132 Assembling spool (642)
12) Assembling into the pilot hole and the 644,645,646
compensating hole 626
(See Fig. 33-111 (E),(D) section)
Put spring seat (644), pilot spring (646) and 625(624)
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating
hole.
: 5 mm 624,625,626
Tightening torque : 12 N•m (8.9 lbf•ft) 627
801
14) Installing block cover (See Fig. 33-112) 629( 628 )
Attach block cover (656).
: 5 mm
630 924
Tightening torque : 12 N•m (8.9 lbf•ft)
Fig. 33-134 Installing cover (C) (629)
This completes assembly.
33-76
33. UPPER STRUCTURE
33-77
33. UPPER STRUCTURE
2 DIVISIONS
D L B H
For main plunger 36 90 50 25
For priority valve poppet 25 30 35 20
assembly
Fig. 33-135 Tools and jigs
33.2.2.2 DISASSEMBLY
The figures in parentheses after part names in this
manual represent those item numbers in the structural
drawing under 24. COMPONENTS SYSTEM.
The disassembly procedure is explained as below.
Assembly is the reverse order of disassembly.
33-78
33. UPPER STRUCTURE
: 10 mm
Tightening torque : 98 N•m (72 lbf•ft)
: 10 mm
Tightening torque : 98 N•m (72 lbf•ft)
32
33
Note that the travel straight select spool has a different 34
spring.
35,36
33
32
Fig. 33-140 Removing plunger and spring
33-79
33. UPPER STRUCTURE
: 10 mm 43
Tightening torque : 78.5 N•m (58 lbf•ft)
AM-2
45 39 40
40
39
38
40
AM-2
39
45
Fig. 33-141 Disassembling the plunger and check
(2) Disassembling the center bypass
Remove cap (87). Then take out spool (89) and
spring (88). 87 88 89
: 46 mm
Tightening torque : 245 N•m (180 lbf•ft)
88
89
33-80
33. UPPER STRUCTURE
: 12 mm
Tightening torque : 176.5 N•m (130 lbf•ft) 93 90 106 100 101 102 93
99
98
99
98
Fig. 33-144 Removing spring (99) and poppet (98)
2) Disassembling the cover (90)
1. Remove cap (93) and take out piston (106).
: 10 mm
Tightening torque : 49 N•m (36 lbf•ft)
2. Remove cap (93), spring (102) and poppet
(101) in that order.
106
: 10 mm
Tightening torque : 49 N•m (36 lbf•ft)
93
33-81
33. UPPER STRUCTURE
1
5 4 3 2
RELIEF SLEEVE
: 36 mm
• When installing the body:
Tightening torque : 78.5 N•m (58 lbf•ft)
: 36 mm
Tightening torque : 98 N•m (72 lbf•ft) (Tightening
with sleeve)
2
5
Fig. 33-149 Disassembling relief sleeve (1)
33-82
33. UPPER STRUCTURE
: 10 mm
Tightening torque : 98 N•m (72 lbf•ft)
(BM-1) (BKT)
: 19 mm
Tightening torque : 78.5 N•m (58 lbf•ft)
83
Fig. 33-151
3) BKT
Remove socket bolt (18), cover (111) and piston
(112) in that order.
: 10 mm
Tightening torque : 98 N•m (72 lbf•ft)
112
Fig. 33-152
(6) Disassembling the check valve 50 85
(7) Disassembling the double check valve
AM-2 (double check) is explained hereafter:
49 49
Remove cap (85). Then take out spring (49) and 86
check (47), (86).
47
: 14 mm (BM-1, BM-2, SW)
47
Tightening torque : 343 N•m (250 lbf•ft) (BKT, OPT-1 or other)
(AM-2)
86
49
47
Fig. 33-154 Disassembling the double check valve
33-83
33. UPPER STRUCTURE
Fig. 33-156
4) Draw out poppet sub-assy (A). Then take out
main poppet (7) and spring (8) from sleeve (6).
NAME OPPOSING
FLATS
1 Adjusting screw 22
2 Nut 30 8
3 Nut 41 7
4 Cap 41
5 Sleeve 27 6
10
PILOT C
ADJUSTING SUB-ASSY B
Fig. 33-158
33-84
33. UPPER STRUCTURE
: 12 mm
Tightening torque : 176.5 N•m (130 lbf•ft)
130
Before reassembling the cover, make certain that an O-
ring is placed on the mouth of the housing.
131
132
133
130
131
132
133
Fig. 33-160 Removing priority valve
3) Hold poppet sub-assembly (133) in the holder,
hold it further in a vise, remove cap (136), and HOLDER
separate spring (135) and check (134).
: 6 mm
Tightening torque : 34.5 N•m (25 lbf•ft)
Degrease the poppet and the holder thoroughly. 133 POPPET SUB ASSY
136
135
134
Fig. 33-161 Disassembling the poppet (133)
33-85
33. UPPER STRUCTURE
127
The spring has repulsive force. Take care so parts do
not fly off when the plate comes off.
125
126
127
Fig. 33-162 Disassembling cover (123)
(10)Disassembling the optional conflux check valve 120 49 47
Remove cap (120). Then take out spring (49) and
check valve (47).
: 41 mm
Tightening torque : 24.5 N•m (18 lbf•ft)
47
49
Fig. 33-163 Disassembling the optional conflux
check valve
33-86
33. UPPER STRUCTURE
: 32 mm
Tightening torque : 78.5 N•m (57.9 lbf•ft)
2
Fig. 33-165
(12)Disassembling bucket conflux check valve
TAPPING M6
1) Loosen socket bolt (1) and remove flange (2).
: 10 mm 5 4 3
Tightening torque : 98 N•m (72 lbf•ft)
Fig. 33-166
2) Draw out sleeve (3). Then remove spring (4) and
check (5).
5
Fig. 33-167
33-87
33. UPPER STRUCTURE
TAPPING M8
Fig. 33-168
1) Remove cap (1). Then draw out plug (2).
: 17 mm
Fig. 33-169
2) Attach the setup over load relief valve. Then
tighten to specified torque.
: 36 mm
Tightening torque : 78.5 N•m (57.9 lbf•ft)
3
Fig. 33-170
33-88
33. UPPER STRUCTURE
33.2.2.3 ASSEMBLY
(1) Cautions to be exercised in assembly
1) Exercise care the same way as in disassembly.
2) Before proceeding to assembly, clean parts free from metallic particles and foreign matter and make sure
that the parts are free from burrs and dents. Eliminate burrs and dents with an oilstone or the like.
3) Replace O-rings and backup rings with new ones.
4) Handle O-rings and backup rings with care so as not to score them.
(Apply a little grease to make the surface smooth.)
5) Tighten bolts and caps to specified torque.
(2) Disassembly procedure
Assembly is the reverse order of disassembly.
If the pressure of the relief valve is not set properly, the hydraulic device may be destroyed in some cases.
This is dangerous. Therefore, never raise the pressure above a level that is specified for each machine
model.
(Z) SURFACE
(A) PISTON
(B)
PILOT POPPET 3 2 1 11 10
(C)
PRESSURE ADJUSTING SPRING
Fig. 33-171 Pressure setting of relief valve
33-89
33. UPPER STRUCTURE
5) Fix sleeve (1) and tighten nut (2) after setting the pressure.
Tightening torque : 98 N•m (72 lbf•ft)
33-90
33. UPPER STRUCTURE
312
302
Apply grease on
rotating and
501
Apply grease on 301 sliding sections.
Be careful the
top section assembling
212 direction
213
151
* 246
* 218-2
211
214
* 218-1
216-2 216-1
241-2 241-1
201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.061 in),
1 pc
PORT PORT
2,4 1,3
Fig. 33-172 Pilot valve (For ATT)
Apply loctite #277 to areas marked
33-91
33. UPPER STRUCTURE
33.2.3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it with
kerosine. 501
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).
302
33-92
33. UPPER STRUCTURE
: 24mm
301
33-93
33. UPPER STRUCTURE
211
101
217
201-1
201-2
212
211
33-94
33. UPPER STRUCTURE
212
213
33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2). 201-1 241-1 216-1
216-2
201-2 241-2
217
33-95
33. UPPER STRUCTURE
221
214 213
PLUG (211)
SEAL (213)
-RING (214)
PUSH ROD
(212) Apply hydraulic oil
(5) Insert push rod (212) in plug (211) and install spring
(*246) and spring seat (*218-1) to push rod (212) on
port 1,3 side.
And install spring seat (*218-2) to push rod on port
2,4 side.
33-96
33. UPPER STRUCTURE
101 211
151
101
A
33-97
33. UPPER STRUCTURE
: 22mm
• Apply Loctite #277 to threads of joint.
Tightening torque : 68.6 N•m (51 lbf•ft)
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
(11)Cover it with boots. GREASE
301
212
33-98
33. UPPER STRUCTURE
33.2.3.6 TROUBLESHOOTING
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer
to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required. The following table does not cover causes
and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and
causes.
33-99
33. UPPER STRUCTURE
33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
(1)
Material ; SCM415 (N)
Carburizing and Quenching
(2) BUSHING
Material ; S45C
SECTION AA
A A
33-100
33. UPPER STRUCTURE
33.2.4.1 CONSTRUCTION
T=Tightening torgue
N.m (lbf.ft) 12-o
12-o
7-h
12-o
12-y
5 12-y
12-x 12-x
13
6 8
f
d
Loctite 262 10
g
T=3
g
14
q 11
T=5 (3.7) r 15
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3~5 (2.2~3.7)
33-101
33. UPPER STRUCTURE
Fig. 33-198
(2) Switch plate removal
1) Remove :
• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm
socket wrench. (See Fig. 33-199 No.1)
* Reassembly :
• Apply a droplet of Loctite #262 on the
locking screw thread.
• Torque :1.2 N•m (0.89 lbf•ft)
* Reassembly :
• Position the axis so that the hole is aligned
with the locking screw as shown on the
picture (See Fig. 33-199 No.3)
4) Mark out the position of the switch plate before
removing it.
Fig. 33-199
5) Repeat the operation for the second switch plate.
6) Reassemble parts in reverse order.
33-102
33. UPPER STRUCTURE
Fig. 33-202
33-103
33. UPPER STRUCTURE
Fig. 33-203
(5) Damping plunger seals replacement
1) Remove
• The pilot control unit from the machine.
• Both rubber boots. (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
WIPER RING
2) Remove the wiper ring of the damping plunger
1 2 DAMPER PLUNGER
(1).
(See Fig. 33-204 No.1) Fig. 33-204
* Reassembly :
• Replace with a new wiper ring.
Always place the damping plunger prior to the wiper
ring, and make sure the wiper ring is correctly
positionned.
Fig. 33-205
4) Using a needle, remove the seal placed inside
the body (See Fig. 33-206 No.3, 4)
* Reassembly :
• Replace with a new seal and grease it.
3 4
Fig. 33-206
33-104
33. UPPER STRUCTURE
Fig. 33-208
33-105
33. UPPER STRUCTURE
Fig. 33-209
• Inspect the return springs. If defects are
detected, replace the 4 springs.
Fig. 33-210
(7) Throttle kit replacement
1) Remove
• The pilot control unit from the machine
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
• The damping plungers and springs (See
33.2.4.2 (5))
Fig. 33-211
33-106
33. UPPER STRUCTURE
THROTTLE
Fig. 33-212
(8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine
Fig. 33-214
33-107
33. UPPER STRUCTURE
Fig. 33-216
(9) Check valve kit removal
1) Remove the pilot control unit from the machine
CHECK VALVE
PLUG
BALL
Fig. 33-218
33-108
33. UPPER STRUCTURE
Fig. 33-219
33-109
33. UPPER STRUCTURE
33.2.5.1 CONSTRUCTION
(1) Swing motor
17
41
42
SECTION A-A
15,16
32 33
A PORT SIDE
RELIEF VALVE
A PORT
b 34
g
TOP DEAD POINT h BOTTOM DEAD POINT
i
B PORT
B PORT SIDE
31 RELIEF VALVE
30 a DRAIN PORT
29
28 34 39 38 37 36 35
MAKEUP PORT
16 15
17 18
14 19
13 20
43 b
c 21
12
MECHANICAL BRAKE
11
RELEASE CHAMBER
10 d 22
9 e 23
8 f 24
7 25
6 26
5 40
4
3 2 1 27
33-110
33. UPPER STRUCTURE
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 INNER RING 1 23 SNAP RING 1
2 OIL SEAL 1 24 CYLINDER 1
TAPERED ROLLER
3 1 25 HOUSING 1
BEARING
4 BACKING SPRING 1 26 COLLAR 1
5 CAM PLATE 1 27 SNAP RING 1
6 RETURN PLATE 1 78 (58) 28 BYPASS VALVE ASSY 2
7 PISTON ASSY 9 29 BACK-UP RING 2
8 LINING PLATE 3 30 O-RING ; 1B P18 2
9 PLATE 3 31 O-RING ; 1B P12 2
10 O-RING 1 32 COVER 1
11 PISTON 1 78 (58) 33 RELIFE VALVE ASSY 2
12 O-RING 1 34 O-RING ; 1B P26 4
13 SPRING 19 284 (209) 35 SOCKET BOLT ; M16×60 4
14 PISTON 2 36 CHECK VALVE 2
29 (22) 15 CAP 3 37 SPRING 2
16 O-RING ; 1B P11 3 137 (101) 38 CAP 2
17 PARALLEL PIN 2 39 BACK-UP RING ; T2 P26 2
18 SCROWAVE 4 40 PLUG 1
19 TEFLON RING 4 41 PISTON 2
20 BUSH 4 42 TEFLON RING 2
21 BALANCE PLATE 1 43 O-RING 1
22 NEEDLE BEARING 1
33-111
33. UPPER STRUCTURE
SECTION A-A
33-112
33. UPPER STRUCTURE
: 14 mm, 10 mm
36
25
: 14 mm
25
33-113
33. UPPER STRUCTURE
32
18
32
33-114
33. UPPER STRUCTURE
25
Oil seal (2) and outer race of taper roller bearing (3) are
left inside of housing (25).
25
33-115
33. UPPER STRUCTURE
25
SOFT CLOTH
ETC. 24
24
33-116
33. UPPER STRUCTURE
24
33-117
33. UPPER STRUCTURE
ROUND AREA
24
24
33-118
33. UPPER STRUCTURE
3
End surface of cylinder (24) is sliding face. So, protect (INNER RACE)
24
27
Be careful not to attach a bond to the roller of bearing
(3). Apply Loctite
Wipe off the bond which came out between a inner ring
24
(1) and bearing (3).
25
33-119
33. UPPER STRUCTURE
JIG 3
Be careful to keep cylinder (24), as it is slippery with oil. Top of housing
25
Check that backing spring (4) is held in place by the
probe part of the return plate (6).
30~40
When assemble cylinder assembly, splined shaft of the (1.18~1.58 in)
PAD
cylinder (24) is protruded from the end of housing,
therefore put pad with length 30~40 mm (1.18~1.58 in) Fig. 33-244 Assembling cylinder assy
under bottom of housing (25).
33-120
33. UPPER STRUCTURE
8
Apply hydraulic oil to each side.
25
11
10
Lubricate O-rings (10), (12) with grease.
25
33-121
33. UPPER STRUCTURE
18
Be cautions of assembling direction of balance plate
(21).
32
32
33-122
33. UPPER STRUCTURE
: 14 mm
Tightening torque ; 137 N•m {101 lbf•ft}
• Assemble bypass valve assembly (28) to cover
(32).
28
32
: 10 mm
Tightening torque ; 78 N•m {58 lbf•ft} Fig. 33-254 Assembling valve assy
33-123
33. UPPER STRUCTURE
(3) Tools
Jig 1 Jig 3
(For assmbling roller bearing (3) and inner race (1)) (For assembling cylinder assembly (24))
Jig 2 Jig 4
(For assembling oil seal (2)) (For assembling brake piston (11))
(0.04")
33-124
33. UPPER STRUCTURE
33.2.5.3.1 Tools
Unit : mm (in)
Code Tool name Remarks
450 (17.7)
Material : Mild steel
330 (13.0)
a Stand
280 (11.0)
22 (0.9)
216 (8.5)
Material : Mild steel
250 (9.8)
13- 24
Spherical bearing (13) (0.9)
b (Position
removing jig (I) space equally)
P.C.D 170
(6.7) VIEW X
X
110 (4.3)
removing jig (II)
160 (6.3)
Material : Mild steel
Oil seal (14)
(0.4)
110 (4.3)
g
9
installing jig
33-125
33. UPPER STRUCTURE
33.2.5.3.2 Disassembly
The numbers in parentheses correspond to the ones in
construction drawings .
(1) Preparation
1) Before disassembly, clean the outside of the
reduction unit thoroughly and check for no
damage and scoring.
2) Drain gear oil from the reduction unit.
3) Disconnect the drain hose.
4) Matching Mark
To facilitate the reassembly of the unit, put
matching mark on the joining parts of the housing
before disassembly.
: 12 mm 4
2
33-126
33. UPPER STRUCTURE
33-127
33. UPPER STRUCTURE
16
17
JIG (a)
JIG (c)
17
16
12
33-128
33. UPPER STRUCTURE
14
• Do not use the removed oil seal and bearing.
13
15
JIG (d)
8 22
Pinions (6) can not be replaced singly. Replace them it
Fig. 33-265 Disassembling #2 spider assy
in a set of four.
33-129
33. UPPER STRUCTURE
33.2.5.3.3 Assembly
(1) Preparation
1) Sufficiently clean every part with wash oil and dry
it with compressed air.
16
12
33-130
33. UPPER STRUCTURE
15
Fig. 33-271
33-131
33. UPPER STRUCTURE
13
15
33-132
33. UPPER STRUCTURE
Fix the snap ring with the sharp edge on the motor side
(top side in the position of Fig. 33-275).
18
4
SNAP RING (20)
Motor side 3
20
Insert shaft (6) into spider (8) so spring pin hole (22) is 11
aligned.
6
19
8 22
33-133
33. UPPER STRUCTURE
15
: 27mm
15
(10)Filling Lube Oil
Fill in 7.0L 1.9gal) of gear oil SAE90 (API Service Fig. 33-280 Installing #1 spider assy
Grade GL-4).
33-134
33. UPPER STRUCTURE
33-135
33. UPPER STRUCTURE
2) Gears
a. Inspect that the gear teeth do not show pitting and seizure.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.
3) Bearing
Turn the bearing and check that it does not develop abnormal sound, catching and other faults.
Do not reuse spherical bearing
33-136
33. UPPER STRUCTURE
Unit : mm (in)
Code Item Repairable level Service Limit Remedy
A Wear in #1 planetary shaft ø40
0
(1.57 -0.0004 ) Replace entire spider assy.
No flaking
B Wear in #2 planetary shaft ø40
0
(1.57 -0.0004 ) Replace four shafts as a set.
There should be no pitting
Replace
Condition of tooth face exceeding 1.6mm (0.0630in) dia,
C Gears (Planetary pinion should be
abnormal wear or seizure.
replaced in a set of four.)
Condition of tooth flank There should be no cracks.
D Thickness of thrust washer 1.6±0.1 (0.06 ±0.0039) 1.3 (0.0512) Replace
E Thickness of thrust washer 2.0±0.1 (0.08 ±0.0039) 1.6 (0.063) Replace
Wear in shaft
F (Diameter of part coming in contact ø105 0
(4.13 -0.003 ) ø104.9 (4.13) Replace
with oil seal )
Apply Three-Bond 1360K and
G Socket bolt tightening torque M14- 181 N•m (130 lbf•ft)
tighten to specified torque.
Gear oil SAE90
H Lube oil 7.0 L (1.9 gal) Replenish or replace.
(API Service Grade GL-4)
33-137
33. UPPER STRUCTURE
33.2.5.5 TROUBLESHOOTING
parts ports and apply a pilot pressure smoothly at a torque of 30~40 parts or the whole motor
of 3.2~4.9 MPa (464~711 psi) N•m (22~30 lbf•ft) it is assembly.
to the brake release port then highlylikely that an internal
check that the output shaft can parts in broken so disassemble
be turned through at by a the motor to investigate.
torque of approximately 30~40
N•m (22~30 lbf•ft).
Miss-setting of the relief Use a pressure gauge to Reset to the regulation
valve in the circuit measure loaded pressure. pressure setting.
Measure the drain volume. If the drain volume is 2.5 L/min See table B.
Excessive slippage
33-138
33. UPPER STRUCTURE
circuit in the drain filter.Open the does not turn smoothly at a Replace the motor
motor inlet and outlet ports and torque of 30~40N•m (22~30 assembly.
apply a pilot pressure of lbf•ft), it is highly likely that an
3.2~4.9 MPa (464~711 psi) to internal part is broken so
the brake release port then disassemble the motor to
check that the output shaft can investigate.
be turned through at by a
torque of approximately 30~40
N•m (22~30 lbf•ft).
Oil leakage from joints
Loose bolts Inspect for loose bolts. Tighten to the correct torque.
Abnormal pressure Investigate the pressure in the Reduce pressure within the Replace the oil seal.
inside the case case and the drain volume. case to 0.3 MPa (44 psi) or less. Repair or replace
If the drain volume is excessive, damaged parts.
disassembly and investigation Replace the motor
is required. assembly.
Table B
33-139
33. UPPER STRUCTURE
)(
"#
$
#
$% #
$
*(
!
33-140
33. UPPER STRUCTURE
16,17
5 (0.197")
Apply Three Bond
6 #1805 to stem
2 places
5
6 places
7 8 9
10,14
4 places 3 4 2 places 4 places
33-141
33. UPPER STRUCTURE
33.2.6.2.1 Tools
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m×1.5m (4ft×5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.
33-142
33. UPPER STRUCTURE
33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure 2
correspond to those of a construction drawing in Fig. 1
33-282. 3
9
(1) Removing cover
1) Mark cover (3) and body (1) with matching marks
for convenient reassembly.
2) Place a V-block on a work bench, place a swivel
joint set on the side, fix it and loosen socket bolt
ALLEN WRENCH
(9) by means of a pipe and wrench. Alternately,
the swivel joint may be fixed by holding stem (2) V-BLOCK PIPE
in a vise.
: 6 mm
PIPE
2
STEM
33-143
33. UPPER STRUCTURE
O-RING
GROOVE
OIL GROOVE
SEAL (5) SEAL GROOVE
33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of
assembly.
(1) Assembling seals to body
1) Apply hydraulic oil to O-ring (6) thinly and insert
it in O-ring groove.
Check the twist of O-ring
2) Slipper ring is assembled, after first inserting the
backup ring, by slightly-distorting the shape as
shown in Fig. 33-289. Also after inserting all of
the seals, be certain that these are installed in
the seal groove by use of the spatula.
3) Apply grease to seal (5) top.
33-144
33. UPPER STRUCTURE
WORK BENC
: 6 mm,
Tightening torque : 30.4 N•m (22 lbf•ft)
ALLEN WRENCH
PIPE
33-145
33. UPPER STRUCTURE
33-146
33. UPPER STRUCTURE
Replace
(With back-up ring)
Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)
BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)
33-147
33. UPPER STRUCTURE
Open stop valve (6) on the side of low pressure
relief valve (5) and while watching the pressure
!
gauge (for low pressure) connected to the body
" ! "
*
side and also by regulating low pressure relief valve
+%,- .
/
(5), gradually increase the pressure and check for
outside leakage with a color check at a pressure of !
!
$ %
33.2.6.3.4 Troubleshooting
33-148
34. TRAVEL SYSTEM
TABLE OF CONTENTS
34-1
34. TRAVEL SYSTEM
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and attaching procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
34-2
34. TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER
6. SPROCKET
TRACK GUIDE LOWER FRAME
GREASE NIPPLE OF THE
3. UPPER ROLLER
TRACK SPRING ADJUSTER
4. LOWER ROLLER
Fig. 34-1 Designation and location of undercarriage
34.1.2 CRAWLER
: 19 mm
34-3
34. TRAVEL SYSTEM
34.1.2.2 INSTALLING
Installing is done in the reverse order of removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in the
figure on the right.
34-4
34. TRAVEL SYSTEM
: 19 mm
Standard dimension A
Dimension of iron crawler in 380~410mm
a max. slackened condition (15.0~16.1in)
34.1.2.3 CONSTRUCTION
1-3
1-8 1
1-1
1-7 3
1-4
1-2 4,5,6
1-6
1-5
1-9 1-10
1-11 2
SK460-8 SK480LC-8
LS60D00008F3 LS60D00009F3
Shoe Shoe
LS60D00008F2 LS60D00009F2
assy assy
LS60D00008F1 LS60D00009F1
No. NAME Q'TY No. NAME Q'TY
1 •LINK ASSY LS62D00004F1 1 1 1 1 •LINK ASSY LS62D00004F2 1 1 1
1–1 ••TRACK LINK R 45 45 45 1–1 ••TRACK LINK R 48 48 48
1–2 ••TRACK LINK L 45 45 45 1–2 ••TRACK LINK L 48 48 48
1–3 ••MASTER LINK R 2 2 2 1–3 ••MASTER LINK R 2 2 2
1–4 ••MASTER LINK L 2 2 2 1–4 ••MASTER LINK L 2 2 2
1–5 ••TRACK BUSHING 45 45 45 1–5 ••TRACK BUSHING 48 48 48
1–6 ••TRACK PIN 45 45 45 1–6 ••TRACK PIN 48 48 48
1–7 ••MASTER BUSHING 2 2 2 1–7 ••MASTER BUSHING 2 2 2
1–8 ••MASTER PIN 2 2 2 1–8 ••MASTER PIN 2 2 2
1–9 ••COLLAR 4 4 4 1–9 ••COLLAR 4 4 4
1–10 ••SEAL 90 90 90 1–10 ••SEAL 96 96 96
1–11 ••PIN 2 2 2 1–11 ••PIN 2 2 2
2 •BOLT LS60D01001P1 188 188 188 2 •BOLT LS60D01001P1 200 200 200
3 •NUT LS60D01002P1 188 188 188 3 •NUT LS60D01002P1 200 200 200
4 •SHOE 600mm 47 — — 4 •SHOE 600mm 50 — —
5 •SHOE 600mm (HD) — 47 — 5 •SHOE 600mm (HD) — 50 —
6 •SHOE 800mm (HD) — — 47 6 •SHOE 800mm (HD) — — 50
34-5
34. TRAVEL SYSTEM
C
H
Fig. 34-10
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Link pitch 228.6 (9.0) 232 (9.13) 234 (9.21) Replace the link
B O.D. of bushing ø 73.33 (2.887) ø 69 (2.717) ø 68 (2.677) assy if the service
C Height of link 129 (5.08) 123 (4.84) 121 (4.76) limit is exceeded
Basic
Tolerance Fit Fit
dimension
Interference between bushing + 0.1
D Interference Interference
and link ø 73.33 (+0.0039)
Shaft 0.30 0.26
(2.887) 0
(0.012) (0.010) Replace
(0)
+ 0.1
Interference Interference
Interference between track pin ø 48.83 (+0.0039)
E Shaft 0.30 0.26
and link (1.922) 0
(0.012) (0.010)
(0)
+ 0.03
Interference Interference
Interference between master ø 48.58 (+0.00118)
F Shaft 0.05 0.03 Replace Link
pin and link (1.913) 0
(0.0020) (0.0012)
(0)
8 (0.32) 10 (0.39)
G Clearance between links 1.5 (0.06) (both side) Replace
(both side) (both side)
H Tightening torque of shoe bolt 1370 N•m (1010 lbf•ft) Reassembly
Unit : mm (in)
NAME OPPOSING FLATS
19, 36
Socket
(2) Jig
NAME SHAPE
34-6
34. TRAVEL SYSTEM
34.1.3.2 REMOVING
(1) Preparation for removal " ! !
Remove crawler (Above mentioned).
: 30 mm
34.1.3.3 INSTALLING
Installing is done in the reverse order of removing. Center of machine
(1) Inspection
Before reassembling, check it that it rotates smooth
manually and for leakage.
3,4
1
(2) Installing upper roller (1)
1) To install the upper roller, turn up nut (4) toward
the center of machine.
2,3
2) Insert it until collar comes in contact with support.
: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
34-7
34. TRAVEL SYSTEM
34.1.3.4 CONSTRUCTION
11 8 6
: 10mm
2
13
6) Removing shaft (2)
Put the extrusion jig (h) against the end face of 3
shaft (2) and push shaft (2) with collar (3) for
floating seal (13), using a press or hammer.
f
34-8
34. TRAVEL SYSTEM
(2) Assembly
f
Assembly of the upper roller is done in the reverse
order of disassembly.
1) Place upper roller (1) on the top end face of jig
(f), with its floating seal setting side facing down.
2) Confirm that the outer surface of bushing (6) is Fig. 34-18 Pushing in bushing
not seized and coat the outer surface of the
inserting side of the bushing, with molybdenum 13
13
disulfide grease.
3 1
3) Put jig (i) into bushing (6) and press it in, using
2
the bore of the bushing and the bore of the roller
as guides.
34-9
34. TRAVEL SYSTEM
5
11) Installing plug (10).
Wind seal tape around plug (10) and screw it into 1
the plug hole of cover (4).
: 6mm,
Tightening torque : 23N•m (17 lbf•ft)
34-10
34. TRAVEL SYSTEM
C
D D
F
J H
Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
A Dia. ø 185 (7.28) ø 177 (6.97) ø 174 (6.85)
Reinforcement
B Tread dia. ø 160 (6.30) ø 152 (5.98) ø 149 (5.87)
weld, repair or
C Width 95 (3.74) 90 (3.54) 85 (3.35)
replace
D Flange width 19 (0.748) 17 (0.669) 15 (0.591)
Basic
Tolerance Standard Limit
dimension
Clearance between shaft and -0.025
E
bushing ø 65 (-0.0010) Clearance Clearance
Shaft
F (+0.0012)
and bushing (2.7559) — 0
0
Tightening torque of socket
H 114.7 N•m (85 lbf•ft) Apply loctite #262
bolt
J Oil Engine oil API grade CD #30, 100cc (6.1cu•in) Refill or replace
Roller rotation Roller rotates smoothly by hand.
34-11
34. TRAVEL SYSTEM
Unit : mm
Name Opposing flats
30
Socket
(2) Jigs
Unit : mm (in)
No. Name Shape
160 (6.30")
120 (4.72") 200 (7.87")
f Stand jig
65 (2.56")
For extruding
g
(0.787")
bushing
20
50 (1.97")
For extruding
h
(1.18")
shaft
(1.953" +0.004" )
+0.1
0
0
69.5
(2.74")
64.6
Bushing fixing
i
jig
20 65 (2.56")
(0.787")
85
(3.35")
34-12
34. TRAVEL SYSTEM
34.1.4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wood) at the front and back
of the lower frame.
: 36mm,
Weight of track guide : B2 : Approx. 49kg (108 lbs)
B3 : Approx. 54kg (119 lbs)
ROLLER
SK480LC-8 LC LS01F00013F1
ITEM NAME Q'TY
B7 B3 B2 B7
B2 TRACK GUIDE : LS63D00001P1 2
B3 TRACK GUIDE : LS63D00002P1 2
This drawing shows LC specification.
B7 CAPSCREW : M24X60(P=2.5) 16 STD,LC
: 32 mm,
Weight of lower roller : Approx. 97kg (214 lbs)
34-13
34. TRAVEL SYSTEM
34.1.4.3 INSTALLATION
(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and
fasten all 4 capscrews temporarily. Then tighten
them to a specified torque.
: 32 mm,
Tightening torque : 731N•m (539 lbf•ft)
(2) Installation of track guide
Capscrews (B7) with Loctite #262 and fasten all 4
capscrews temporarily. Then tighten them to a
specified torque.
: 36 mm,
Tightening torque : 932N•m (687 lbf•ft)
(3) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
: 19 mm,
Tightening torque : 59N•m (43 lbf•ft)
34-14
34. TRAVEL SYSTEM
34.1.4.4 CONSTRUCTION
8 JIG P
4) Removing shaft (4)
In addition, push out and remove shaft (4) 2 or 3
together with the lower collar (2) or (3) and O-ring
1
(8).
4
JIG M
The shaft (4) extrusion operation may cause the
remaining lube oil to flow out. Prepare an oil container
beforehand.
3 or 2
34-15
34. TRAVEL SYSTEM
11
JIG M
34-16
34. TRAVEL SYSTEM
(2) Installing 8 4
1) Attach O-ring (8) to one side
Install O-ring (8) to groove on shaft.
• Grease O-ring.
• Replace O-ring with new one without fail at Fig. 34-33 Attach O-ring (8) to one side
reassembling.
2,3
34-17
34. TRAVEL SYSTEM
11
• Check that the seal surface is free from flaws,
rusts, etc. before reusing the floating seal.
4
6) Inserting roller (1)
Insert roller (1) from the side where collar (2) or 2,3
8
(3), O-ring (8) is not press-fitted to the shaft (4).
Fig. 34-37 Inserting roller (1)
7) Installing O-ring (8)
PRESS
Install O-ring (8) to groove on shaft.
• Grease O-ring.
2 or 3
• Replace O-ring with new one without fail at
reassembling. 8
: 6 mm,
Tightening torque : 21.6~24.5 N•m Fig. 34-39 Installing filling oil plug (9)
(16~18.1 lbf•ft)
34-18
34. TRAVEL SYSTEM
C C
D
A
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A O.D. of flange ø 268 (10.6) — — Reinforcement weld,
B Tread dia. ø 220 (8.66) ø 205 (8.07) ø 204 (8.03) repair or replace
C Flange width 23.5 (0.925) — —
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 89.94 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft
(3.5409) - 0.090 0.7 (0.276) 1.0 (0.394) Replace bushing
(-0.00354)
+ 0.035
Interference between ø 93.94 (+0.0014) Interference Interference
E Hole
roller and bushing (3.6984) 0 0.18 (0.0071) 0.16 (0.0063)
(0)
F Oil Engine oil API grade CD #30, 500cc (30.5 cu•in) Refill
Execute air leak test at 0.2MPa (28psi)
H Plug (9)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
34-19
34. TRAVEL SYSTEM
Unit : mm
NAME OPPOSING FLATS
19, 32, 36
Socket
Allen wrench 6
(2) Jig
Unit : mm (in)
No. NAME SHAPE
K V-block
180(7.09)
Pin (6)
(0.630)
L
16
extrusion rod
16 (0.630)
360(14.2)
Bushing
N
extrusion rod
450(17.7)
260(10.2)
M Stand jig
(8.66)
220
450(17.7)
Shaft
P
(3.39)
extrusion jig
86
(0.984)
25
120(4.72)
100(3.94)
Bushing
75(2.95)
Q
fixing jig
+0.1
89.6 0
(3.53 +0.004
0 )
34-20
34. TRAVEL SYSTEM
1 4
The grease nipple is on the outer
side of the frame.
T=60N.m (43 lbf.ft)
Fig. 34-41 Front idler assy
34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
(3) Installing
Installing is done in the reverse order of removing.
3 4
34-21
34. TRAVEL SYSTEM
34.1.5.3.1 CONSTRUCTION
: 5 mm
U
2
34-22
34. TRAVEL SYSTEM
34-23
34. TRAVEL SYSTEM
: 5 mm
Tightening torque : 11N•m (8.8 lbf•ft) Fig. 34-52 Installing collar (2) and filling oil
210(8.27")
C
F
D
E
B
A
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. of idler projection ø 726 (28.6) — —
B Tread dia. ø 676 (26.6) ø 665 (26.2) ø 662 (26.1) Replace
C Flange width 107 (4.21) 101 (3.98) 99 (3.90)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 110 (-0.00118) Clearance Clearance
Shaft Replace
(4.3307) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
+ 0.035 Clearance
Interference between idler and ø 125 Interference
E Hole (+0.00138) 0.01
bushing (4.9212) 0
0 (0.0004)
F Oil Engine oil API grade CD #30, 400cc (24.4cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble
34-24
34. TRAVEL SYSTEM
Unit : mm
NAME OPPOSING FLATS
36
Socket
Allen wrench 5
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
(0.709)
(1.18)
18
30
R Pin striking jig
(0.591)
160(6.30) 15
450 (17.7)
400(15.7)
Approx.200
(8)
Approx.900
(36)
U Stand
Approx.
500(20)
2 pcs.
(0.787)
160(6.30)
20
110(4.33)
jig
+0.1
109.6 0
(4.315 +0.004
0 )
34-25
34. TRAVEL SYSTEM
34.1.5.4.1 CONSTRUCTION
H d E
C
A,B F
BRACKET
SECTION H-H
Fig. 34-55
34-26
34. TRAVEL SYSTEM
34.1.6 SPROCKET
34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to "34.1.2 CRAWLER",
lift up crawler frame with attachment, and put it on
square timbers to float and stabilize.
: 36 mm
34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction unit
and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.
: 36 mm
Tightening torque : 932 N•m (690 lbf•ft)
34-27
34. TRAVEL SYSTEM
115.4mm NUMBER OF
PITCH 23
(4.54in) TEETH
SPECIFICATION
ø73.33mm 847.304
ROLLER DIA. PITCH DIA.
(2.89in) (33.4in)
B
R .23
6 6
(0
67 (2.64")
")
R 46"
(1
37 )
.
R5 ")
97
1
( 0.
A
Fig. 34-59 Sprocket
Unit:mm (in)
REPAIRABLE SERVICE
No. NAME STANDARD VALUE REMEDY
LEVEL LIMIT
Reinforcement weld,
A O.D. of sprocket ø 876 (34.5) ø 868 (34.2) ø 866 (34.1)
repair or replace.
B Width of sprocket teeth 89 (3.504 ) 83 (3.27) 81 (3.19) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 773.3 (30.4) ø 765 (30.1) ø 763 (30.0)
repair or replace.
Unit : mm
NAME OPPOSING FLATS
36
Socket
34-28
34. TRAVEL SYSTEM
Unit : mm (in)
34-29
34. TRAVEL SYSTEM
34.1.7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
(2) Removing cover (1)
Remove sems bolt (14) M12×25 and also remove
covers (1).
14
: 19 mm
1
(3) Preparation of oil pan
(4) Removing hydraulic pipe
Release pressure from travel circuit, and bleed air Fig. 34-62 Removing and installing cover (1)
in hydraulic oil tank, then remove all pipes
connecting to travel motor. Then plug up all pipes
and joint section to protect them from entry of dust.
34-30
34. TRAVEL SYSTEM
: 36 mm
3
Fig. 34-64 Removing and installing sprocket
(6) Loosening travel motor attaching bolts (2) REMOVE PIPES (DISCONNECT)
Apply match marks on travel motor and crawler
frame, and remove 27 (one side) capscrews (2)
M24×75.
: 36 mm
34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the TOOLS NO. TIGHTEING
NAME SIZE TORQUE REMARKS
reverse order of removal. HEX N.m(lbf.ft)
34-31
34. TRAVEL SYSTEM
FRONT A A
2
Apply Loctite #262 or equivalent
Tightening torque 1177 N.m (868 lbf.ft)
SECTION AA
34.1.8.2 REMOVING
(1) Matchmarks
SWING BEARING
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame. OUTER RACE
INNER RACE
(2) Remove 36 capscrews (2) M27×90 for installation
inner race. MATCHMARKS
: 41 mm
GREASE BATH
34-32
34. TRAVEL SYSTEM
34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust
and dirt.
(2) Installing
Install swing bearing on lower frame meeting the FRONT A A
matchmarks and positioning the S mark on inner
race as shown in Fig. 34-70.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) temporarily.
: 41 mm
INNER S ZONE POSITION OF
(4) Regular tightening of inner race SWING BEARING
Tighten the capscrews (2) at 180 degrees intervals Fig. 34-70 Location of S mark on swing bearing
alternately to a specified torque.
: 41 mm,
Tightening torque : 1177 N•m (868 lbf•ft)
(5) Filling grease 1
Fill grease bath with 22kg (48.5 lbs) of grease
(NIHON GREASE CO.LTD EP-2K) or equivalent. LOCTITE #262 OR
2 EQUIVALENT
TO BE APPLIED
SECTION AA T=564N.m (416 lbf.ft)
34.1.8.4 CONSTRUCTION
6
SWING BEARING LS40F00008F1
1 1-2
No. NAME Q'TY No. NAME Q'TY
9
1 OUTER RACE 1 4 RETAINER 107
1-3
1-2 PLUG 1 5 SEAL 1 3
1-3 TAPER PIN 1 6 SEAL 1
5
2 INNER RACE 1 9 GREASE NIPPLE(PT1/8) 1 2
3 BALL 107
Fig. 34-72 Sectional view of swing bearing
34-33
34. TRAVEL SYSTEM
2
4
3
Fig. 34-74 Removing balls (3) and retainers (4)
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1) and
the groove for seal (5) located on the outer
surface of inner race (2). Coat the grooves with 1
adhesive Cyano Bond PX-3000 equivalent, fit PUSH ROD 6
seal (5) and place it on a surface plate.
2) Lower outer race (1) to the position where upper 2
surface of inner race (2) and lower portion of seal SQUARE 3
WOODEN BLOCK 5
groove is mated, put adjusting washer under
outer race (1) so that outer raceway surface of Fig. 34-75 Fitting balls (3)
ball (3) aligns with inner raceway, and support it.
EYE BOLT
3) Insert ball (3) and retainer (4), on which grease
is applied, through plug (8) hole on outer race
(1), alternately.
HOOKED ROD
To insert ball (3) and retainer (4), use a push rod, etc.,
to protect persons from injury from inserting fingers into 4
plug hole. SQUARE
WOODEN BLOCK
4) Fit plug (1-2) to outer race (1) while checking it Fig. 34-76 Fitting retainer (4)
for direction and position of taper pin hole.
5) Coat seal (6) with adhesive Cyano Bond PX-
3000 equivalent and fit it in the groove of outer
race (1).
6) After completion of assembly, caulk the edge of
taper pin (1-3) by punching.
7) Check that grease nipple (9) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.
• Shell Albania EP#2 ; 330cc (20.1cu•in)
34-34
34. TRAVEL SYSTEM
34-35
34. TRAVEL SYSTEM
56-3 56-2 56-1 56-12 56-13 56-4 56-9 56-8 56-12 56-10 56-11 56-6 56-7 56-5
34-36
34. TRAVEL SYSTEM
34-37
34. TRAVEL SYSTEM
34.2.3.1 TOOLS
(2.76")
(0.79")
20
70
100 (3.94")
(1.46")
37
P.C.D. 251 (9.88")
o 280 (11.0")
o 215 (8.47")
o 195 (7.68")
(1.58")
(0.95")
o 40
o 24
2-M18X35 (1.38")
(0.26")
o 6.5
2 - 20 (0.79")
drill hole
20 (0.79")
100 (3.94")
25 (0.98") ")
0.08
R2(
In case of using Hex. socket
head bolt for mounting
100 (3.94")
(1.42")
7.7 (0.30")
.5 )
o 36
o 67.5 (2.66")
(0
o 90 (3.54")
3
(0.12")
Jig for inserting oil seal
Jig for inserting rear bearing
34-38
34. TRAVEL SYSTEM
34.2.3.2 DISASSEMBLY
a. GENERAL INSTRUCTIONS
(1) Generally, hydraulic equipment is precisely
manufactured and clearances between each parts
are very narrow.
Therefore, disassembling and assembling works
should be performed on the clean place where
dusts hardly gather.
Tools and kerosene to wash parts should also be
clean and handled with great care.
(2) When motor is removed from the host machine,
wash around the ports sufficiently, and put the
plugs so that no dust and / or water may invade.
Take off these plugs just before the piping works
when re-attach it to the host machine.
(3) Before disassembling, review the sectional drawing
and prepare the required parts, depending on the
purpose and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not
reusable. There are some parts that should be
replaced as a sub-assembly.
Consult with the parts book in advance.
(4) The piston can be inserted to whichever cylinder
block for the initial assembling.
However, their combination should not be changed
if they are once used. To reuse them, put the
matching mark on both pistons and cylinder block
before disassembling.
(5) Take great care not to pinch your hand between
parts while disassembling nor let fall parts on your
foot while lifting them.
b. DISASSEMBLY PROCEDURES
(1) Removing accessory valves
Before disassembling motor, remove accessory
valves.
34-39
34. TRAVEL SYSTEM
Put the matching mark on both spool assy (25) and rear
cover (23) so that spool assy (25) should not be
reversed on re-assembling.
It is impossible to disassemble this spool assy (25)
further because spool assy (25) is fixed by adhesive.
34-40
34. TRAVEL SYSTEM
: 14mm
Put the matching mark on both valve plate (53) and rear
cover (23) so that valve plate (53) should not be
reversed on re-assembling.
50
34-41
34. TRAVEL SYSTEM
• Put piston assys (17) into the cylinder block (12)
matching the matching mark with shoe retainer (16)
as if assembled.
The purpose is to put piston assys (17) in the same
bore of cylinder block (12) as before when
reassembled.
• Take care not to scratch sliding surfaces.
Do not reuse damaged ones. Fig. 34-83 Removing cylinder block
• It is impossible to disassemble piston and shoe
because they are calked together.
34-42
34. TRAVEL SYSTEM
Be aware of shifter piston (5) popping out. Fig. 34-84 Enlargement figure of matching surface
of casing
16) Shaft (8) can comes out now.
34-43
34. TRAVEL SYSTEM
56-3 56-2 56-1 56-12 56-13 56-4 56-9 56-8 56-12 56-10 56-11 56-6 56-7 56-5
34-44
34. TRAVEL SYSTEM
GREASE
34-45
34. TRAVEL SYSTEM
(4) Insert shaft (8) into casing (1) after coating grease
on the contact surface to oil seal (3) lip.
(5) Put shifter piston assy (5), (6), (7) into casing (1).
34-46
34. TRAVEL SYSTEM
34-47
34. TRAVEL SYSTEM
Guide pin
: 14mm
Tightening torque : 324N•m (239 lbf•ft)
34-48
34. TRAVEL SYSTEM
: 32 mm
Tightening torque : 98~117.6N•m (72.3~86.7 lbf•ft)
34-49
34. TRAVEL SYSTEM
34-50
34. TRAVEL SYSTEM
Lap together the surfaces of both cylinder block and valve plate to remedy
their roughness. (Lap with #1200 powder)
34-51
34. TRAVEL SYSTEM
(1.34" +0.008"
+0.004" )
Dial gauge o34 ( +0.2
+0.1)
85 (3.35")
Piston
Jig
MagnetStand
26 (1.02")
Shoe
Work stand
o32 (1.26")
Method Play
o43 (1.69")
Jig
Fig. 34-95 Method & Play & Jig
Allowable
ITEM & MEASURING METHOD Check Items Criteria Disposition
Roughness
(4) Parking brake torque
Replace all
After completion of assembly, set
902N•m 812N•m separator and
the torque wrench on the shaft Parking brake torque
(670 lbf•ft) (600 lbf•ft) friction plates
end, and measure the braking
springs
torque generated when the shaft
starts to rotate.
Standard of replacing friction and
separating plate.
34-52
34. TRAVEL SYSTEM
(6) Bearing Replace bearings (9), (50) before hour meter of host machine indicates
10,000 hours.
Replace bearing (9), (50) after
decided hours.
• In case replacing the bearings(9), (50), replace both inner and outer races
at the same time.
• Also the bearing shims (51) must be re-adjusted when replaced shaft (8)
and/or bearings (9), (50). Contact dealers for jigs and tools required.
(7) Splines If the wear of splines is less than 0.3 mm (0.012"), the spline is reusable.
Replace if the wear of splines
exceeds the allowable value.
(8)Overload relief valve Replace relief valve part as an assembly each time the host machine works
for 10,000 hours.
Do not try to adjust the valve,
since special hydraulic test bench
is required for inspecting and
adjusting the pressure.
34-53
34. TRAVEL SYSTEM
34-54
34. TRAVEL SYSTEM
34-55
34. TRAVEL SYSTEM
34.2.7.1 TOOLS
jigs and measuring instruments.
200 or more
(20.9")
(7.87")
415
(16.3")
34.2.7.2 DISASSEMBLY
(1) Preparation before removal
1) The travel unit removed from the machine has dust and mud. Wash them with cleaning oil.
2) Loosen drain or oil filling plug (29) and drain the oil out of the reduction unit.
When oil is hot, pressure is built up inside. Take care as the oil gushes out in some cases.
• The numbers in the parentheses after part names correspond to those in the assembly drawing on Fig. 34-
79.
34-56
34. TRAVEL SYSTEM
: 8mm
28
27
34-57
34. TRAVEL SYSTEM
12
(13,14,15,16)
34-58
34. TRAVEL SYSTEM
4) Remove Hex. socket head bolts M20×120 (4), Fig. 34-104 Disassembling housing assy
leaving two of them diagonally.
: 17mm
34-59
34. TRAVEL SYSTEM
23
2) Tap carrier pins 1 (23) out from carrier 1 (19).
19
3) Remove thrust washers 1 (21), planetary gears
1 (20) and needle bearings (22) from carrier 1
(19). 19
19
4) Knock out spring pins 6×36 (24) from carrier pins
1 (23) for re-assembling.
21
34-60
34. TRAVEL SYSTEM
16
15
When carrier pins 2 (15) are to be re-used, mark each 11
pin with its mated hole of carrier 2 (11) to assure the 11
same combination as before.
34-61
34. TRAVEL SYSTEM
34.2.8 ASSEMBLING
(1) GENERAL INSTRUCTIONS
11
1) Clean every part by kerosene and dry them by air
blow. Surfaces to be applied by Loctite must be
degreased by solvent.
12(13,14)
16
2) Install carrier pins 2 (15) into carrier 2 (11) where
the holes for spring pins 10×63 (16) are to be in 11
line with those of carrier 2 (11).
3) Install spring pins 10×63 (16) into carrier 2 (11) Fig. 34-110 Drive spring pin
and at the same time into carrier pins 2 (15).
(Sink spring pins of 1 - 2 mm (0.04"~0.08") from
surface)
34-62
34. TRAVEL SYSTEM
: 8mm
Tightening torque : 53.9N•m (39.8 lbf•ft)
34-63
34. TRAVEL SYSTEM
: 17mm
Tightening torque : 461N•m (340 lbf•ft)
34-64
34. TRAVEL SYSTEM
S
When measuring the assembling width "A", rotate D A
3) Measure the motor side assembling width "B" for Fig. 34-116 Deciding shim thickness
bearings (2).
34-65
34. TRAVEL SYSTEM
34-66
34. TRAVEL SYSTEM
: 14mm
Tightening torque : 147.1N•m (108 lbf•ft)
34-67
34. TRAVEL SYSTEM
Fig. 34-124
Maintenance standards
Mark Items Criteria Allowable limit Disposition
Smooth, without abnormal Replace 3 pieces
A Wear of planetary shaft ←
wear or seizure as a set
Replace (Replace 3
Smooth, without abnormal Not over 1.6mm (0.063") of
B Condition of tooth surface pieces as a set for
wear or seizure pitching nor cracks at root
planetary gears)
Adjust shim
Thrust clearance of angular From -0.08 mm To 0.02 mm
C ← thickness
bearings (2) (-0.0031"~0.0008")
[Refer to 34.2.8(6)]
Thickness of thrust washer 1 From 3.9 mm To 4.1 mm 0.1 mm (0.004")
D Replace
(21) (0.15"~0.16") of wear
Thickness of thrust washer 2 4.4±0.2mm 0.15 mm (0.006")
E Replace
(17) (0.17"~0.18") of wear
4.5±0.16mm 0.15 mm (0.006")
F Thickness of thrust plate (26) Replace
(0.171"~0.183") of wear
G Lubrication oil 2,000 working hours (engine hour meter) Replace
34-68
34. TRAVEL SYSTEM
34-69
34. TRAVEL SYSTEM
[MEMO]
34-70
46. TROUBLE SHOOTING
(BY ERROR CODES)
TABLE OF CONTENTS
46
46-1
46. TROUBLE SHOOTING (BY ERROR CODES)
46-2
46. TROUBLE SHOOTING (BY ERROR CODES)
Preface
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred. This
manual describes how to solve the specific
phenomenon systematically as early as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equipment.
46-3
46. TROUBLE SHOOTING (BY ERROR CODES)
46-4
46. TROUBLE SHOOTING (BY ERROR CODES)
46-5
46. TROUBLE SHOOTING (BY ERROR CODES)
46-6
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting
condition range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Service Screen No. 2 G-3 SPEED SET
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table46-2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within
condition the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Service Screen No. 9 E-1 P1 PUMP
diagnosis Screen No. 9 E-2 P2 PUMP
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
46-7
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-3
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-4
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Control can be done by default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-8
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-5
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-6
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Control in the
Normal control is available.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-9
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-7
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-8
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch on
SE-3 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-10
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-9
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
Control in the
mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-10
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-11
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-11
Error code B022
Trouble Boom down pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-12
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
SE-4 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-127F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-12
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-13
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-14
Error code B032
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-out operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B032 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-13
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-15
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
SE-8 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B033 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-131F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-16
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-14
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-17
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B042 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-18
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
SE-7 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B043 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-130F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-15
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-19
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-20
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-16
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-21
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B053 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-22
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B054 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-17
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-23
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket dump pressure sensor When B062 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket dump When B062 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F
CN-101F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-24
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket dump pressure sensor When B063 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket dump When B063 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-18
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-25
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket dump pressure sensor When B064 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket dump When B064 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-26
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The swing operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B072 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-19
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-27
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B073 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B073 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-28
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B074 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B074 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-20
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-29
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel right
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-30
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B093 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B093 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-21
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-31
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B094 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B094 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-32
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-22
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-33
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B103 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B103 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-34
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B104 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B104 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-23
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-35
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B113 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B113 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-36
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B114 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B114 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-24
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-37
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-304F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-38
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B163 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-25
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-39
Error code B164
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B164 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-40
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B172 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B172 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-303F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-26
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-41
Error code B173
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B173 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B173 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-42
Error code B174
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B174 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B174 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-27
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-43
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-44
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C013 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C013 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-28
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-45
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C014 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-46
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-29
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-47
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C023 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C023 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-48
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C024 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-30
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-49
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-50
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-31
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-51
Error code C043
Trouble Boom rod pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom rod pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-4 BOOM-ROD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom rod pressure sensor When C043 is cancelled and other error occurs by turning starter switch on
SE-25 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom rod When C043 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-705F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-52
Error code C044
Trouble Boom rod pressure sensor’s power source is shortcut.
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-4 BOOM-ROD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom rod pressure sensor When C044 is cancelled and other error occurs by turning starter switch on
SE-25 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom rod When C044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-705F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-32
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-53
Error code D012
Trouble P1 bypass cut proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Set output of P1 bypass cut proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 bypass cut proportional When D012 is cancelled and other error occurs by turning starter switch on
valve after exchanging the connector with other sensor.
PSV-D Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 bypass cut When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-54
Error code D013
Trouble P1 bypass cut proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 bypass cut proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 bypass cut proportional When D013 is cancelled and other error occurs by turning starter switch on
valve after exchanging the connector with other sensor.
PSV-D Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 bypass cut When D013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-33
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-55
Error code D022
Trouble P2 bypass cut proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 bypass cut proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 bypass cut proportional When D022 is cancelled and other error occurs by turning starter switch on
valve after exchanging the connector with other sensor.
PSV-B Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 bypass cut When D022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-56
Error code D023
Trouble P2 bypass cut proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 bypass cut proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 bypass cut proportional When D023 is cancelled and other error occurs by turning starter switch on
valve after exchanging the connector with other sensor.
PSV-B Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 bypass cut When D023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-34
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-57
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-58
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-35
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-59
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-60
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-36
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-61
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-62
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-37
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-63
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E022 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-64
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E023 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-38
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-65
Error code F011
Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom ATT boost is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F011 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-66
Error code F013
Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F013 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-39
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-67
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-2 SWING-BRAKE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If
failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-68
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-40
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-69
Error code F031
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-70
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-41
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-71
Error code F041
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-72
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-42
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-73
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
Table46-74
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
CN-136F
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
46-43
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-75
Error code G042
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller Especially check wiring for false disconnection and noise included.
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.
46-44
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-76
G043
When cranking is executed for 60 seconds or more, this error code might be displayed. In case
Error code that the engine does not start, check by the table of "Section 47.3 Engine related
Troubleshooting". Execute the following check when the error code G043 is displayed after
starting the engine.
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller
condition indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.
46-45
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-77
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-78
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.4k
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-46
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-79
Error code H023
Trouble Boom angle potentiometer’s wiring is disconnected.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-80
Error code H024
Trouble Boom angle potentiometer’s power source is shortcut.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-47
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-81
Error code H033
Trouble Arm angle potentiometer’s wiring is disconnected.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-82
Error code H034
Trouble Arm angle potentiometer’s power source is shortcut.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-48
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-83
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-84
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-49
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-85
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from engine controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F (There is a possibility of false disconnection.)
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-86
Error code I113
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly. It has been affected little.
condition
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20°C.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-5 WATER TEMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
46-50
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-87
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-600F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-88
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch
condition ON signal turned OFF
The power on the battery relay secondary side does not turn OFF even if the key switch is turned
Symptom
OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No. 4 K-3 KEY SWITCH OFF
checking screen Screen No.
Checking object Checking contents and remedy
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
• Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
• Alternator relay The failure may be occurred in case where the power falls after the relay was
R-28 removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box Replace fuse/relay box.
E-1
4 • Mechatro controller Check that the error is corrected after replacement of controller.
46-51
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-89
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 PREVENT ARC
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay,
R-31 check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed
prevention relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R014 is left displayed
E-1
Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-52
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-90
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R024 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-53
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-91
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move after forward rotation.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CCW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R034 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-54
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-92
Error code R044
Trouble Washer motor relay error
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 MOTOR RELAY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit
R-32 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-112F, CN2-1 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R044 is left displayed
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-93
Error code R134
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Right swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D13
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R134 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-55
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-94
Error code R144
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Left swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D14
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R144 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-95
Error code R154
Trouble Travel alarm relay error
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 23 D15
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit
R-8 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-56
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-96
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay
R-24 unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between auto idle When R164 is left displayed with the relay removed
stop relay 2 and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-57
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-97
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-3 ENG STOP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between engine When R174 is left displayed with the relay removed
forcibly Check that no power 24V is produced on relay (-) line according to the wiring
stop relay and controller checking procedure and replace it if necessary.
CN-109F, CN2-2 When no failure found after checking on wiring and R174 is left displayed.
• Fuse & relay box Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-58
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-98
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-4 LOCK LEVER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between safety lock When R184 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-99
Error code R214
Trouble Safety relay error
Judging
The mechatro controller output line to safety relay is short-circuited with the power source.
condition
Symptom Safety relay does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-2 SAFETY RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit
R-26 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between safety lock When R214 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R214 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-59
46. TROUBLE SHOOTING (BY ERROR CODES)
[MEMO]
46-60
47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS
47
47-1
47. TROUBLESHOOTING (BY TROUBLE)
47-2
47. TROUBLESHOOTING (BY TROUBLE)
47-3
47. TROUBLESHOOTING (BY TROUBLE)
47-4
47. TROUBLESHOOTING (BY TROUBLE)
47-5
47. TROUBLESHOOTING (BY TROUBLE)
47-6
47. TROUBLESHOOTING (BY TROUBLE)
47-7
47. TROUBLESHOOTING (BY TROUBLE)
47-8
47. TROUBLESHOOTING (BY TROUBLE)
47-9
47. TROUBLESHOOTING (BY TROUBLE)
47-10
47. TROUBLESHOOTING (BY TROUBLE)
47-11
47. TROUBLESHOOTING (BY TROUBLE)
47-12
47. TROUBLESHOOTING (BY TROUBLE)
47-13
47. TROUBLESHOOTING (BY TROUBLE)
47-14
47. TROUBLESHOOTING (BY TROUBLE)
47-15
47. TROUBLESHOOTING (BY TROUBLE)
47-16
47. TROUBLESHOOTING (BY TROUBLE)
47-17
47. TROUBLESHOOTING (BY TROUBLE)
47-18
47. TROUBLESHOOTING (BY TROUBLE)
47-19
47. TROUBLESHOOTING (BY TROUBLE)
(16)Travel deviation
47-20
47. TROUBLESHOOTING (BY TROUBLE)
47-21
47. TROUBLESHOOTING (BY TROUBLE)
47-22
47. TROUBLESHOOTING (BY TROUBLE)
(19)Machine does not travel straight in simultaneous operation of traveling and attachment
(20)Breaker works slowly and power is poor (in case of conflux, check P1 side bypass valve and pump)
47-23
47. TROUBLESHOOTING (BY TROUBLE)
47-24
47. TROUBLESHOOTING (BY TROUBLE)
47-25
47. TROUBLESHOOTING (BY TROUBLE)
47-26
47. TROUBLESHOOTING (BY TROUBLE)
47-27
47. TROUBLESHOOTING (BY TROUBLE)
47-28
47. TROUBLESHOOTING (BY TROUBLE)
47-29
47. TROUBLESHOOTING (BY TROUBLE)
47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.
47-30
47. TROUBLESHOOTING (BY TROUBLE)
(3) Auto accel does not actuate. (The engine speed does not automatically slow down).
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
47-31
47. TROUBLESHOOTING (BY TROUBLE)
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position
Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF
R-30: Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.
47-32
47. TROUBLESHOOTING (BY TROUBLE)
Checking
Filters Liquid Leak, clogging
Muffler clogged
Engine oil leak
Coolant level
Trouble
47-33
47. TROUBLESHOOTING (BY TROUBLE)
Hydraulic switch
Starter motor
Battery relay
Safety relay
Glow relay
Glow plug
Alternator
Trouble
47-34
47. TROUBLESHOOTING (BY TROUBLE)
Factors
47-35
47. TROUBLESHOOTING (BY TROUBLE)
Engine body
Factors
Damage of dumper
Trouble
47-36
51. ENGINE
PREFACE
This service manual explains the single engine. Note that this manual is edited without
modification by based on the service manual of HINO MOTOR.
51
51-1
51. ENGINE
51-2