Training Text SK125srl

HYD.
EXCAVATOR
YV05- 04501~
YY05- 12001~
YH05- 07001~

Book Code No. S6YY00201ZE01

Printed in Japan 2008.01 (K)
CONTENTS
1. OUTLINE
1.1 SK125SR, SK135SR-2, SK135SRLC-2 ................................................................... 1-3
2. CONSTRUCTION & FUNCTION

2.1 NAME OF COMPONENTS ...................................................................................... 2-3
2.2 SPECIFICATIONS AND PERFORMANCE .............................................................. 2-4
2.3 OPERATOR CAB NOMENCLATURE...................................................................... 2-5
2.4 SUMMARY OF MECHATRO CONTROL SYSTEM ................................................. 2-8
2.5 HYDRAULIC SYSTEM ............................................................................................. 2-25
2.6 HYDRAULIC COMPONENTS .................................................................................. 2-45
2.7 ELECTRICAL EQUIPMENT AND HARNESS LAYOUT........................................... 2-73
2.8 AIR-CONDITIONER SYSTEM ................................................................................. 2-89
3. MECHATRO CONTROL SYSTEM

3.1 ADJUSTMENT OF MECHATRO CONTROLLER .................................................... 3-3
3.2 SUMMARY OF MULTI DISPLAY ............................................................................. 3-9
3.3 SELF DIAGNOSIS DISPLAY ................................................................................... 3-14
3.4 SERVICE DIAGNOSIS DISPLAY FUNCTION ......................................................... 3-17
3.5 TROUBLE HISTORY DIAGNOSIS........................................................................... 3-27
3.6 TROUBLE DIAGNOSIS MODE................................................................................ 3-28
3.7 SET PROCEDURE OF MAINTENANCE SCHEDULE............................................. 3-33
3.8 ADJUSTING PROCEDURE OF DISPLAY ............................................................... 3-34
3.9 MECHATRO CONTROL EQUIPMENT .................................................................... 3-38
3.10 ELECTRIC EQUIPMENT ......................................................................................... 3-49
4. ENGINE
4.1 ENGINE SPECIFICATIONS..................................................................................... 4-3
4.2 ENGINE OUTSIDE VIEW......................................................................................... 4-5
4.3 ENGINE MOUNTING ............................................................................................... 4-6
4.4 SYSTEM FLOW DIAGRAMS ................................................................................... 4-7
4.5 ENGINE SERIAL NUMBER LOCATION .................................................................. 4-10
4.6 REMOVING FUEL SYSTEM .................................................................................... 4-11
4.7 FUEL INJECTION SYSTEM (COMMON RAIL SYSTEM)........................................ 4-12
4.8 HIGH PRESSURE PUMP ASSEMBLY .................................................................... 4-19
4.9 INSTALLING LUBRICATION SYSTEM.................................................................... 4-20
4.10 REMOVING INLET AND EXHAUST SYSTEM ........................................................ 4-21
4.11 REMOVING ELECTRICAL SYSTEM ....................................................................... 4-22
1
CONTENTS
4.12 TROUBLESHOOTING BY DIAGNOSIS CODES..................................................... 4-24

4.13 SCAN TESTER ........................................................................................................ 4-25
4.14 DIAGNOSIS CODE CROSS REFERENCE ............................................................. 4-28
4.15 INSPECTING SENSORS......................................................................................... 4-30
5. MACHINE STRUCTURE
5.1 BOOM ...................................................................................................................... 5-3
5.2 ARM ......................................................................................................................... 5-6
5.3 BUCKET................................................................................................................... 5-10
5.4 LOWER PARTS ....................................................................................................... 5-13
5.5 REMOVING AND INSTALLING PROCEDURE OF ASSY
(RELEVANT UPPER FRAME) ................................................................................. 5-22
5.6 WEIGHT OF COMPONENTS .................................................................................. 5-35
6. CHECK-UP & SERVICE

6.1 CHECK-UP & MAINTENANCE ................................................................................ 6-3
6.2 LUBRICANT, FUEL & COOLANT SPECIFICATIONS ............................................. 6-10
6.3 MAINTENANCE PARTS .......................................................................................... 6-12
6.4 USE OF BIO-DEGRADABLE OILS.......................................................................... 6-13
6.5 REQUIRED TOOLS ................................................................................................. 6-14
6.6 INSPECTION & MAINTENANCE CHART ............................................................... 6-16
6.7 PERFORMANCE INSPECTION STANDARD TABLE ............................................. 6-20
7. DATA 1
7.1 WORKING RANGES................................................................................................ 7-3
8. DATA 2 (CIRCUIT DIAGRAM)

8.1 SUMMARY OF MECHATRO CONTROL SYSTEM ................................................. 8-3
8.2 HYDRAULIC CIRCUIT DIAGRAM ........................................................................... 8-4
8.3 HYDRAULIC CIRCUIT N&B SPECIFICATION (OPTION)....................................... 8-5
8.4 ELECTRIC CIRCUIT DIAGRAM .............................................................................. 8-6
8.5 ELECTRICAL EQUIPMENT LIST ............................................................................ 8-11
2
1. OUTLINE
1-1
1. OUTLINE
1-2
1. OUTLINE
1.1 SK125SR, SK135SR-2, SK135SRLC-2

Comparison between new and former models
Item Contents (Former --> New model)
Concept
Major review of unit layout Only 4 places accessible (from the ground) --> 8 places Easier maintenance
accessible
(1) Control valve, Rear side of hydraulic tank --> Machine right front
(2) Solenoid block Cab floor under side --> Machine right front
structure
(3) Multi control valve Main control valve side --> Machine right front
Upper
(Side of control valve)

(4) Fuel tank Cab rear side --> Place in parallel to hydraulic oil tank on
right side of machine
(5) Washer tank Radiator front side (Left side) --> Cab floor under side
(6) Battery Machine right front side --> Rear side of cab
(Under side of "iNDr" filter)
One-sided slanted roof type track frame is One-sided slanted roof type --> One-sided slanted Mud stack prevention
continued from conventional model roof type (Continued)
Change of travel motor drain piping from tube to hose Tube --> Hose Cost down
cariage
Under
Material of lower roller shaft is reinforced Improvement of durability

Shoe link assembly is reinforced Bushing and pin diameter were changed to large size Improvement of durability
Teeth numbers of slewing bearing is increased From 89 to 93 teeth Slewing torque was increased
(4.5% increased)
Arm is reinforced Reinforcement with metal patch --> Steel plate welding Improvement of durability of
structure is adopted (2 type of GD and HD) attachment at heavy-load and
full capacity
Arm foot boss is reinforced Steel plate welding at boss part --> Penetration boss Ditto
structure is adopted
Arm top bushing is changed to two-layer bushing No flanged one layer bushing --> Flanged two-layer bushing Ditto
Attachment
(Outside flanged bushing and inside bushing). (Offset, 40 feet, and telescopic arm are not changed)
Durability up of U-packing and buffer seal of hydraulic Heat-resistant urethane is continued Measures to oil leak
cylinder is continued
Long interval unlubricated bushing is continued 4 places on bucket: 250 hours and other places: 500 hours Prolongation of lubrication
(Offset, 40 feet, and telescopic arm are not changed) interval
Greasing points of attachment are brought together Centralized lubrication at arm foot part --> New grease Improvement of durability
nipple was added to side of arm
Greasing point of arm foot part was changed
Change of bucket capacity 0.50 m3 (SK125SR was 0.45 m3)
Connection pin diameter between bucket link and bucket 60 mm in dia. --> 65 mm in dia.
cylinder was changed (Conventional extension arm is not availab
New control valve is equipped. Low fuel consumption by

piping and components
decreasing back pressure

Diameter of pipes for attachment is enlarged. Hose size is not changed Ditto
Pipe connection for control valve is changed. ORS is continued Ditto
N&B spool provided in standard ORS --> 4 bolts flange Ditto
Hydraulic tubes,
N&B piping size is changed to large size Optional valve is added --> Built-in type in main control Field modification is abolished
valve is adopted
H side: 1 3/16-12UNS --> 1-11UNS, R side: 1-14UNS --> Breaker starts blow, when operator
1 3/16-12UNS presses the toe of the pedal like
other companies machine.
N&B selector valve changes to ADD-ON type Separately placed manual switching --> ADD-ON type Upgrade of specification
(Mode is selectable from inside of cab) remote switching
Fuel tank capacity is up 168 litter --> 200 litter Prolongation of lubrication interval
Fuel tank
Inner diameter size of drain valve for sedimentation water 5 --> 9mm Easier maintenance
is enlarged
Flanged construction of tank bottom continued Flanged connection --> Continued Ditto
Design improved Design of machine is improved

Counter
weight
and noise is reduced remarkably

Weight is reduced 3.49 ton --> 3.40 ton (In case of SK125SR, counterweight Stability is improved
is 2.84 ton)
New design of engine bonnet, guard and so on

Guard
Cover for maintenance made larger in size Bolt fastening --> Opening and closing type by latch Easier maintenance
Open/close of right rear maintenance cover made easier Grid plates arranged in parallel --> Grid plates in radial Ditto
Improve visibility of front guard for demolition machine arrangement from operator's eyes Improvement of visibility
Cab almost similar to PDA standard cab is mounted Spacious foot room (for and aft length): 565mm --> 745mm To improve spacious and
(100 mm shorter than PDA standard type) comfortable interior for operator
Ditto Door open width --> 30mm increased Ditto
New automatic lock mechanism for front window is adopted Two manual locks --> One automatic locking type catch To make open and close front
is adopted window easier
Cab
Standard cab can be retrofitted with 3-face-guard Not provided --> Brackets and tapped blocks are Field modification is abolished
equipped in standard
Removable 2-piece floor mat for easy cleaning To make cleaning easier
Skylight guard provided in standard specification To secure safety equivalent to
FOPS level 1
Noise in cab was reduced 72 dB (A) --> 65 dB (A) (At no-loaded and in high idling) Noise reduction
1-3
1. OUTLINE
Comparison between new and former models

Item Contents (Former --> New model)
Concept
New design instrument panel Switches were brought together in right panel To lessen influence of dust and rain
Same flip-up angle of left console Flip-up angle --> Same (Continued)
New design of rear storage (Hot & cool box are canceled) No full reclining seat --> Full reclining seat To improve spacious and
Interior
comfortable interior for operator

New large size cluster gauge for visibility For better visibility
New mounting way of arm rest Arm rest is mounted on seat --> Mounted on side console Prevent interference to left
control lever and switches
Operating force of control lever Control lever operating force was reduced 10 % Operator does not fire after long
hours of work
conditioner
Locate air conditioner unit under seat Inside of rear cover --> Underneath of the seat Easier cleaning for air conditioner
filters (Inner & outer)
Air
MMC engine is adopted (Electric controlled common rail Isuzu 4 cylinders --> MMC 4 cylinders To meet Tier 3 emission regulation
and EGR system)
Engine horsepower up 62.5 kW/2,050rpm --> 69.2 kW/2,000rpm Maximum performance among
same class engine
"iNDr" (above-mentioned) system is applied Super-low noise (98 dB) --> Ultra-super-low noise (93 dB) Noise reduction
Note) Label is for Super-low noise indication.
"iNDr" filter is attached Coarse mesh screen --> Pleated 60 mesh filter Reduction of cleaning frequency
of radiator and so on
New arrangement of oil cooler, radiator and intercooler Inline arrangement --> Parallel (Side by side) arrangement Easier cleaning of radiator and
so on
Improvement of removal and installation ability of oil Only radiator is removable --> All units are removable Easier cleaning
cooler, radiator and intercooler
Relocation of fuel filter In engine chamber --> In pump chamber Easier maintenance of filter
Relocation of engine oil filter from the ground
Power plant
Located under the engine --> Over the engine Easier maintenance of filter
from the machine
Change of fuel filter Conventional type --> Integrated type High-performance filter responds
(water separator/feed pump) to common rail system
Fuel stop valve is standardized Easier maintenance of fuel filter
Large capacity air cleaner is adopted --> Cleaner doubles interval of clogging alarm Prolongation of maintenance
interval
Double element type air cleaner is standardized Single element --> Double elements To meet machine for recycling
Relocation of air cleaner Rear of cab --> Inside of iNDr filter Reduction of intake air noise
and improvement of dust inhale
Easier engine oil change No drain valve --> Drain valve is standardized Easier engine oil change
Increasing area of fire wall between engine and pump For fire prevention
Cooler for fuel cooling was added Horizontally placed mechatro controller --> Vertically To secure the performance of
placed (New ECU) fuel pump, the control of fuel
temperature is required
Vertical installation of mechatro/ECU controllers Double-face circuit board --> Single-face circuit board Preventing electric trouble from
(Large element/Large space between patterns) dew condensation
Electric system
Improve reliability of mechatro controller board No gasket --> With gasket Preventing failure
Improve waterproof and dustproof of mechatro controller Individual arrangement of relay and fuse --> Bring them Improvement of waterproof and
casing together behind seat /Integrated into one box dustproof
Integrated relay/fuse into one box Increase resin content of wiring and improve shape of Easier maintenance
casing caulked part --> Continued
Continue conventional improved waterproofing Improvement of waterproofing
proportional valve
Valve plate is improved and casing shape is modified New pump adopted the same specifications as upper For noise reduction by decrease
Pump
model of hydraulic pulsations pressure

rising gradient
Pump displacement capacity is increased 57.6 cc/rev --> 65.2 cc/rev Upgrade of specifications
Swing
motor
Change of shaft sealing NBR made seal is continued without changing
Emergency
Control valve emergency mode is newly set None --> Automatic switching with controller is equipped Prevention from machine
(Unload valve) stoppage
mode
Continue main pump KPSS release mode of conventional Pump delivery rate is fixed to about 70% at KPSS release Ditto
machine position --> Continued
1-4
2-1
2-2
2.1 NAME OF COMPONENTS

2.1.1 SK125SR, SK135SR-2
BUCKET CYLINDER
ARM
MONITOR PANEL
ARM CYLINDER
CAB
CONTROL VALVE
OIL COOLER
SWING MOTOR
FUEL TANK
IDLER LINK
BUCKET LINK RADIATOR
HYD TANK
BOOM
GUARD
BOOM CYLINDER MUFFLER
HYD PUMP
SHOE
BUCKET
FRONT IDLER
ENGINE
IDLER ADJUST COUNTERWEIGHT
LOW ROLLER
AIR-CLEANER
GUIDE, TRACK
JOINT, SWIVEL
UPP ROLLER
PROPELLING MOTOR
SLEWING BEARING
BATTERY
2-3
2.2 SPECIFICATIONS AND PERFORMANCE

2.2.1 SK125SR, SK135SR-2
2.2.1.1 SPEED AND CLIMBING CAPABILITY
Model
SK125SR SK135SR-2 SK135SRLC-2
Item
Swing speed min-1 {rpm} 11.5 {11.5}
Travel speed (1-speed/2-
km/h (mile/h) 3.4 / 5.6 (2.1 / 3.5)
speed)
Gradeability % (degree) 70 (35)
2.2.1.2 ENGINE
Engine model MITSUBISHI D04FR-74kW

Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine
Type
with inter cooler turbo-charger
4 -ø102 mm × 130 mm
Number of cylinders—Bore×Stroke
(4.02 in × 5.12 in)
Total displacement 4.249 L (259.27 cu•in)
Rated output / Engine speed 69.2 kW (94 PS) / 2,000 min-1
Maximum torque / Engine speed 375 N•m (277 lbf•ft)/ 1,600 min-1
Starter 24 V / 5.0kW
Alternator 24 V / 50A
2.2.1.3 HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

Hydraulic motor (swing) Axial piston motor × 1
Variable displacement axial piston motor × 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve × 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type
2.2.1.4 WEIGHT
Unit : kg (lbs)
Fully equipped weight 13,000 (28,600) 13,800 (30,420) 13,900 (30,640)
Upper structure 6,710 (14,789) 7,298 (16,085) ←
Lower machinery
4,031 (8,884) ← 4,224 (9,310)
(500mm grouser shoe)
Attachment
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 1,962 (4,324) — —
+0.45m3 (0.59cu•yd) Bucket
Attachment
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm — 2,126 (4,686) ←
+0.50m3 (0.65cu•yd) Bucket
2-4
2.3 OPERATOR CAB NOMENCLATURE

2.3.1 LOCATION OF CONTROL DEVICES (SK125SR, SK135SR-2)
3 4 5 6
7
24
8
25
23
9
2
11
10
12
13 DETAIL A
15
14
16
17
19
18
22
19
20
21
A
No. NAME No. NAME

1 Left Hand Operator Control Lever (Horn Switch) 14 Working Light Switch (Boom, Deck)
2 Safety Lock Lever (For Hydraulics) 15 Travel Alarm Select Switch
3 Left Travel Pedal 16 Conflux/Single Flow Change Switch (Option)
4 Left Travel Lever 17 Tuner
5 Right Travel Lever 18 Air Conditioner Control Panel
6 Right Travel Pedal 19 Cap (For Opt. Switch)
7 Hour Meter 20 Cigarette Lighter
8 Gauge Cluster 21 Life Hammer
9 Cup Holder 22 Operator Seat
10 Ash Tray 23 Swing Parking Brake Release Switch
11 Right Hand Operator Control Lever (Power Boost Switch) 24 KPSS Release Switch
12 Starter Key Switch 25 Fuse & Relay Box
13 Throttle Potentiometer
2-5
2.3.2 LOCATION OF SWITCHES AND METERS (SK125SR, SK135SR-2)
62
64
63
61
60 51
52
55
53 DETAIL A
54
56
57
58
59
No. NAME No. NAME

51 Starter Key Switch 58 Cap (For Opt. Switch)
52 Throttle Potentiometer 59 Cigarette Lighter
53 Working Light Switch (Boom, Deck) 60 Horn Switch
54 Conflux/Single Flow Change Switch (Option) 61 Power Boost Switch
55 Travel Alarm Switch 62 Hour Meter
56 Tuner 63 Swing Parking Brake Release Switch
57 Air Conditioner Control Panel 64 KPSS Release Switch
2-6
2.3.3 GAUGE CLUSTER (SK125SR, SK135SR-2)

The gauge cluster is made up of gauges (fuel level,
engine coolant temperature), various switch panels and
multi-display. 11
22:00
• When caution sign was displayed on the multi- S
display, stop the work immediately and check and
service the section in point.
For checking and servicing, refer to the section for 1
the checking and servicing.
• The display on the multi-display does not entirely
assure the condition of machine. 2
• For the maintenance and inspection of machine, the 3
visual checking should be carried out further without
completely depending on the display on the multi- 10
display. 6
4 9 8 5 7
No. NAME
1 Engine Coolant Temperature Meter
2 Fuel Level Meter
3 Screen Change Switch
4 Buzzer Stop Switch
5 KPSS Mode Select Switch
6 Washer Switch
7 Wiper Switch
8 Travel Speed Select Switch
9 Auto Accel Switch
10 Select Switch
11 L.C.D Display
2-7
ELECTRIC
CONTROLLER INPUT SIGNAL
HYDRAULIC MAIN CONTROL VALVE
PILOT SECONDARY PRESSURE VOLTAGE OUTPUT
SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE
SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT SE-29
LH RH LH RH
OPTION PILOT VALVE ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT
(8) (2) (4) (3) (6) (8) SV-13
PILOT VALVE
P1 UNLOAD
PILOT VALVE
SELECTOR VALVE
CONFLUX
BOOM UP
FOR TRAVEL
BOOM LOW SPEED

FOR ATT
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
SE-9
SE-10
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
SOL
SE-11
MULTI CONTROL VALVE OR SENSOR BLOCK
P1 P2
LOW PRESSURE SENSOR
SE-4 (1) (3) (5) (7)
(4)
SUMMARY OF MECHATRO CONTROL SYSTEM
DIGGING UP REVERSE REVERSE RIGHT ARM IN

SE-3
(3) SOLENOID VALVE
GAUGE CLUSTER
SE-2
(2)
LCD DISPLAY
FOR SELECTION SE-1
(1)
FUEL GAUGE
COOLANT TEMP. GAUGE SE-8
(8)
LOWER SW.
SCREEN CHANGE SE-7
(7)
BUZZER STOP
MECHATRO CONTROL SYSTEM IN GENERAL
2-8
MODE (6)
WASHER SWING MOTOR PARKING RELEASE
WIPER SE-5
(5)
OUTPUT VOLTAGE
TRAVEL
DECEL
TRAVEL MOTOR 1,2 SPEED SELECT
SERIAL COMMUNICATION
BOOM CYLINDER
ACCEL DIAL BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE

SE-16
SAFETY LOCK LEVER

SE-23
PROPORTIONAL VOLTAGE
TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
HIGH PRESSURE SENSOR
ARM IN 2 SPEED
C-1 SE-22
P1 UNLOAD
P2 UNLOAD
MECHATRO CONTROLLER A1 A2
ENGINE A3
INJECTOR SPEED SENSOR
SE-13
ARM CYLINDER
ARM OUT CONFLUX
KPSS ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV
RELEASE SWITCH PSV -P1 -A -D -C -B -3 -1 -4
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR
(FOR P1,P2 : 2pcs) PSV -P2
(7)
: INJECTOR P2 PUMP PROPORTIONAL VALVE
ARM IN
: E/G SPEED SENSOR CAN COMMUNICATION BUCKET CYLINDER
C-8 DIGGING / DUMP CONFLUX
: LOW PRESSURE SENSOR ENGINE CONTROLLER
(ATT : 7pcs, TRAVEL : 2pcs) ENGINE SPEED
COMMAND CURRENT
VOLTAGE 24V PROPORTIONAL VALVE
) BLOCK
2.4.1
2.4
PROPORTIONAL COMMAND CURRENT SOLENOID VALVE
2.4.2 UNLOAD VALVE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective
low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by
mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the
pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
2-9
2.4.3 POSITIVE CONTROL & P-Q CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE
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
2-10
(1) Positive control

1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low
pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator, and
consequently the working speed according to the lever manipulated movement will be obtained.
(2) P-Q control
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller and
the mechatro controller processes pilot signal and operates the command according to the input voltage
(load pressure).
2) The lower value between command values calculated by positive control and operated value found by P-Q
control {operated value found in item 1)} is selected and is output to each pump proportional valve as
command value.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and
consequently working speed will be obtained according to lever movement.
POSITIVE CONTROL P-Q CONTROL
PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

SECONDARY PRESSURE
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
PILOT PRESSURE PUMP DELIVERY PRESSURE
2-11
2.4.4 BOOM UP CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
BOOM UP PILOT SECONDARY PRESSURE SECONDARY PRESSURE
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload 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 and switches P1 and P2 unload pressure
control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also
with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and
consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
2-12
2.4.5 ARM IN RECIRCULATION & CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTION (N&B)
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
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
ARM IN PILOT SECONDARY PRESSURE
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE
2-13
(1) Recirculation and conflux (Low loading)

1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool
and low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves,
P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor
and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal
according to the combined operation and outputs command, which is different from the arm-in independent
operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for
arm-in 2 spool.
3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it
switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls
recirculation rate and conflux rate.)
The other proportional valves output proportional secondary pressure according to command from mechatro
controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload
valve.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload
spools and arm 2 spool are switched according to the command output by mechatro controller, and
consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil
during arm operation.
(2) Recirculation cut
The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is
raised during arm operation the mechatro controller processes pilot signal processing according to the pressure
detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for
arm-in 2 spool.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command
output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently
recirculation passage is blocked.
2-14
2.4.6 ARM-IN ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi PILOT SIGNAL
PROCESS REVERSE PROPORTIONAL
VALVE CONTROL PROCESS
FOR ARM 2 SPOOL PSV-Bpi

pi
VALVE FOR ARM VALVE FOR ARM 2 SPOOL
2 SPOOL COMMAND PSV-A pi
ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low
pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot
signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2
unload proportional 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.
2-15
2.4.7 ARM-OUT CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE

pi
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
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.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valves.
(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 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
2-16
2.4.8 BUCKET DIGGING (DUMP) CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE 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.
pilot signal and outputs command according to the input voltage to P1 pump proportional valve, and P1 unload
proportional valve.
by mechatro controller and changes P1 pump delivery rate and switches P1 unload valve.
2-17
2.4.9 SWING PRIORITY CONTROL
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
VALVE
TRAVEL LEFT
N&B
SELECTOR
BUCKET
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
(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 is input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2
unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool.
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel
straight spool, arm 2 spool.
(4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched
enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil
on arm cylinder rod side is recirculated into arm cylinder head side.
(5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate
is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum
speed drop possible.
2-18
2.4.10 TRAVEL STRAIGHT CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTIONAL
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
SECONDARY PRESSURE PILOT SECONDARY PRESSURE
2-19
(1) Judgment travel straight

1) During travel operation (right and left), pilot pressure switches each spool and is input to low pressure sensor
on carrying out attachment system operation.
2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in
the table from the low pressure sensor and turns travel straight signal on.
3) On turning travel straight signal on, the following commands are output to each proportional valve.
(2) Operation of each proportional valve
(Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in travel
straight condition.)
1) Travel straight proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system operating
(Boom, arm, bucket, swing, option) pilot pressure during operation.
2) P1 unload proportional valve
pilot pressure during operation.
3) P2 unload proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot pressure during
operation.
4) P1 pump proportional valve
pilot pressure during operation.
5) P2 pump proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot pressure during
operation.
ATT operation Boom Arm Bucket Swing Option

In travel operation (P1)
In travel operation (P2)
2-20
2.4.11 PRESSURE RELEASE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
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 P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi
PILOT SIGNAL
P1 UNLOAD
VALVE PSV-D
MECHATRO
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 2.5.3.5.
(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) Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes P1 and
P2 unload valves to the maximum opening.
(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 valve opened.
2-21
2.4.12 N&B SWITCH CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
SE-29
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
B MODE SWITCH MECHATRO

CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
(1) Nibbler circuit

1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main
control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display
is output to gauge cluster.
(2) Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display
is output to gauge cluster.
2-22
2.4.13 NIBBLER CONFLUX CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTION (N&B)
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
PILOT VALVE
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
P1 UNLOAD
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE
OPTION PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
(1) Select the Conflux with the aid of Conflux/Single switch.

(2) On starting nibbler operation, option operating pilot pressure switches option spool and is input to low pressure
sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and
P2 unload pressure proportional valves and travel straight proportional valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of the control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1
pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
2-23
2.4.14 N&B SOLENOID RELIEF VALVE CONTROL
SOLENOID RELIEF
PSV-E
BOOM UP CONFLUX
VALVE
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
SOLENOID RELIEF
PILOT P2 P1
VALVE
VALVE
PSV-I
RELIEF VALVE
SOLENOID
OUTPUT
LOW
PRESSURE
SENSOR
SE-11
OPTION PILOT
SECONDARY PRESSURE
(1) Solenoid relief valve

Using solenoid relief valve, relief pressure is able to set in advance.
1) Using gauge cluster, setting pressure of A and B mode is selectable individually.
2) When optional operation is done, command value according to setting pressure which is selected with
solenoid relief valve is output from mechatro controller.
3) Each proportional valve outputs pilot proportional secondary pressure according to command value from
mechatro controller, and the pressure switches relief pressure.
2-24
2.5 HYDRAULIC SYSTEM

2.5.1 SUMMARY (SK125SR, SK135SR-2)
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety,
mass volume handling and low fuel consumption.
Perfor- Device
mance Function Features
Travel straight Travel straight at combined operation

Travel 2-speed change & Auto 1st (low) speed return 1-2 travel speed change and low speed / high torque at heavy duty
Travel
Auto parking brake Automatic braking when parking

Motor overrun protection Prevents overrunning of travel motor on the down hill slope.
Travel pilot operation Prevents hunting by the built in travel shockless mechanism
Reverse rotation protective function Easy positioning to protect it from swinging back when stops swinging.
Swing priority circuit Easy operation of stable swing speed, arm slanted leveling,
Swing
(simultaneous operation of arm in and swing motions) swing press digging

Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever

Easy operability and safety
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Attachment
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Boom safety valve Prevention of boom falling when boom head side
and arm rod side pipings break
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
Return circuit To prevent hydraulic oil from contamination

Cooling hydraulic oil by oil cooler To prevent hydraulic oil from being deteriorated.
Pressure draining circuit To release the main circuit pressure for piping repair work.
Main control valve with optional valve Optional piping and additional work are easy
Switching of return line for N&B machine in the cab Switching of return line for N&B machine is able to
(Option) change with a switch in the cab
consumption Mass handling capability
Electric flow controlled variable displacement pump Pump delivery rate control by a current command to the
Pump
solenoid proportional valve of the variable displacement pump

Positive flow rate control Flow control by positive pilot control pressure
Boom up conflux circuit Speed up of boom up operation
Attachment
Arm conflux circuit Speed up of arm operation

Optimum operation by work mode select (H,S,A,B) Efficient operation in all work modes
Auto accel Reduce fuel consumption and noise by lowering engine

computer
Low fuel
speed when control lever is in neutral position.

Micro
2-25
This page is blank for editing convenience.
2-26
2.5.2 HYDRAULIC CIRCUITS AND

COMPONENTS (SK125SR, SK135SR-2)
STD. SCHEMATIC HYD. LINES YY01Z00069P1 (02)

Item Component name Part No. Model No.
Hyd. pump assy (OCE) YY10V00013F1 K7V63DTP174R-0E13-VC
1
Hyd. pump assy (S.E.ASIA) YY10V00009F1 K7V63DTP179R-0E13-VC
2 Control valve (main) YY30V00058F1 KMX13YD/B44904
3 Swing motor unit YY15V00016F1 M2X63CHB
4 Travel motor unit YY15V00015F1 GM21VX-A-45/75-2
5 Boom cylinder (RH & LH) YY01V00053F1 ø100×ø70×1092
6 Arm cylinder YY01V00054F1 ø115×ø80×1120
7 Bucket cylinder YY01V00055F1 ø95×ø70×903
8 Swivel joint YN55V00053F1
9 Pilot valve (ATT) YN30V00111F1 PV48K2017
10 Pilot valve (travel) YN30V00105F1 6TH6 NRZ
11 Inline filter YN50V00020F1 Y-457400
12 Suction strainer YN50V00025F2 SB281J0A022A
13 Solenoid valve assy YY35V00013F1 8KWE5A-30/G24WRX-827
14 Return filter YV52V01001F1 FZ1F183A001A
15 Air breather YN57V00004F1 AB0210GA008A
Multi control valve (STD) lever less YN30V00113F1
16
Multi control valve (OPT.) YF30V00009F1
17 Restrictor YN21V00005F3 07580-00000
The part numbers may be changed due to modification,

so use only the numbers for references.
2-27
2.5.3 HYDRAULIC CIRCUITS EXPLANATION 2.5.3.1.2 AUTO ACCELERATION OPERATION

(1) Principle :
2.5.3.1 BUCKET CIRCUIT
Auto acceleration actuates according to signals
(SK125SR, SK135SR-2)
from low pressure sensor.
This section describes the following.
(2) Operation :
(1) Bucket digging pilot circuit
<When lever is set to neutral position>
(2) Auto accel operation In the event where the sensor does not receive
(3) Flow control in the work mode signal for 4 seconds or more even though the
acceleration dial is set to MAX position, the engine
2.5.3.1.1 PILOT CIRCUIT FOR BUCKET
speed should be raised to 1000rpm.
DIGGING
<When lever is operated>
(1) Mechatronics : When the pressure 0.6MPa (87psi) is input to low
1) When the operation for bucket digging is pressure sensor in STD specification (travel,
performed, the pilot proportional secondary bucket, swing, arm), proportional voltage from low
pressure is delivered through port 1 of the right pressure sensor inputs in mechatro controller, and
pilot V (9), flows to PAc port, and acts on the low then the engine speed returns to the dial set
pressure sensor (SE-1), and at the same time position corresponding to the lever operation.
the bucket spool is switched.
2.5.3.1.3 STAND-BY CURRENT CONSTANT
2) The voltage output by low pressure sensor
CONTROL
inputs in mechatro controller. The mechatro
(1) Principle :
controller performs signal processing and
When the engine speed is intermediate speed or
outputs current corresponding to the increase
lower, command current value to have the pump
of pump flow rate to pump proportional valve
delivery rate constant is output.
(PSV-P1) on the P1 pump side, and at the
same time the command current is output to P1 (2) Operation :
unloading valve (PSV-D). Even if the engine speed specified by acceleration
In the following pages, the relation of operation potentiometer is low speed, as the delivery rate
of low pressure sensor to both the increase of corresponds to the intermediate speed, the
pump flow rate and unloading proportional actuator moves earlier than the movement
valve is the same. Therefore the explanation is equivalent to the control lever angle rate in light
omitted. load operation.
3) The secondary pressure output by P1 pump
proportional valve (PSV-P1) exerts on pump
regulator, actuating the pump onto the delivery
flow increase side.
4) The secondary pressure delivered in P1
unloading valve (PSV-D) is led to PBp1 and
PCb ports provided in control valve (2).
The secondary pressure from proportional
valve which has exerted on PBp1 port holds the
by-pass cut spool on CLOSE side, like the
operation in the lever neutral position.
The secondary pressure from proportional
valve which has exerted on PCb port switches
the unloading spool in CLOSE side.
2-28
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D PA PB
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa P P P P P P
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
HYD. TANK PBr PBs H M K
Pss SE-5 8 7 6 5 4 3 2 1
BOOM LCb LCs SWING P
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
TRAVEL 37.8MPa ARM 1 PAa1 VALVE
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
PSV-A RIGHT TRAVEL FORWARD P P
17 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 2-1 BUCKET CIRCUIT : Bucket digging, Auto-accelation and Standby flow rate constant control
2-29
2.5.3.2 BOOM CIRCUIT

(SK125SR, SK135SR-2)
This section describes the boom raise conflux
operation.
(1) Boom up pilot circuit
(2) Boom up 2 pumps conflux main circuit in C/V
2.5.3.2.1 BOOM RAISE PILOT CIRCUIT

(1) Operation :
1) If boom up operation is performed, the
secondary pilot proportional pressure from the
right pilot valve (9) gets out of port 3 and acts
upon the low pressure sensor (SE-3). At the
same time, the pressure acts upon the PAb and
PB1 ports.
2) The secondary pressure which enters the PAb
port of C/V (2) shifts the boom spool. The
secondary pressure which enters the PB1 port
shifts the boom conflux spool.
2.5.3.2.2 BOOM UP 2 PUMPS CONFLUX MAIN

CIRCUIT IN C/V
(1) Purpose :
Boom up speed up
(2) Principle :
Confluxing oil from 2 pumps
(3) Operation :
1) The oil delivered through A1 port of P1 pump
flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since P1
unloading valve is closed, the boom spool is
moved and bypass circuit is closed, the oil
opens load check valve LCb through parallel
circuit and flows into boom spool.
2) Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led
into H side of boom cylinder through C/V (2) Ab
port.
3) Meanwhile, the oil delivered from the A2 port of
the P2 pump enters the P2 port of C/V (2) and
due to shut off the P2 unloading valve, the oil
then passes through the parallel circuit and via
the restrictor on the circumference of the boom
conflux spool, pushes the load check valve
CCb open from the boom conflux circuit, and
combines the oil delivered by the P1 pump
internally.
4) The return oil from boom cylinder R side flows
into tank circuit through boom spool from C/V
(2) Bb port.
2-30
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 2-2 BOOM CIRCUIT : Boom up operation, Confluence function.
2-31
This section describes boom lower operation. 2.5.3.2.5 CONSTANT RECIRCULATION

(1) Boom down pilot circuit FUNCTION OF BOOM DOWN MAIN
CIRCUIT
(2) Prevention of natural fall by lock valve and
actuation at lowering (1) Purpose :
Prevention of cavitation during boom
(3) Constant recirculation function of boom down main
lowering motion.
circuit
(2) Principle :
2.5.3.2.3 BOOM DOWN PILOT CIRCUIT The oil returning from the boom cylinder head (H) is
(1) Operation : recirculated to the rod (R).
1) If the boom down operation is performed, the (3) Operation :
secondary pilot proportional pressure comes When the oil is supplied to the boom cylinder rod
out of port 4 of the right pilot valve (9) and acts (R) side during boom down operation, the boom
upon the low pressure sensor (SE-4). moves faster than it should do in some cases by the
At the same time, the pressure acts upon the self weight of the attachment.
PBb port of C/V (2). On that occasion, the circuit pressure on the rod (R)
2) The voltage output of the low pressure sensor side is on the negative side.
(SE-4) enters the mechatro controller and The oil supplied to the boom cylinder rod (R) flows
processed in it. into the A1 port of the P1 pump and the P1 port of
C/V. The oil then passes through the boom spool
3) Then, the proportionl secondary pressure fed
and goes out of the Bb port.
into C/V (2) PBb port and branches off in two
On that occasion, the oil returning from the head
lines and switches boom spool and releases
(H) goes through the recirculation path in the boom
boom lock valve.
spool, pushes the check valve in the spool open, is
2.5.3.2.4 PREVENTION OF NATURAL FALL recirculated to the Bb port and is supplied to the rod
BY LOCK VALVE AND ACTUATION (R). When the (R) pressure is larger than the head
AT LOWERING (H) pressure, the check valve in spool closes.
(1) Purpose : Thereupon, the recirculation is stopped.
Prevention of natural fall when the lever is neutral
(2) Principle :
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation :
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from making a
natural fall.
2-32
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 2-3 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.
2-33
2.5.3.3 ARM CIRCUIT and then is flowed into arm cylinder head (H)
This section describes the following operations. side through Aa port of C/V (2).
(1) Arm in, light-load operating pilot circuit 3) The return oil from arm cylinder (R) side flows
in Ba port of C/V (2) and passes through the Ba
(2) Arm in, light-load variable normal recirculation main
port because the arm lock valve CRa is open,
circuit / internal conflux main circuit
and is flowed into arm 2 spool through arm 1
2.5.3.3.1 ARM IN, LIGHT-LOAD OPERATING spool.
PILOT CIRCUIT 4) Because arm 2 spool is switched to normal
(1) Purpose : recirculation position, causing restriction of
Speed-up and Anticavitation when the arm is at passage to tank, the return oil from arm cylinder
light loaded. (R) side flows into arm cylinder (H) side.
(2) Principle : • Because, at light load, the pressure in
The oil returning from the arm cylinder rod (R) is cylinder rod (R) side is higher than that in
recirculated variably to the head (H) at arm 2 spool the head (H) side, it opens the check valve
in C/V. housed-in arm 2 spool and is recirculated in
(3) Operation : the head (H) side, resulting in the speed up
of arm-in operation at light load.
1) When the arm in operation is performed, the
secondary pilot proportional pressure gets out 5) Cavitations prevention control in arm-in
of port 7 of the left pilot valve (9) and acts upon operation
the low pressure sensor (SE-7). Command current is output to arm 2 solenoid
At the same time, the pressure is branched off proportional valve by signal processing of E/G
in two flows, acts upon the PAa1 port and the speed and arm-in pilot pressure, accordingly
PLc2 port, changes over the arm spool and the the arm 2 spool is switched to neutral
arm lock valve CRa. releases. (cavitations prevention) position, resulting in
cavitations prevention.
2) The output voltage by the low pressure sensor
is input into mechatro controller, and is pilot
Position of arm 2 spool
signal-processed, and is output to P1, P2 pump
proportional valve (PSV-P1), (PSV-P2) and arm Neutral position
(Anticavitation position)
2 inverse proportional valve (PSV-A). Normal recirculation position
3) The secondary pressure from pilot proportional Recirculation
valve, which is reduced by arm 2 inverse
proportional valve (PSV-A) switches arm 2
spool. From arm out
P/V
2.5.3.3.2 ARM-IN, LIGHT-LOAD VARIABLE From arm 2 inverse
proportional valve
NORMAL RECIRCULATION,
INTERNAL CONFLUX MAIN CIRCUIT Reference :
In light-load arm-in operation (normal recirculation,
(1) Operation :
conflux), when the attachment to which the circuit in
1) The P2 pump delivery oil flows in travel left P1 pump side is applied is operated, the meter-in
section through P2 port of C/V (2) and is path of arm 2 spool is closed, resulting in single flow
branched off in by-pass circuit and parallel operation.
circuit, but because arm 1 spool is switched, the
delivery oil which goes through parallel circuit Spool position at arm in,
opens load check valve LCa and is flowed into light load and combined operation
(This position is not shown in hydraulic diagram)
arm 1 spool. Meter-in passage (Close)
2) On the other hand, P1 pump delivery oil flows in Neutral position
P1 port of C/V (2), and the flows in travel

straight section and travel right tandem path.
Then because arm 2 spool was switched, the
Normal recirculation position
delivery oil opens load check valve LCAT2,
Arm 2 spool
goes through arm 2 spool, and confluences
with P2 pump delivery oil in the valve section,
2-34
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 2-4 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
2-35
This section describes the following operations. the return oil goes through arm lock valve CRa
(3) Arm in, heavy load operating pilot circuit and flows in arm 2 spool.
(recirculation cut) 4) The return oil returns directly into tank circuit
(4) Arm in, heavy load operating sequence confluxed because arm 2 spool is switched to
main circuit recirculation cut position.
2.5.3.3.3 ARM IN, HEAVY LOAD OPERATING Position of arm 2 spool

PILOT CIRCUIT
Recirculation cut position Neutral position
(1) Operation :
1) In arm-in operation, when the heavy loading is
applied to arm and the P2 pump pressure From arm out
P/V
increases to the set pressure, the voltage
output by P2 pump pressure sensor (SE-23) is From arm 2 inverse
proportional valve
converted to signal (signal processing) by
mechatro controller, consequently the current
of arm 2 solenoid proportional valve is
controlled according to the load pressure and
the arm variable recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light load
operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.
2.5.3.3.4 ARM IN, HEAVY LOAD OPERATING

RECIRCULATION CUT MAIN
CIRCUIT
(1) Purpose :
Speed up for arm in operation
(2) Principle :
Cut the recirculation and reduce rod pressure.
(3) Operation :
1) P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in by-pass circuit and parallel
circuit. Consequently the arm spool is switched
and pushes and opens load check valve LCa
through parallel circuit, and flows in the arm
spool.
2) On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and flow in travel right
tandem passage through travel straight section.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2, and
confluences with P2 pump delivery oil in the
valve section, and is flowed into arm cylinder
head (H) side through Aa port of C/V(2).
3) The return oil from arm cylinder (R) side flows
in Ba port of C/V(2) and is flowed to arm lock
valve , but because the arm lock valve is open,
2-36
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 2-5 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function
2-37
This section describes the following operations. 2.5.3.3.7 NATURAL FALL PROTECTION WITH
(5) Arm out pilot circuit ARM 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 and bucket.
2.5.3.3.5 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 (9), and acts upon 1) When the secondary pressure for arm
the low pressure sensor (SE-8). At the same operation disappears and the arm cylinder
time, the oil is branched off in two flows and act stops, the pressure on the rod (R) side passes
upon the PBa1 and PBa2 ports of C/V (2). through the selector of the lock valve from the
2) The operating proportional secondary pressure Ba port of C/V (2), acts the back pressure on
flowed in PBa1 port of C/V (2) switches the arm the lock valve CRa and seats the lock valve.
1 spool. 2) Since the oil flow into the arm spool from the
3) Then, the operating secondary pressure flowed lock valve is shut off completely, natural fall of
in PBa2 port of C/V (2) switches the arm 2 spool the arm due to oil leaks through the arm spool
valve. is prevented.
2.5.3.3.6 ARM OUT 2 PUMPS CONFLUX MAIN

CIRCUIT
(1) Purpose :
Arm out operation speed up.
(2) Principle :
The oil delivered by the P1 pump is confluxed with
that delivered by the P2 pump in C/V (2).
(3) Operation :
1) P1 pump delivery oil opens load check valve
(LCAT2) by switching arm 2 spool and
confluxes with P2 pump delivery oil just short of
the arm lock valve.
2) And, P2 pump delivery oil flows through arm 1
spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRa with
free flow and is flowed into arm cylinder rod (R)
side through Ba port of C/V(2).
3) On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and returns
into tank circuit through arm 1 spool and arm 2
spool.
The return line which does not pass through
boost check valve is used for this return circuit
to reduce the pressure loss.
2-38
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 2-6 ARM CIRCUIT : Arm out operation, Confluence function
2-39
2.5.3.4 SWING CIRCUIT the bypass line and the parallel circuit. However,
(SK125SR, SK135SR-2) since the bypass line is closed as the swing spool
This section describes the following operations. is shifted, the oil pushes the load check valve LCs
open through the parallel circuit, enters the B port
(1) Swing left pilot circuit
of the swing motor via the As port of C/V (2), and
(2) Swing auto parking brake
rotates the swing motor counterclockwise.
(3) Swing main circuit
2.5.3.4.4 SWING MOTOR CIRCUIT
(4) Swing motor circuit
(1) Anti cavitation circuit at swing deceleration
2.5.3.4.1 PILOT CIRCUIT FOR LEFT SWING
(2) Shockless relief valve that prevents the swing
(1) Operation : motor from being reversed.
1) When the left swing operation is performed, the
pilot proportional secondary pressure is
delivered through port 5 of left pilot V (9), and
the secondary pressure acts on PAs port of C/V
(2), and simultaneously flows out from Pss port
of C/V and acts on low pressure sensor (SE-5).
2) The voltage output by the low pressure sensor
is input in the mechatro controller, and is signal
processed.
3) Then, the secondary pressure led into PAs port
of C/V (2) switches the swing spool.
2.5.3.4.2 SWING AUTO PARKING BRAKE

(1) Purpose :
Swing lock in neutral position and parking
(2) Principle :
Release mechanical brake only when required to
operate swing and arm in.
(3) Operation :
1) The swing parking system excites the swing
parking SOL (SV-1) usually if the key switch is
turned on and works by the action of the
mechanical brake.
2) The mechanical brake is released if the swing
parking solenoid is de-excited only when the
secondary operating pressure in the swing and
arm in actions acts upon any of the low
pressure sensors (SE-5, 7).
3) The swing parking solenoid (SV-1) is excited
five seconds after the pressure of the swing low
pressure sensors (SE-5) is reduced to zero.
In the case of arm in operation, the swing
parking solenoid (SV-1) is excited the moment
the pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.
2.5.3.4.3 SWING MAIN CIRCUIT

(1) Operation :
The oil delivered from the A2 port of the P2 pump
enters the P2 port of C/V (2) and is branched off into
2-40
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 2-7 SWING CIRCUIT : Swing operation (LH)
2-41
2.5.3.5 PRESSURE DRAINING switches the P1, P2 unloading valves to OPEN

(RELEASING) CIRCUIT position.
This section describes the following operations.
2.5.3.5.2 PRESSURE RELEASE MAIN
(1) Pressure drain (releasing) pilot circuit CIRCUIT
(2) Pressure drain (releasing) main circuit (1) Operation :
2.5.3.5.1 PRESSURE RELIEVING PILOT
CIRCUIT
(1) Purpose : When the hydraulic pressure releasing is
To release the pressure in main circuit for piping performed, make sure to place bucket on the
repair works. ground.
(2) Principle :
After the mode is switched to "Pressure Relief When the operating lever is shifted to neutral during
Mode" with switch on gauge cluster, mechatro engine running, "DRAINING HYD. PRESS." is
controller outputs the following commands. displayed on the gauge cluster while the mode
switch is changed to pressure relieving mode. In
1) Minimum tilting command value to pump
this time the intermittent buzzer sounds
proportional valve (PSV-P1, PSV-P2).
continuously. When right and left operating levers
2) Output "Pressure relief control speed command are operated 4 or 5 times to their full stroke,
value" at ECU. (Electric system) pressure is relieved.
3) Stand-by command value to P1, P2 unloading After draining pressure is completed, turn off the
proportional valves starter key and buzzer sound stops. If the pump
pressure is determined to be more than 1 MPa (145
How to switch to "Pressure release mode"
psi) by the output value of the high pressure sensor
1) Select the service diagnosis mode. or the high pressure sensors (SE-22,23) are
(Keeping pressing of the "BUZZER STOP broken, "FAIL DRAIN HYD. PRESS" is displayed
SWITCH" [ ] on gauge cluster, turn the starter and the buzzer sounds continuously. In that case,
key on.) also the buzzer is not stopped unless the engine
2) Select the service adjustment mode 1. key is turned to OFF. Repeat the pressure releasing
(Under the condition that "Screen No.1" of procedure once again.
"Service diagnosis mode 1" is indicated, (2) Hydraulics :
keeping pressing of the "BUZZER STOP Unload spool is switched to open position, and the
SWITCH", press the selector switch [ ] 3 oil delivered by each pump is unloaded to the tank
times. When "LANGUAGE/LOGO", passage.
"ADJUSTING MODE 1" and "PRESET BY If the spools are switched by pilot operation, the
FACTORY" are displayed, press [ ] or [ ] remaining pressure from the actuators may be
switch, and highlight "ADJUSTING MODE 1", relieved to the tank circuit, i.e. the main circuit
and then press "Selector Switch" again.) pressure may be released.
3) When "ADJUSTING MODE 1" screen is
displayed, press [ ] or [ ] switch, and "DRAIN
HYD. OFF" screen appears.
4) Press "Selector Switch" and highlight "OFF",
and press [ ] switch to change to "DRAIN
HYD. ON", and then press "Selector Switch"
again.
(3) Operation :
1) Pump proportional valve reduces the pump flow
rate to the minimum.
2) Unloading proportional valves (PSV-D, PSV-B)
output secondary pressure and the secondary
pressure flows in PCb, PCa ports of C/V(2) and
2-42
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
Fig. 2-8 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.
2-43
2-44
2.6 HYDRAULIC COMPONENTS

2.6.1 HYDRAULIC PUMP • REGULATOR
2.6.1.1 Summary (SK125SR, SK135SR-2)
PSV1 MAX. FLOW RATE

ADJUSTING SCREW
2X4-M10
Dr1 Depth 16
A3
A2
a5
a4
A1
PSV2 B3
B1
EYE BOLT (M10) VIEW
4 4
a4 PSV1 PSV2 a5
a5
a6
2 2 PSV2 PSV1
MIN. FLOW RATE
ADJUSTING SCREW
Dr1 Dr1 B3 Dr1

B3
B1 3
B1
A3
a1 a2 Dr1 a3
B3
a3 Dr3
A1 A2 PH2
1 Dr3 Dr1
4-M12 Depth 18
Hydraulic ports
No. Parts Q'TY Code Ports name Size
1 Main pump assy 1 A1,2 Delivery port SAE 6000psi 3/4"
2 Regulator assy 2 B1 Suction port SAE 2500psi 2 1/2"
3 Gear pump assy(for pilot) 1 Dr1 Drain port PF1/2-19
4 Solenoid proportional reducing valve 2 PSV1,2 Servo assist port PF1/4-13
PH1,2 Pressure sensor port PF3/8-17
a1,a2 Gauge port PF1/4-15
a3 Gauge port PF1/4-14
a4,a5 Gauge port PF1/4-13
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15
Fig. 2-9 Hydraulic pump • regulator
2-45
2.6.1.2 Hydraulic circuit diagram (SK125SR, SK135SR-2)
(FRONT) PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (REAR)

(KR76-0E13-V) (KR76-0E13PV)
(KDRDE5K) (KDRDE5K)
Solenoid proportional Solenoid proportional
reducing valve (PSV-1) reducing valve (PSV-2)
a4 a5
Regulator
Regulator
Dr1
Gear pump for pilot
Main pump a3
B1 B3 Dr3 A3
PTO.
Gear Case
Fig. 2-10 Hydraulic circuit diagram of pump
2.6.1.3 Specifications (SK125SR, SK135SR-2)
Item Main pump Gear pump

Without PTO YY10V00009F1
Pump assy -
Parts No. With PTO YY10V00013F1
Single Pump YY10V00014F1 YY10V00015F1
Without PTO K7V63DTP179R-0E13-V
Pump model ZX10L7RZ2-07G
With PTO K7V63DTP174R-0E13-V
Max.displacement capacity cm3 65.2 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2000
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure -
Max. flow L/min (gal/min) 130 (34) X 2 at 7.8MPa (1130 psi) 20 (5.3)
Max. input horse power kW (PS) 64.9 (88.3) 3.1 (4.2)
Max. input torque N.m (lbf.ft) 310 (229) 14.7 (10.8)
Part No. YM10V01002F2, YM10V01002F1
Model KR76-0E13-V, KR76-0E13PV
Regulator Control function Electric flow control, positive flow control
With solenoid proportional reducing valve
Others
(KDRDE5K-31/30C50-123)
Without PTO 82 (181)
Weight kg (lb)
With PTO 84 (185)
Note) Without PTO ................... S.E.ASIA SPEC.

With PTO ........................ OCE SPEC.
2-46
2.6.1.4 CONTROL CURVE OF PUMP (SK125SR, SK135SR-2)
250
[1] 49kW H mode at operating attachment
[2] 64kW H mode at traveling or optional working Input revolution ; 2000 min-1, 1800 min-1
[3] 44kW S mode at operating attachment Input horse power ; 64 kW
Input torque ; 303 N.m
200 Reference value in ( )
Two pumps are loaded at the same time
Delivery flow rate Q [ L/min ]
150
Q 2000min-1
(H mode)
1800min-1
(S mode)
100
[3] [2]
[1]
50
Min.Flow(at 2000min-1)
0 5 10 15 20 25 30 35 40
Delivery pressure Pd [MPa]
2-47
2.6.1.5 PTO gear case (For Oceania)
125
711 468
118 825 710 728
117
126
326 262
115
128
826
414
435
886
885
No. Parts Q’ty No. Parts Q’ty

115 Idle shaft 1 435 Flange socket ; M10×20 4
117 2nd gear 1 468 VP plug ; PF3/4 1
118 3rd gear 1 710 O-ring ; 1B G80 1
125 Ball bearing 2 711 O-ring ; 1B G85 1
126 Roller bearing 1 728 O-ring ; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Sprig pin 1
414 Capscrew ; M10×20 4 886 Pin 2
2-48
2.6.2 PILOT VALVE (ATT) (SK125SR, SK135SR-2)
2.6.2.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
The adjust nut

(opposing flats : 22) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by PF1/4
means of spanner or the like. T=29.4 (21.7)
Then tighten the mating lock
nut to 41 + 3 N.m (302.2 lbf.ft). T=Tightening torque
: N.m (lbf.ft)
VIEW A
Part No. YN30V00111F1

Model PV48K2004
Operating torque Refer to the curve below
Max. primary pressure 6.9 MPa (1000 psi)
Primary pressure 5.0 MPa (725 psi)
Rated flow 20 L/min (5.3gal/min)
Weight Approx. 1.9 kg (4.2 lbs)
A
PORT 1, 3 PORT 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)

Secondary pressure [MPa (psi)]
Secondary pressure [MPa (psi)]

Operation torque [N.m (lbf.ft)]
Operation torque [N.m (lbf.ft)]

(464)3.2 (464)3.2
(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)
SINGLE OPERATING TORQUE SINGLE OPERATING TORQUE
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
(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

0.94(0.69) 0.94(0.69)
(87)0.6 (87)0.6
1.17 (0.86) 1.17 (0.86)
0.98 (0.72) 0.98 (0.72)
0 0 0 0
0 1.1 2 4 6 7 0 1.12 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)
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
2-49
2.6.3 PILOT VALVE (TRAVEL) (SK125SR, SK135SR-2)
2.6.3.1 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
(3) Performance characteristics

Secondary pressure
[MPa (psi)] Secondary pressure
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
2-50
2-51
2.6.4 CONTROL VALVE
2.6.4.1 SPECIFICATIONS
2.6.4.1.1 OUTSIDE VIEW (SK125SR, SK135SR-2)

PTb PCa
PBL
MU2
P2
P6 P5
P1
PCb PAL
T1
CT1 T2 CT2
PTb CMR1
P1 unload PCb PAL
CMR2 PL CP2
Travel PCb PAL Travel left PBL
straight
AL BL
CP1
Br Ar Travel PAr PB1 DR PCa
PBr PAr PB1 Boom CCb
right P2
Ab conflux unload
PAb Bb (ROD) LCb (HEAD) Bs
PBs As LCs
PBb PBs Swing
Boom PBb PAs
CRb
Pss
Pss CRa
Ac (HEAD) LCc Bucket
Bc PBc PAa1 Arm 1 PBa1
(ROD) LCa
PAc PBc PAa1 Aa
(ROD) LCo
MU1 PAa2
PBa2 Arm 2 PAa2 PAo PAo Option PBo
LCAT2 LCAP2 Ao Ba
(HEAD)
PBp1 PBp2 Bo
PAo PAa2
PAa2
PBa2
Arm 2 Option
PBo
PAc PBa1
Bucket Arm 1
(P3) (P4) PAb
PAa
Boom Swing
PBr PCa
Travel right P2 unload
T3
PTb PBL
Travel Travel left
straight
PBa2 PBo
A VIEW A
Fig. 2-11 Outside view
2-52
2.6.4.1.2 PORTS (SK125SR, SK135SR-2)
Port size Tightening torque Ports Description

PF3/4 150~180 N•m (111~133 lbf•ft) (MU1), (MU2) Pluged
T3
Ar Right travel motor port (forward)
Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
Ao Optional pilot port
Bo Optional pilot port
PF1/2 98~120 N•m (72~89 lbf•ft) (P3), (P5) Pluged
(P4), (P6) Pluged
PF3/8 69~78 N•m (51~58 lbf•ft) PAa1 Arm 1 (in) pilot port
PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PAL Travel left (forward) pilot port
PBL Travel left (reverse) pilot port
PAr Travel right (forward) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PBa2 Arm 2 (out) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port
PF1/4 34~39 N•m (25~29 lbf•ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PBp1 Bypass cut valve (P1 side) pilot port
PBp2 Bypass cut valve (P2 side) pilot port
(PL)
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
M10 49~65N•m (36~48 lbf•ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
2-53
Port size Tightening torque Ports Description

M12 83~110N•m (61~81 lbf•ft) T1 Tank port 1
T2 Tank port 2
2.6.4.1.3 SPECIFICATIONS (SK125SR, SK135SR-2)
Item Specifications
Model KMX13YD/B44004
Maximum flow rate [L/min (gal/min)] 130 (34)×2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 30×2L/min (8×2gal/min)]
Overload relief valve set pressure [MPa (psi)] 37.8 (5480) [at 30L/min (8gal/min)]
2-54
2.6.4.1.4 HYDRAULIC CIRCUIT DIAGRAM
P1 T1 T2 P2
CMR1
(PL) CMR2
PTb PBL
Travel straight
PCb PAL Travel left
P1 unload
AL
CT2 CP2 BL
CT1
T3 Boom conflux
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr
CCb
PBs
LCb LCs Pss
Boom PAb PAs Swing

As
Bs
PBa1
(ROD) Bb
CRb LCa
(HEAD) Ab PAa1
Arm 1
PBb
Aa (HEAD)
LCc
CRa
PLc2
Bucket PAc
Ba (ROD)
(ROD) Bc
(HEAD) Ac
LCo
PAo Option
PBc
LCAT2
LCAP2
PAa2
Arm 2 Ao
Bo
PBa2 PBo
(MU)
PBp1 PBp2
(P3) (P4)
Fig. 2-12 Hydraulic circuit diagram
2-55
2.6.4.1.5 OPERATION (SK125SR, SK135SR-2)

(1) Lever in neutral position (Unload valve is actuating)
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through
tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system,
because the by-pass cut valve (605) located on the downstream of center by-pass passage (52) opens, the
hydraulic oil through hydraulic pump P1 port passes through travel straight spool (307), and then flows though
the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut
valve (605) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to
the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic
oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut
valve (605) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic
pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which
passes through travel left, swing, arm 1 and option and the by-pass cut valve (605) on P2 side, and flows into
low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
52
605 (D)
517
307
T1
T1
P2
P1
309
605
(D)
Connected to low
55 310 pressure circuit of
P2 side casing
Fig. 2-13 In neutral position
2-56
2-57
2.6.5 SWING MOTOR UNIT (SK125SR, SK135SR-2)
2.6.5.1 SPECIFICATION
(1) General view
PB L,IP DP Port
Symbol Port name
size
THREAD FOR
EYE BOLT 2-M10 A,B Main port PF1/2
B DEPTH 18
DB Drain port PF3/8
GN C Make-up port PF3/4
PA PA,PB Pressure measuring port PF1/4
C PG Parking brake release port PF1/4
L Level gauge PF3/4
IP Filling port of gear PF3/4
PG DP Outlet port of gear oil PF1/2
A
DP2 Outlet port of gear oil PF1/2
AN C Dr GN Inlet povt of grease PF1/4
A,B
AN Air vent port PF1/4
PG
IP
DP2
B A
DP PB PA
AN Safety relief valve

C
DB
GN PG
Hydraulic diagram
2-58
(2) Specifications
Swing motor unit part No. YY15V00016F1

Type M2X63CHB-13A-36/285-60
Part No. YY15V00018F1
Hydraulic motor
Displacement cm (in ) / rev

3 3 60 (3.66)
Rated pressure MPa (psi) 28.0 (4060)
Braking torque N•m (lbf•ft) 314 (232)
Release pressure MPa (psi) 2.3 (334)
Relief set pressure MPa (psi) 28.0 (4060) at 110L/min (29 gal/min)
Weight kg (lbs) 29 (64)
Type RG06D19J2
Part No. YY32W00004F1
Reduction unit
Reduction ratio 19.2

Lubicate oil Gear oil SAE#90~#140 (API class GL-3~4 grade)
Lubicate oil volume L (gal) 1.65 (0.44)
Grease Extreme pressure lithum base #2 grease
Grease volume cm (in )
3 3
500 (30.5)
Total weight kg (lbs) 113 (249)
2-59
2.6.5.2 CONSTRUCTION
(1) Swing motor
992
451 452
303 131 444
b
A
351
355 SECTION A-A
051
401
488 469 (051-1)
468
106 487 444 433 981 390 438 452 980
391
Tightening forgue
303
472 Tightening Widfh
No. Size torque
across flat
451 . .
N m (lbf ft)
707
712 051 M33X1.5 177(131) 41
A 706
A 401 M16 240(177) 14
131
982
468 G1/4 36(27) 6
702
114 469 M22X1.5 108(80) 10
111
117 980 G3/8 1.7(1.3) 6
743 981 G3/4 4.4(3.2)
121 14
742 982 G1/4 0.9(0.66) 6
113
992 PT3/4 98(72) 14
123
116
117
301
432 471 443 106 101 491 304 437 124 122
2-60
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Drive shaft 1 443 Roller bearing 1
106 Spacer 3 444 Roller bearing 1
111 Cylinder 1 451 Pin 2
113 Retainer (spherical bushing) 1 36 (27) 468 Plug : PF1/4 2
114 Cylinder spring 1 108 (80) 469 Plug : M22 2
116 Push rod 12 471 O-ring : 1B G80 1
117 Spacer 2 472 O-ring 1
121 Piston 9 487 O-ring : 1B P11 2
122 Shoe 9 488 O-ring : 1B P20 2
123 Set plate 1 491 Oil seal 1
124 Shoe plate 1 702 Brake piston 1
131 Valve plate 1 706 O-ring 1
301 Casing 1 707 O-ring 1
303 Casing 1 712 Brake spring 20
304 Front cover 1 742 Friction plate 3
351 Plunger 2 743 Separator plate 4
355 Spring 2 1.7 (1.2) 980 Plug : PF3/8 1
240 (177) 401 Socket bolt : M16×75 4 4.4 (3.3) 981 Plug : PF3/4 1
432 Snap ring 2 0.9 (0.6) 982 Plug : PF1/4 1
433 Ring 1 98 (72) 992 Plug : PT3/4 1
437 Snap ring 1 177 (131) 051 Relief valve : M33 2
438 Snap ring 1 051-1 O-ring : 1B G30 2
2-61
(2) Swing reduction unit
602 230 231 204 286 211 912 285 287 911 283 403 603 922
210
921
282
202
*
203
913
285
*
402
910
801
925
920
390
926
102
401
Apply Three Bond #1217 on . 915
201
Tightening torque Tightening torque

102 Casing 1 402 Roller bearing 1
201 Pinion shaft 1 403 Needle bearing 3
202 Ring gear 1 98 (72) 602 Socket bolt : M12×100 8
203 No.2 planetary gear 4 603 Socket bolt : M12×135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Retaining ring 3
230 No.2 spider 1 912 Retaining ring 1
231 No.1 spider 1 913 Retaining ring 1
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 (48) 920 Adapter : PT1/2 1
285 Side plate t=1 7 108 (80) 921 Hose : PF1/2 1
286 Thrust washer t=2 1 108 (80) 922 Plug : PF1/2 1
287 Side plate t=2 3 925 relief fitting 1
401 Roller bearing 1 926 Grease nipple : PT1/4 1
2-62
2.6.6 TRAVEL MOTOR (SK125SR, SK135SR-2)
2.6.6.1.1 General view
18-M16 X P2.0 Mounting surface of sprocket

20-M16 X P2.0
Oil filling port
(PF1/2)
A PF3/4
Oil level
D PF1/2 check port
(PF1/2)
Y Z
X
B PF3/4
Oil drain port
(PF1/2)
Oil filling port

P PF1/4 (PF1/2)
Oil level check port
(PF1/2)
VIEW Y
DIRECTION INLET OUTLET

(VIEW X) PORT PORT
CLOCK WISE A B Oil drain port
C . CLOCK WISE B A (PF1/2)
VIEW Z
2.6.6.1.2 SPECIFICATIONS
Part No. YY15V00015F1

Item
Type GM21VA-A-45/76-2
Revolution min-1 51.4/31.3
Reduction ratio 54.0
reduction unit
Lubricant oil Gear oil SAE#90 GL4
Lubricant oil valume L (gal) 2.1 (0.55)
Max. displacement cc (cu•in)/rev 44.9/75.5 (2.74/4.61)
Max. speed min-1 2777/1688 (2nd/1st)
Hydraulic motor
System pressure MPa (psi) 34.32 (4976)
2 speed changeover
MPa (psi) 1.96~6.86 (284~995)
pressure
Brake torque N•m (lbf•ft) 206 (152)
Parking brake
Release pressure MPa (psi) 0.76 (110)
2-63
2.6.6.1.3 CONSTRUCTION
(1) Outline
HIGH LOW
SPEED SPEED 2-SPEED
CHANGE
PISTON
PARKING
BRAKE
REDUCTION 2-SPEED
UNIT CHANGE
PISTON
HYDRAULIC MOTOR
BRAKE VALVE
PARKING BRAKE
HIGH AND LOW SPEED SHOCKLESS
CHANGE MECHANISM RELIEF
LOAD CHECK VALVE KIT
VALVE
&
CONTROL VALVE ANTI
CAVITATION
VALVE
BREKE
VALVE
HYDRAULIC PUMP
HYDRAULIC CIRCUIT DIAGRAM
2-64
2-65
(2) Hydraulic motor
116
115
135
324 112
336 139
328 109
325
326 341
331 377
354
327 301
330
380 383358
352 113
353 150
329
398 376
396 358 352 343 323

327
353
358 352
381 383
380 379
366 330
398 378 331
363 399 398 326
359 208 201 325
357 384 210
208 207 328
210
209 336
324
212
203
103
204 202
106
105
213 206
211 107
205
108
151
104
110
114
110
145 132
149
102
171
167
185
161
162
2-66
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

102 Shaft 1 185 Spring 1 341 Parallel pin 1
103 Swash plate 1 201 Valve seat 1 343 Socket bolt 10
104 Cylinder block 1 202 Valve 1 352 Plug 3
105 Piston 1 203 Sleeve 1 353 Ball 2
106 Shoe 1 204 Collar 1 354 Plug 5
107 Retainer plate 1 205 Plug 1 357 Plug 1
108 Thrust ball 1 206 Spring 1 358 O-ring 3
109 Timing plate 1 207 O-ring 1 359 O-ring 1
110 Washer 2 208 Back-up ring 2 363 Spool 1
112 Piston 1 209 O-ring 1 366 Spring 1
113 Spring 10 210 Back-up ring 2 376 Orifice 1
114 Spring 1 211 O-ring 1 377 Filter 1
115 Friction plate 3 212 O-ring 1 378 Ball 1
116 Separator plate 4 213 Shim 1 379 Plug 1
132 Oil seal 1 301 Rear flange 1 380 Plug 2
135 O-ring 1 323 Spool 1 381 Piston 1
139 O-ring 1 324 Plug 2 383 O-ring 2
145 THS snap ring 1 325 Washer 2 384 Orifice 2
149 Bearing 1 326 Plug 2 396 Plug 2
150 Bearing 1 327 Valve 2 398 Plug 8
151 Needle roller 3 328 Spring 2 399 Name plate 1
161 Piston 1 329 Orifice 2
162 Shoe 1 330 Spring 2
167 Pivot 2 331 O-ring 2
171 Parallel pin 2 336 O-ring 2
2-67
(3) Reduction unit
22 24
29
24
29
23
2
33
34 32 35
14
13
4
36
15
6
3 16
8
10
717
31 30
11
27
5
11
12
28
9
12

1 Hub 1 16 Parallel pin (1) 3
2 Spindle 1 17 Parallel pin (2) 3
3 Spider (1) 1 22 Lock washer 2
4 Sun gear (1) 1 23 Shim 1
5 Planetary gear (1) 3 24 Bearing 2
6 Pin (1) 3 27 Needle bearing 3
7 Spider (2) 1 28 Needle bearing 3
8 Sun gear (2) 1 29 Floating seal 2
9 Planetary gear (2) 3 30 Plug 3
10 Pin (2) 3 31 O-ring 3
11 Thrust washer (1) 6 32 O-ring 1
12 Thrust washer (2) 6 33 O-ring 2
13 Thrust plate 1 34 Parallel pin 2
14 Cover 1 35 Socket bolt 12
15 Coupling 1 36 Snap ring 1
2-68
2.6.7 SWIVEL JOINT (SK125SR, SK135SR-2)
2.6.7.1 GENERAL VIEW

Fig. 2-14 General view of swivel joint
Item Specifications
Assy parts No. YN55V00053F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
F Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length : L 368 mm (14.5")
Weight 25 kg (245 lbs)
2-69
2.6.8 CYLINDER
(1) General view
Fu
lly
ex
ten
de
dl
en
gth
B
Fu
lly
ret
rac
ted
len
gth
A
Part No.and Manufacturing No.

Stamp position
Fig. 2-15 General view of cylinder

(2) Specifications (SK125SR, SK135SR-2)
Unit : mm (ft-in)
Center distance of pins

Part No. of Cylinder bore / Dry weight
Use Stroke Full extend B / Full Cushion
cylinder assy Rod Dia. kg (lbs)
retract A
ø100 / ø70 1,092 2,648 / 1,556 With cushion on
Boom YY01V00053F1 101 (223)
(3.94" / 2.76") (3-7) (8-8.3 / 5-1.3) rod side
ø115 / ø80 1,120 2,835 / 1,715 With cushion on

Arm YY01V00054F1 148 (326)
(4.53" / 3.15") (3-8.1) (9-3.6 / 5-7.5) both sides
ø95 / ø65 903 2,293 / 1,390 With cushion on

Bucket YY01V00055F1 98 (216)
(3.74" / 2.56") (2-11.6) (7-6.3 / 4-6.7) rod side
2-70
2.6.9 RADIATOR & OIL COOLER (SK125SR, SK135SR-2)
2.6.9.1 General view
Oil cooler
Radiator
Inter cooler
Fuel cooler
Shroud
In case of previous machine, radiator , oil cooler and intercooler were installed in order separately. Incase of this
machine all components become built-in and have been integrated as one unit.
2-71
2.6.10 MULTI CONTROL VALVE (SK125SR, SK135SR-2)
2.6.10.1 PREPARATION FOR REMOVAL

(1) Bleed pressure air in hydraulic oil tank (See )
(2) Remove under cover (3). (See )
(3) Remove plate (A6) and panel assy (A2).
(See Fig. 5-44)
Fig. 2-16 Removing multi control valve
2.6.10.2 REMOVAL
(1) Attach tag on which hose name is entered to the
remote control hoses between multi control valve
0 2
and pilot V, and write numbers P1 to P8 on it.
P/V
See Tools (3) P2
P6 P5
: 19 mm, 22 mm 6 5
P/V C4 P/V
(2) Attach tag on which hose name is entered to the
C3 C6 PBb
remote control hoses between multi control valve C/V
and main control valve, and write numbers C1 to C8 C1
PBs
C7 PAb C5 C/V
on it. C/V P1
See Tools (3) PAa1 PAc PAc PBc
C/V C/V C/V C/V
1
: 19 mm, 22 mm
P/V PBa2
(3) Remove 4sems bolts (B15) M8×35, and remove C/V
multi control valve (0) from machine. Fig. 2-17 Removing hoses between main C/V, P/V
and multi control valve
2.6.10.3 INSTALLATION
(1) Installing is done in the reverse order of removing
(2) Relations between pilot valve and multi control P3
valve hose 3
P/V
P/V Hose ISO Multi Mark-
Port Size Color Control pattern port ing P7
1 3/8 Red Bucket digging P1 1 7
2 3/8 Blue P8
Right side
Bucket dump P2 2 P/V

3 3/8 Green Boom up P3 3
4 3/8 Gray Boom down P4 4
8
P 1/4 Black Pilot primary - - P4
P/V
T 3/8 Black Drain - -
5 3/8 Gray Swing left P5 5
6 3/8 Red Swing right P6 6
Left side
4
7 3/8 Blue Arm in P7 7
P/V
8 3/8 Green Arm out P8 8
P 1/4 Black Pilot primary - - B15
T 3/8 Black Drain - -
Fig. 2-18 Removing hoses between main C/V, P/V
(3) Tightening torque and multi control valve
Tool Tightening torque

Tightening position
mm N.m (lbf.ft)
Sems bolt (B15) 13 35.3 (26.1)
2-72
2.7 ELECTRICAL EQUIPMENT AND HARNESS LAYOUT

2.7.1 UPPER HARNESS ASSY (1/8) (OCE/S.E.ASIA) (SK125SR, SK135SR-2)
UPPER HARNESS ASSY YY13E00040F1 (04) TO ENG. REVOLUTION

FIX WHITE TAPING CLIP SENSER
ITEM PART NAME PART No. Q'TY REMARKS TO PUNP
POSITION CLIP ENG. SWING FLASHER RIGHT
1 HARNESS YY13E01166P2 1 UPPER GND CABLE
NOTES:
1-3 FUSE YY73S00003P1 1 (1) TIGHTENING TORQUE OF
BATTERY TERMINALS ARE 3.4N.m. (2.5lbf.ft)
1-4 BOX,FUSE LE73E00001S001 1 (2) TIGHTENING TORQUE OF
GROUNDING CABLES ARE 10.7N.m. (7.89lbf.ft)
2 CABLE YY13E01144P1 1 BATTERY-BATTERY (3) UNLESS OTHERWISE SPECIFIED
TIGHTENING TORQUE IS SHOWN BELOW.
3 CABLE YY13E01130P1 1 BATTERY-GND M6 : 9.6N.m (7.08lbf.ft)
M8 : 23.5N.m (17.3lbf.ft)
4 CABLE YY13E01139P1 1 BATTERY-RELAY M10 : 46.1N.m (34lbf.ft) SEMS-BOLT
M12 : 79.4N.m (58.6lbf.ft) GND
5 CABLE YY13E01138P1 1 STARTER (4) UNLESS OTHERWISE SPECIFIED, THE
INSTALLING PROCEDURE IS SHOWN BELOW. SECTION AA TIGHTEN AFTER
CHECKING NO PAINT.
6 HARNESS YY13E01148P1 1 SUB HARNESS (ECU)
CLIP ECU HARNESS
7 CABLE LE13E01006P1 1 FLOOR GND CLIP 6
UPP HARNESS
HARNESS
SE-13 : CLIP
E-13 :TRAVEL ALARM (OCE) SEMS-BOLT
ENG. REVOLUTION STARTER FIX WHITE TAPING POSITION
SE-5 : SENSOR
SE-15 :FUEL SENSOR CABLE TO STARTER MOTOR ANND
PRESS SENSOR
TO ATT HARNESS TO GLOW ALTERNATON
: SWING SE-23 :PRESS SENSOR: PUMP P2
CLIP
PSV-P2 :PUMP 2 PROPORTIONAL SOL. FIX WHITE TAPING POSITION
E-6 :HORN LOW
SECTION BB
E-5 :HORN HIGH BATTERY CABLE
2
PSV-P1 :PUMP 1 PROPORTIONAL SOL. SEMS-BOLT
L-2 :
GND
FRAME WORKING SE-22 :PRESS SENSOR:PUMP P1 TIGHTEN AFTER
LIGHT RIGHT CHECKING NO PAINT.
CLIP L-4 :SWING FLASHER RIGHT
FIX WHITE TAPING 3
TO HARNESS OF ATTACHED ENG.
POSITION GND CABLE
CLIP
SEMS-BOLT
FIX WHITE TAPING
POSITION
1 5
UPP HARNESS STARTER CABLE
CLIP
L-10 :HIGH REACH 4
ROTARY LIGHT BATTERY RELAY CABLE
FIX WITH THE CLIP FOR
DRAIN HOSE
UPP HARNESS CLIP
SEMS-BOLT DERAIL OF BATTERY
TO AIR FILTER RESTRICTION SW.

RECEIVER DRIER
SWING FLASHER LEFT
STARTER UPP HARNESS
FIX WHITE TAPING POSITION
CABLE DRAIN HOSE STARTER CABLE
L-3 :SWING FLASHER LEFT
SW-8 :AIR FILTER RESTRICTION SW.
7 E-10 :RECEIVER DRIER

FLOOR GND CABLE
SEMS-BOLT
GND TO BATTERY TO HIGH REACH
TIGHTEN AFTER ROTARY LIGHT
CHECKING NO PAINT. CLIP
VIEW SEMS-BOLT
2-73
FIX AND PUT WHITE TAPING POSITION

OF UPP HARNESS AND ECU HARNESS
CONNECT WITH ENG. ACCESORIES HARNESS CLIP
TO GLOW CLIP
CLIP P-11 TO UNDER FLOOR FRAME GROUND

SEMS-BOLT MECHATRO CONTROLLER ; C-1
CLIP CLIP P-10,P-16 TO UNDER FLOOR FRAME GROUND
FIX A CONNECTOR SEMS-BOLT MECHATRO CONTROLLER ; C-1
BY A CLIP ON BRACKET FIX WHITE TAPING POSITION
KPSS RELEASE SWITCH ; SW-22
OPT. SELECTOR SWITCH SOLENOID ; SV-13
12 PIN TO FLOOR PLATE
UPPER P-4,P-15 TO UNDER FLOOR FRAME GROUND
16 PIN ECU HARNESS
BATTERY RELAY ; R-1
STARTER CABLE
UPP HARNESS GND FUSE & RELAY BOX ; E-1
UPP HARNESS SEMS-BOLT AIR FILTER CLOGGING SWITCH ; SW-8
CLIP ECU HARNESS GND DIODE ; D-4
SEMS-BOLT TIGHTEN AFTER
CONNECT TO CAB HARNESS
FIX WITH THE CLIP FOR DRAIN HOSE CHECKING NO PAINT
UPP HARNESS
P-2,P-9 TO UNDER FLOOR FRAME GROUND
LEVER LOCK SOLENOID ; SV-4
ECU HARNESS DECK WORK LIGHT ; L-2
CLIP TRAVEL 2 SPEED SOLENOID ; SV-3
FIX A UPP HARNESS TO ECU HARNESS FOWARD CLIP SEMS-BOLT
GND
DRAIN HOSE CLIP SWING PARKING SOLENOID ; SV-1
DETAIL aa FIX WHITE TAPING TIGHTEN AFTER CHECKING NO PAINT
WATER SEPALATER RESTRICTI ON SW. ; SW-36
POSITION P-1 ECU HARNESS GROUND
OPT. HAND CONTROL,
ENGINE CONTROLLER ; C-6 ENGINE CONTROLLER ; C-6
FOWARD CONNECT A HARNESS WITH IN CAP. VIEW XI
FIX WHITE TAPING POSITION SE-15 : FUEL SENSOR
CLIP FIX A CONNECTOR TO THE BRACKET
L-4 :SWIBG FLASHER RIGHT CLIP CLIP CLIP
TO ENG. REVOLUTION SENSOR

CLIP
SEMS-BOLT
CLIP
TO PUMP
SEMS-BOLT
E-13 :
TRAVEL ALARM (OCE) CLIP
TO ENG.
REVOLUTION SENSOR
CLIP
FIX A HARNESS
TO GUARD
TO TRAVEL ALARM
AND FUEL SENSOR
CLIP
FIX A CONNECTOR HAS TAG OF

"ALARM" ON BRACKET
FOWARD
VIEW (DETAIL OF TRAVEL ALARM INSTAL)

VIEW IX
2-74
SV-4 :
FIX WHITE TAPING POSITION OPERATING LEVER LOCK SOL.
FIX WHITE TAPING POSITION E-5 :HORN HIGH
CLIP
FIX WHITE TAPING POSITION SV-1 :
CLIP SWING PARKING BRAKE SOL.
SV-3 : TO WATER SEPALATER

TWO-SPEED SELECT SOL. RESTRICTION SW.
PSV-B :
P2 UNLOAD
CLIP PROPORTIONAL SOL.
TO WATER SEPALATER PSV-C :
FIX TO THE CONNECTOR RESTRICTION SW. TRAVEL PRIORITY
WITH CLIP REMAINING PROPORTIONAL SOL.
LENGHT OF THE WATER PSV-D : CLIP
E-6 :HORN LOW
SEPALATER RESTRICTI ON P1 UNLOAD FIX A HARNESS TO THE GUARD
SIDE HARNESS PROPORTIONAL SOL. FIX WHITE TAPING POSITION
CLIP
CLIP PSV-A :
ARM TWO-SPEED INVERSE CLIP
PROPORTIONAL SOL. FIX A HARNESS TO THE GUARD
SW-36 :
WATER SEPALATER
RESTRICTI ON SW.
FIX A CONNECTOR TO VIEW
THE BRACKET
FOWARD
L-2 :
FRAME WORKING CLIP
LIGHT RIGHT
DETAIL bb
CLIP
SMSE-BOLT
FIX WHITE TAPING POSITION FIX WHITE TAPING
POSITION VIEW
VIEW
FIX A CORRUGATERD TUBE NOT
VIEW FIX A HARNESS TO CONTACT LOCK OF CONNECTOR.
SE-1 : A CONNECTOR
PRESS SENSOR : FOR PIP BY A CLIP
SE-1 : BUCKET DIGGING. CLIP M-CONNECTOR
PRESS SENSOR : SE-7 :
SE-3 : BUCKET DIGGING. CLIP
PRESS SENSOR : PRESS SENSOR :
BOOM RAISING SE-3 : ARM IN
PRESS SENSOR :
BOOM RAISING SENSOR
SE-8 : SE-8 :
PRESS SENSOR : PRESS SENSOR :
ARM OUT ARM OUT
SE-4 : SE-4 :
PRESS SENSOR : CLIP
PRESS SENSOR : FIX WHITE TAPING POSITION FIX A HARNESS PART OF
BOOM LOWERING. BOOM LOWERING. INSTALL TO REMAIN HOLE WHITE TAPING WITH CLIP
TO HORN LOW
AND WATER OF CONTROL VALVE
SE-2 : SE-2 : SEPALATER CLIP
PRESS SENSOR : PRESS SENSOR : CLIP SE-5 :
PESTRICTION SW. SEMS-BOLT PRESS SENSOR : SWING
BUCKET DUMP BUCKET DUMP
CLIP
FOWARD FIX WHITE TAPING POSITION
FIX A CORRUGATERD CLIP

TUBE NOT CONTACT
LOCK OF CONNECTOR.
SE-7 :
PRESS SENSOR : M-CONNECTOR
ARM OUT
CLIP CLIP
FIX A HARNESS PART OF FIX A HARNESS PART OF
COULGATED FOR PRESS SENSOR OF CLIP
COULGATED FOR PRESS DETAIL dd
SENSOR OF CLIP
SENSOR
DETAIL cc : CASE OF MULCH DETAIL cc : CASE OF SENSOR BLOCK VIEW
2-75
FIX A HARNESS PART

OF COULGATED FOR
SOL. OF CLIP FIX A HARNESS TO THELUG
CLIP BY A CLIP
CLIP
FIX A HARNESS PART OF FIX A HARNESS TO THELUG BY A CLIP
PSV-P1 : FIX A HARNESS PART OF COULGATED COULGATED CLIP
PUMP P1 FOR SOL. OF CLIP FOR SOL. OF CLIP
PROPORTIONAL SOL. CLIP PSV-P1 : CLIP FIX A HARNESS PART FOR SOL. OF CLIP
PUMP P1 CLIP
PROPORTIONAL SOL.
PSV-P2 : PSV-P2 :
CLIP PUMP P2 PROPORTINAL SOL.
PUMP P2
CLIP PROPORTIONAL SOL.
SEMS-BOLT
TIGHTENING TORQUE 25.5N.m (18.8lbf.ft)
SEMS-BOLT
TIGHTENING TORQUE 25.5N.m (18.8lbf.ft) CLIP
SEMS-BOLT
CLIP TIGHTENING TORQUE 25.5N.m (18.8lbf.ft)
SEMS-BOLT
TIGHTENING TORQUE 25.5N.m (18.8lbf.ft)
VIEW
VIEW (DETAIL OF PUMP P1, P2 PROPORTICNAL SOL. INSTALL)
(DETAIL OF PUMP P1, P2 PROPORTICNAL SOL. INSTALL) (CASE OF PUMP AUTO EMERGENCY FUNCTION)
FIX A HARNESS PART OF COULGATED

FOR PRESS SENSOR OF CLIP FIX A HARNESS PART OF COULGATED
FOR PRESS SENSOR OF CLIP
SE-22 : CLIP
SE-23 : SE-22 : CLIP SE-23 :
PRESS SENSOR : PUMP P1 PRESS SENSOR : PUMP P1
PRESS SENSOR : PUMP P2 PRESS SENSOR : PUMP P2
VIEW
VIEW
(DETAIL OF PRESS SENSOR : PUMP P1, P2 INSTALL)
(DETAIL OF PRESS SENSOR : PUMP P1, P2 INSTALL) (CASE OF PUMP AUTO EMERGENCY FUNCTION)
2-76

USE NUT OF ATTACHED GLOW CLIP
TIGHTENING TORQUE SEMS-BOLT
3.2 ~ 4.4N.m (2.4 ~ 3.2 lbf.ft)
E-2 :
GLOW ALTERNATOR
FIX WHUTE TAPING POSITION TIGHTENING TORQUE

FIX A HARNESS BY A CLIP ON 4.9 ~ 6.9N.m (3.6 ~ 5.1 lbf.ft)
THE BRACKET B TERMINAL M-1 :
CLIP STARTER MOTOR
CLIP
FIX TO THE CONNECTOR WITH
CLIP REMAINING LENGTH OF THE
ENGREVOLUTION SENSOR SIDE
HARNESS ENG. GROUND CABLE
SE-13 :
ENG. REVOLUTION SENSOR TIGHTEN AFTER
FIX A CONNECTOR TO THE BRACKET CHECKING NO PAINT.
GND
WASHER
CLIP
SEMS-BOLT
CLIP
TIGHTENING TORQUE
38.2N.m (28.2 lbf.ft)
FIX WHITE TAPING POSITION STARTER CABLE
CLIP UPP HARNESS

FIX A UPP HARNESS
WITH A HARNESS OF
ATTACHED ENG.
E-11 :
AIR COMPRESSOR
FOWARD
E-2 : CLIP
VIEW ALTERNATOR
TWO TERMINALS ARM IN TOUCH WITH

USE NUT OF ATTACHED EACH OTHER TO THEIR BACK AND
STARTER MOTOR INSTAL AS DRAWING. CLIP
TO AIR COMPRESSOR FIX HARNESS BY
TIGHTENING TORQUE M-1 : A CLIP TO THE CONNECTOR
15.7 ~ 19.6N.m (11.6 ~ 14.5 lbf.ft) STARTER MOTOR VIEW
B TERMINAL BRACKET
FIX THE HARNESS WITH CLIP
UPP HARNESS AS THIS DRAWING.
AFTER CONNECT WITH
STARTER CABLE STARTER CABLE AIR COMPRESSOR SIDE HARNESS
R TERMINAL, CLIP
S TERMINAL UPP HARNESS FIX THE HARNESS
AS THIS DRAWING
CLIP
TO ALTERNATOR
CLIP
SEMS-BOLT
CLIP
CLIP
FIX WITH UPP HARNESS AND STARTER CABLE
SEMS-BOLT
FIX WITH THE I/C TUBE BRACKET
STARTER CABLE TIGHTENING TORQUE
39.2N.m (28.9 lbf.ft)
UPP HARNESS
VIEW
DETAIL OF STARTER MOTOR DETAIL OF AIR COMPRESSOR
2-77
FASTEN UPP HARNESS AND

ECU HARNESS ON
FLOOR HARNESS BY CLIP.
SW-22 : E-1 :
CLIP
E-1 : KPSS RELEASE SW. FUSE & RELAY BOX
FUSE & RELAY BOX
C-8 :
C-1 :
ENG. CONTROLLER
MECHATRO FLOOR HARNESS
CONTROLLER
CLIP CAB SUB HARNESS
CONNECT TO KPSS RELEASE SW.

FIX WHITE
TAPING POSITION "CNT-1" WITH TAG.
CONNECTOR OF CONNECT
TO FLOOR HARNESS
CLIP
FASTEN UPP HARNESS "CNT-2" WITH TAG. FIX A ECU HARNESS BY A CLIP
C-8 :
ON FLOOR HARNESS CONNECTOR OF CONNECT
ENGINE CONTROLLER
BY CLIP. CLIP TO FLOOR HARNESS
CLIP
CLIP
FASTEN UPP HARNESS ON
FLOOR HARNESS CAB SUB HARNESS BY CLIP
"CNT-5" WITH TAG. CLIP

CONNECTOR OF CONNECT
TO FLOOR HARNESS
ECU HARNESS
FLOOR HARNESS
UPPER HARNESS
SECTION CC
CLIP
FIX TO A FLOOR HARNESS
GROMMET ENG. CONTROLLER CONNECT CONNCTOR WITH "CN 4-1"CONNECT CONNCTOR WITH "CN 5"
PUT WHITE TAPING CHECK CONNECTOR TAG OF ITEM 1 : HARNESS
POSITION TOGETHER TAG OF ITEM 6 : HARNESS
UPP HARNESS
E-1 :
FUSE & RELAY BOX
ECU
HARNESS
FOWARD FOWARD
C-1 :
GROMMET R-19 : MECHATRO CONTROLLER
PUT WHITE TAPING POSITION TOGETHER FLASHER RELAY
E-14 : RESISTER
DETAIL OF FUSE & RELAY BOX CONNECTION. CONNECT CONNCTOR WITH "CN4-2" CONNECT CONNCTOR WITH "CN1"
CLIP TAG OF ITEM 1 : HARNESS TAG OF ITEM 1 : HARNESS
FIX UPPER HARNESS AND
FLOOR HARNESS TO STAND VIEW X VIII
CLIP CASE OF UNCONNECTION,
FASTEN UPP HARNESS ON BUNDLE AND FIX HARNESS
FLOOR HARNESS BY CLIP. C-1 :
MECHATRO CONTROLLER
1P CONNECTOR OF
CONNECT TO CAB HARNESS
CAB SUB HARNESS

16P CONNECTOR 17P CONNECTOR
31P CONNECTOR
28P CONNECTOR 24P CONNECTOR
VIEW X VII VIEW X IX
2-78

L-10 : HIGH REACH ROTARY LIGHT SW-8 :
FIX THE CONNECTOR WITH CLIP AIR FILTER RESTRICTION SW.
"L-10" TAG TO THE BRACKET L-3 : SWING FLASHER LEFT
E-10 :
RECEIVER DRIER
GROMMET FIX A HARNESS OF

WHITE TAPING POSITION
OF CLIP TO THE SWITCH.
CLIP
HOSE
CLIP CLIP
FIX WHITE TAPING
POSITION TO THE FAN GUARD
HARNESS
CLIP
FIX WITH THE FAN GUARD
AND CLIP TO SWING FLASHER LEFT CLIP
FIX A HARNESS
TO THE HOSE
TO RECEIVER DRIER,
CLIP AIR FILTER RESTRICTION SW.
FOWARD
FOWARD
VIEW X X
SE-29 : A CLIP DOES NOT HIT A RUBBER CAP.

M-CONNECTOR FIX A CORRUGATERD
PRESS SENSOR : FIX A HARNESS OF WHITE TAPING POSITION
TUBE NOT CONTACT
SELECTOR DETECTION OF CLIP TO THE SWITCH.
FOWARD LOCK OF CONNECTOR.
CLIP CLIP CONNECT A CONNECTOR SENSOR CLIP
WITH "SELECTOR TAG."
SEMS-BOLT
INSTALL TO REMAIN HOLE
CLIP
VIEW X OF CONTROL VALVE.
PLATE SW-8 :
SEMS-BOLT SV-13 : AIR FILTER
OPT SELECTOR SOL. FIX A HARNESS PART OF RESTRICTION SW.
CONNECT A CONNECTOR WHITE TAPING WITH CLIP
CLIP WITH "SELECTOR TAG."
FIX A HARNESS TO
HOSE METAL FITTING
BY A CLIP. CLIP
CLIP
SEMS-BOLT
WHEN THERE IS NO OPT OF SE-29, SV-13,
OR THERE IS REST HARNESS FOR SE-29, IT
BUNDLES AND FIXES HERE.
CLIP
VIEW X X I
VIEW X II
2-79
CLIP
FIX WHITE TAPING POSITION SEMS-BOLT
BATTERY RELAY CABLE
GROUND CABLE
STARTER CABLE
UPP HARNESS
VIEW VIII
R-3 :
ADJUST THE LOCK OF THE FUSE FIX FUSE BOX WITH THE BRACKET
GLOW RELAY CONNECT THE TERMINAL WITH "A" OF HARNESS
BOX COVER TO THE UPPER SIDE PLATE
SEMS-BOLT
BATTERY RELAY CABLE
FIX A 1P CONNECTOR NUT

TO THE BRACKET ROCK WASHER
FIX A 2P CONNECTOR
TO THE BRACKET CONNECT THE TERMINAL WITH "B" OF HARNESS
CONNECT THIS TERMINAL

WITH BATTERY RELAY CABLE
TIGHTENING TORQUE CLIP
7.8N.m (5.8 lbf.ft) MAX FIX WITH HARNESS FOR FUSE BOX AND BATTERY RELAY
BATTERY RELAY
CONNECT THIS TERMINAL WITH FUSE BOX CABLE AND STARTER CABLE
FIX A CONNECTOR TIGHTENING TORQUE 7.8N.m (5.8 lbf.ft) MAX
TO THE BRACKET
CLIP
SEMS-BOLT
STARTER CABLE
UPP HARNESS
INSERT HARNESS FOR SLIT OF INSULATION
SECTION DD
2-80
2.7.2 UPPER HARNESS ASSY (FLOOR) (1/3) (OCE/S.E.ASIA) (SK125SR, SK135SR-2)
UPPER HARNESS ASSY YY13E00041F1 (02)
ITEM PART NAME PART No. Q'TY REMARKS E-32 :

1 HARNESS YY13E01167P1 1 FLOOR PRESS SENSOR
DOZER
3 CABLE LE13E01005P1 1 FRAME GROUND NOTE
FLOOR HARNESS 1. ATTACHMENT OF WELDING CLIP WITHOUT
4 HARNESS YB13E01054P1 1 CAB SUB DIRECTIONS IS MADE INTO THE FOLLOWING.
CLIP
SW-1 : C-1 :
KEY SW. MECHATORO CONTROLLER E-1 : HARNESS
SE-16 : FUSE & RELAY BOX
ACCEL POTENTIO
TO TUNER
C-8 : HARNESS
ENG. CONTROLLER
FIX A CORRUGATERD TUBE
NOT CONTACT LOCK OF
CLIP
CLIP CONNECTOR.
M-CONNECTOR
PLATE
SENSOR
SENSOR
FIX A HARNESS PART OF
WHITE TAPING WITH CLIP SECTION CC (SECTION SENSOR INSTAL)
VIEW (DETAIL OF CONNECT TO PRESS SENSOR : DOZER)
SW-13 :
TRAVEL ALARM SW.
CASE OF TRAVEL ALARM SW-37 :
SW-30 : CONNECT WITH NAME INDEPENDENT TRAVEL SW.
FOWARD NIBBLER CLOSE SW. (GREEN TAPING) TUBE OF "ALARM" CONNECT WITH NAME TUBE OF "TRAVEL"
SW-10 :
HORN SW. LEFT (BLUE TAPING)
SW-34 :
REVOLUTION LEFT SW.(OPT)(RED TAPING) TO SLACK HARNESS SW-12 :
OF LEVER SW. OVER ROAD ALARM SELECT SW.
SIDE, THIS POSITION. CONNECT WITH NAME TUBE OF "OVER L"
SW-40 :
ROTARY LIGHT SW.
SW-1 : SW-11 : CLIP CONNECT WITH NAME TUBE OF "ROTARY"
KEY SW. LEVER LOCK SW. FIX A HARNESS OF SW SIDE
FIX A HARNESS WITH CAB CLIP

SIDE COVER ON CLIP CLIP FIX HARNESS BY A CLIP ON HOLE
FIX HARNESS BY A CLIP OF STAND BOAD.
SE-16 : ON NOLE OF STAND BOAD. FIX WHITE TAPING POSITION
ACCEL POTENTIO FASTEN FLOOR HARNESS
AND LEVER SW. HARNESS
CLIP
CAB HARNESS IT BUNDLES AND FIX WHITE TAPING POSITION
FIX WITH TILTED LEVER. FIX THE HARNESS FOR THE PLATE
AS SHOWN IN FIGURE WITH CLIP.
THROUGH THE HARNESS AT SEAT
FIX WHITE TAPING CLIP SIDE OF BRACKET.
POSITION SW-33 : CLIP
REVOLUTION RIGHT SW.
(OPT)(BLUE TAPING)
FIX A HARNESS WITH CLIP
CLIP SW-5 :
CAB SIDE COVER ON CLIP FIX WHITE TAPING POSITION
FIX HARNESS BY A CLIP HORN SW. RIGHT
ON HOLE OF SEAT STAND
CLIP
CLIP (OPT)(BLUE TAPING) E-7 : TUNER FIX WHITE TAPING POSITION
FASTEN WHITE TAPING POSITION OF SW-29 : FIX HARNESS BY A CLIP ON HOLE
HARNESS WITH CLIP SIDE BY PILOT
E-32 :
NIBBLER OPEN SW. OF SEAT STAND
HOUSE PRESS SENSOR
(GREEN TAPING)
FIX WHITE TAPING POSITION DOZER
VIEW VIEW VIEW
2-81
C-1 :
MECHATORO CONTROLLER
E-1 :
FUSE & RELAY BOX
CAB SUB HARNESS CLIP
CONNECT TO ROTATION PARKING CANCEL SW.AND

CONNECTOR WITH NAME TUBE OF "PARKING"
CLIP
C-8 :
ENG.CONTROLLER
REFERENCE DRAWING OF ASSEMBLING
TO RIGHT
INST-PANEL E-1 :
FUSE & RELAY BOX
C-1 :
TO IT CONTROLLER HARNESS MECHATORO
CONTROLLER
TO LEFT
INST-PANEL
CLIP
TO FUSE & RELAY BOX
GROMMET
CONNECT THE "CNT-1" TAG
OF CONNECTOR WITH ECU
HARNESS
FIX TO THE UPPER

PART OF PLATE WITH CONNECT THE "CNT-2" TAG
CLIP. OF CONNECTOR WITH UPP
FOWARD HARNESS
DETAIL OF FUSE & RELAY BOX CONNECTION CONNECT THE "CNT-5" TAG
CONNECT CONNECTOR WITH "CN2-2" OF CONNECTOR WITH UPP
CONNECT CONNECTOR WITH "CN2-1" TAG OF ITEM 1:HARNESS HARNESS
TAG OF ITEM 1:HARNESS
TO LEFT INST-PANEL
ROTATION PARKING
CANCEL SW.
TO RIGHT
INST-PANEL.
CONNECT CONNECTOR
WITH "CN12" TAG OF ITEM
1:HARNESS
4
CAB SUB HARNESS
22P CONNECTOR 28P CONNECTOR 22P CONNECTOR
34P CONNECTOR 1
FLOOR HARNESS
CONNECT CONNECTOR WITH "CN2-3"
CONNECT CONNECTOR WITH "CN3-1" TAG OF ITEM 1:HARNESS
VIEW TAG OF ITEM 4:HARNESS
CONNECT CONNECTOR WITH "CN3-2"
TAG OF ITEM 4:HARNESS TO UNDER FLOOR
VIEW SECTION AA (STAND RIGHT SIDE A INSIDE)
2-82
E-1 : FIX A CORRUGATED TUBE NOT CONTACT

FUSE & RELAY BOX M-CONNECTOR LOCK OF CONNECTOR
SE-20 :
E-22 : SENSOR
PRESS SENSOR : P1 OPT FIX HARNESS PART
1 DC-DC CONVERTER
OF WHITE TAPING
CLIP WITH CLIP FIX WHITE TAPING POSITION
FOWARD CLIP
M-4 :
CONNECT TO DC-DC WASHER MOTOR
4 TIGHTENING TORQUE
CONVERTER. 10.7N.m (7.9lbf.ft)
TIGHTEN AFTER
CHECKING NO PAINT
TO LEFT INST-PANEL LOCK WASHER
ROTATION PARKING CONNECT THE "CNT-4" TAG OF ITEM 1: HARNESS
CANCEL SW.
WASHER
WITH THE "CNT-4" TAG OF CAB HARNESS P-31
NUT
CONNECT TO CAB HARNESS FIX WHITE
CONNECT WITH TAPING POSITION
FIX WHITE TAPING POSITION GROUND CABLE CLIP
OF UPPER FRAME
CLIP
P-31 CONNECT TO FRAME GROUND
TUNER ; E-7 3
SE-10 :
REVOLUTION RIGHT SW. ; SW-33
PRESS SENSOR :
HORN SW. (RH) ; SW-5 TRAVEL LEFT
NIBBLER OPEN SW. ; SW-29 SE-9 :
REVOLUTION LEFT SW. ; SW-34 PRESS SENSOR :
HORN SW. (LH) ; SW-10 TRAVEL RIGHT
WASHER MOTOR ; M-4
SE-11 :
NIBBLER OPEN SW. ; SW-30 PRESS SENSOR :
CONNECT TO ECU HARNESS P2 OPT
ENG. CONTOROLLER HARNESS SHIELD
CLIP 1 CLIP TO THE FRONT SIDE OF FLOOR PLATE
FIX A CORRUGATED TUBE NOT CONTACT

M-CONNECTOR LOCK OF CONNECTOR VIEW FROM THE BACK SIDE OF FLOOR PLATE.
ONLY SEPARATE SENSOR

SE-20 : SWING N&B SPEC.
PRESS SENSOR : P1 OPT USES THE CLIP OF ITEM 6 FIX HARNESS PART
SE-33 : OF WHITE TAPING FLOOR HARNESS
CLIP WITH CLIP FIX WHITE TAPING POSITION
PRESS SENSOR : SEPARATE CLIP
M-4 :
TIGHTENING TORQUE WASHER MOTOR CAB SUB HARNESS
10.7N.m (7.9lbf.ft)
TIGHTEN AFTER
CHECKING NO PAINT
LOCK WASHER
WASHER
P-31
NUT
FIX WHITE TAPING
CONNECT WITH POSITION
GROUND CABLE CLIP
OF UPPER FRAME
3
SE-10 :
PRESS SENSOR :
TRAVEL LEFT
SE-9 :
PRESS SENSOR :
TRAVEL RIGHT
SE-11 :
PRESS SENSOR : FIX WHITE TAPING CLIP
P2 OPT POSITION.
CLIP 1 CLIP TO THE FRONT SIDE OF FLOOR PLATE

TO FRONT
VIEW FROM THE BACK SIDE OF FLOOR PLATE. (CASE OF SEPARATE SWING N&B) SECTION BB (PART OF FIX A HARNESS ON SEAT STAND)
2-83
2.7.3 CAB HARNESS ASSY (OCE/S.E.ASIA) (SK125SR, SK135SR-2)
CAB HARNESS ASSY YB14E00018F1 (03)
ITEM PART NAME PART No. Q'TY REMARKS

1 HARNESS YB14E01027P1 1 CAB
5 HARNESS YN14E01106P1 1 KEY S/W GROUND
C-1 : E-1 :
MECHATRO CONTROLLER FUSE & RELAY BOX
CAB SUB HARNESS

SEMS BOLT
TIGHTENING TORQUE 4.4N.m (3.2 lbf.ft)
TIGHTEN AFTER CHECKING E-9 :
NO PAINT. SPEAKER RIGHT
THIGHTEN WITH THREE EYELET TERMINALS.
FIX WHITE TAPING
P-1,P-2 CAB HARNESS GROUND POSITION
CLIP
GAUGE CLUSTER CONNECT TO
CAB WORK LIGHT SW. UPPER HARNESS
AIR-CON UNIT CONNECT WITH CAB WORK LIGHT
CLIP
UPPER HARNESS (GND)
BOOM DECK WORK LIGHT SW. E-23 :
CAB WORK LIGHT FRONT 12V SOCKET CONNECT WITH ROOM LIGHT
WIPER INTERLOCK SW. E-14 : CAB HARNESS
HOUR METER CIGARETTE
WIPER MOTOR LIGHTER CONNECT WITH WIPER INTERLOCK SW.
FIX WHITE
CIGARETTE LIGHTER TAPING
12V POWER SOURCE SOCKET CLIP TO THE CUTTING HOLE
SKY ROOF WIPER (OPT) POSITION
SW-15 : ON THE DUCT
CONFLUX / SINGLE CHANGE SW. CLIP CLIP
CONFLUX / SINGLE FLOOR HARNESS
CAB WORK LIGHT
ROTARY LIGHT SELECT SW.
FIX WHITE TAPING
SW-55 : CONNECT TO
POSITION
BOOM , DECK WORKING CLIP CAB SUB HARNESS
5 LIGHT SW.
SW-1 :
KEY SW. E-8 : CONNECT "CNT-4" TAG TO
P-1 SPEAKER LEFT FLOOR HARNESS
1 P-2
C-2 : FLOOR HARNESS

GAUGE CLUSTER
CLIP
TO AIR
CLIP
CONDITIONER UNIT UPPER HARNESS
CLIP
DETAIL A
E-3 :
HOUR METER
SW-15 :
CONFLUX / SINGLE SELECT SW. SW-41 : SW-17 :
SW-55 : GREEN CONNECT WITH HIGH REACH CRANE SW. ROOF WIPER SW.
CONNECT WITH BOOM , DECK WORKING LIGHT SW. NAME TUBE OF "CONFLUX" BLACK CONNECT WITH NATURAL COLOR CONNECT WITH
M-3 : CAB WORK LIGHT BLUE CONNECT WITH NAME TUBE OF NAME TUBE OF NAME TUBE OF "WIPER"
WIPER MOTOR CLIP CAB SUB FRONT. "BOOM, DECK" "CRANE" TAGGED
FIX WHITE TAPING SW-26 :
CLIP TIE UP FLOOR HARNESS WITH TO AIR HARNESS TO ROOF WIPER
POSITION CAB WORK LIGHT SW.
CAB HARNESS USING CLIP CONDITIONER UNIT (OPT)
FIX WHITE TAPING NATURAL COLOR CONNECT WITH
E-14 :
POSITION NAME TUBE OF "CAB LIGHT"
CIGARETTE LIGHTER
CLIP E-14 :
FIX TO THE BRACKET CIGARETTE LIGHTER
WR B
(+) (-)
DETAIL B
DETAIL OF HOUR METER VIEW I
2-84
2.7.4 BOOM HARNESS ASSY (OCE/S.E.ASIA) (SK125SR, SK135SR-2) 2.7.5 BOOM LIGHT INSTALL (OCE SPEC.) (SK125SR, SK135SR-2)
BOOM HARNESS ASSY YY15E00009F1 (01) INSTALLING BOOM LIGHT YN80E00011F1 (04)
ITEM NAME PARTS No. Q'TY REMARKS ITEM NAME PARTS No. Q'TY REMARKS
1 HARNESS YY15E01021P1 1 BOOM 1 LIGHT YW80S00001F1 1
FIX WHITE
TAPING POSITION
1 CLIP
CLAMP TO THE
TUBE FOR GREASE
L-1 :
BOOM WORKING LIGHT LEFT
TO UPP HARNESS
1
2.7.4-1 BOOM HARNESS : YY15E01021P1
TIGHTENING TORQUE : 18.6N.m (13.7 lbf.ft)

SECTION AA

2-85
2.7.6 UPPER LIGHT INSTALL (OCE/S.E.ASIA) (SK125SR, SK135SR-2) 2.7.7 TRAVEL ALARM ASSY (SK125SR, SK135SR-2)
UPPER LIGHT INSTALL YY80E00008F1 (01) TRAVEL ALARM ASSY YY53E00002F1 (01)
ITEM PART NAME PART No. Q'TY REMARKS ITEM PART NAME PART No. Q'TY REMARKS
1 LIGHT YT80S00002F1 1 1 ALARM YN53S00004F1 1
3 SWITCH YN50S00040DF 1
5 RELAY YN24S00010P1 1
T=TIGHTENING TORQUE
1
SEMS-BOLT
T=23.5N.m
(17.3 lbf.ft)
1
E-13 :
UPP HARNESS TRAVEL ALARM
CLIP
FIX TO THE CONNECTOR
3 WITH CLIP REMAINING LENGTH
E-13 : OF THE ALARM SIDE HARNESS.
TRAVEL ALARM
CONNECT WITH NAME VIEW
NUT (SUPPLIED WITH LIGHT) TUBE OF "ALARM"
T=18.6 N.m (13.7 lbf.ft)
VIEW 4
TRAVEL ALARM RELAY
(HOW TO INSTALL LIGHT AT RIGHT SIDE DECK)
RIGHT CONSOLE BOX

(DETAIL OF TRAVEL ALARM SW. INSTAL) DETAIL OF FUSE & RELAY BOX
2-86
2.7.8 ENGINE HARNESS ASSY (OCE/S.E.ASIA) (SK125SR, SK135SR-2) 2.7.8.4 ENGINE SUB CABLE : YY16E01009P1
ENGINE HARNESS ASSY YY16E00005F1 (01) (12.2")

ITEM PART NAME PART No. Q'TY REMARKS TERMINAL TERMINAL
4 CABLE YY16E01009P1 1 ENGINE SUB
T=TIGHTENING TORQUE
AV60B
Corrugate tube to be installed
SEMS-BOLT
T=38.2 N.m
(28.2 lbf.ft)
BRACKET
SEMS-BOLT FORWARD
T=51.9 N.m
(38.3 lbf.ft)
2-87
2-88
2.8 AIR-CONDITIONER SYSTEM

2.8.1 PIPING (SK125SR, SK135SR-2)
2.8.1.1 AIR CONDITIONER
JAM NUT FOR

40 TENSION PULLEY
T=46.1 (33)
30
D
27
A
L
B
25
C
25 E
26
53
4
INITIAL BELT TENSION
When the belt is pushed by the
force of 23N, adjust the
deflection of L
l part
partto
tobe
be3mm.
3mm.
26
53
NOTE 66 58 69 61
1. Apply oil for refrigerant R134a to the 62
O-rings of all air-conditioner hose fittings.
33
16
2. Refrigerant volume : 800 50g
3. T : Tightening torque N.m(lbf.ft) 33
6
60 33
22 9
10
32
A B
Fig. 2-19 Air conditioner piping (1/2)
2-89
53
12
8 26
8 65 13
25
63 2
1 1
2 5
54 X
5
53 51
52 50
55 5 64 53
8 67
24
53
X
15
39
C D
3
23
35
8 59
23
17
25
14
19
68
34
56
57
E
Fig. 2-20 Air conditioner piping (2/2)
2-90
Air conditioner YY20M000017F1 (04)
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
1 Hose : L = 2700 1 46.1 (33.0) 33 Pulley assy 1
2 Hose : L = 2800 1 34 Condenser 1
3 Bracket 1 35 Air dryer assy 1
4 V-belt 1 39 Filter 1
3.92~4.9 (2.9~3.6) 5 Clip 4 40 Solar radiation sensor 1
6 Sems bolt : M10×25 4 50 Connector 1
7 Sems bolt : M6×20 2 51 Connector 1
8 Sems bolt : M8×20 7 52 Clip 1
9 Capscrew : M8×100 4 46.1 (34.0) 53 Sems bolt : M10×20 5
10 Washer 4 54 Grommet 1
12 Tube for heater : L = 2400 1 55 Grommet 1
13 Tube for heater : L = 2400 1 4.4 (3.2) 56 Capscrew : M6×50 4
14 Tube for D hose : L = 2600 1 57 Washer 4
15 Tube for S hose : L = 2950 1 59 Bracket 1
16 Bracket 1 60 Pulley 1
17 Tube for L hose : L = 900 1 46.1 (34.0) 61 Capscrew : M10×25 1
19 Tube for L hose : L = 300 1 62 Washer 1
46.1 (34.0) 22 Sems bolt : M10×45 4 63 Support 1
23.5 (17.3) 23 Sems bolt : M8×25 6 64 Insulation 1
24 Clip 1 46.1 (34.0) 65 Sems bolt : M10×30 1
25 Clip 10 66 Nut 2
26 Clip 3 67 Bracket 1
27 Air conditioner assy 1 68 Bracket 1
30 Panel 1 70 Clip 1
32 Compressor assy 1
UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT

UNIT CONNECTION BOLT S TUBE
AIR CONDITIONER ASSY S D HOSE
COMPRESSOR ASSY
RECEIVER CONNECTION BOLT

S HOSE
L TUBE
L HOSE
L HOSE CONDENSER
RECEIVER DRYER RECEIVER DRYER MOUNTING BRACKET
2-91
2.8.1.2 AIR DRYER ASSY
B
A
C
8 5
A
4 6 5
10 6
4 11
3
8
2
1 7
B C
Fig. 2-21
Air dryer assy YY96V00009F1 (01)

1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
20~25 3 Capscrew 2 9 S tube 1
(14.8~18.4)
8~12 (5.9~8.9) 4 Capscrew 2 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1
2-92
3-1
3-2
3.1 ADJUSTMENT OF MECHATRO CONTROLLER

3.1.1 ENGINE CONTROL INPUT / OUTPUT
INJECTOR
C-8:
ENGINE CONTROLLER
E-1:
C-2: FUSE&RELAY (ECU)
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
Fig. 3-1 INPUT / OUTPUT
3.1.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT)
3.1.2.1 PURPOSE OF THE ADJUSTMENT

There are 2 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function
to ensure performance of machine.
(1) Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with
engine rated output.
(2) Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of unloading valve to improve the operability further.
3.1.2.2 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;

When the following parts are replaced or repaired, carry out the adjustment without fail.
(1) Mechatro controller
(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve
3-3
3.1.2.3 PREPARATION
(1) Raise the oil temperature to about 50°C (122°F) to warm up the engine.
(2) Turn the air-conditioner 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, A035
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.
3-4
3.1.2.4 ADJUSTING PROCEDURE
MULTI DISPLAY
BUZZER STOP SWITCH WORK MODE SELECT SWITCH
WASHER SWITCH
WIPER SWITCH
SELECT SWITCH
Fig. 3-2 Gauge cluster

(1) Adjustment of pump ("B" adjustment)
Procedure
1) Turn starter key switch ON keeping the work mode selector switch on the

gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If
the engine is started, the following indication is not displayed. Therefore do not
start the engine.)

2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release
it and the screen for selecting adjustment is displayed. When adjustment data
ADJUST
READY
is not entered in mechatro controller, "READY" is indicated. If the adjustment FEED
operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Press selector switch on gauge cluster to display "START ENG".

"Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration

command voltage) are indicated.

4) The adjustment automatically shifts from engine starting to pump, the speed

shifts from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed.

And the unloading proportional valve and pump proportional valve actuate,

accordingly the loading of pump is increased.

The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value) are indicated.
5) After detection of the engine rated speed, the adjustment of pump is
FINISH PUMP
automatically completed. And "FINISH PUMP" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared PUMP PRESSURE
C-1 35.0M C-2 35.0M
and the adjustment is completed. The unloading adjustment required later is PROPO-VALVE
E-1 300mA E-2 300mA
not performed, and default value is written.)
3-5
(2) Adjustment of unloading valve ("C" adjustment)

Procedure
1) The adjustment shifts from pump to unloading, and the unloading valve
MEMORY UNLOAD
actuates, accordingly the pump pressure is detected. And "MEMORY ENGINE SPEED
2000rpm
UNLOAD" is displayed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PROPO- PROPO-VALVE
D-1 300mA D-2 300mA
VALVE" voltage (command value) are indicated.
2) When the unloading valve operates to the specified value, the adjustment of

unloading proportional valve is automatically terminated. And "FINISH

UNLOAD" is displayed.

The speed is shifted to the speed corresponding to acceleration potentiometer.

The adjusting current value is indicated on the display of current of P1, P2

unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.)
(3) Corrective actions taken when the adjustment can not be performed;
1) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
P1 and P2 average pump pressure at the time when the adjustment is E-1 300mA E-2 300mA
completed is 25MPa or less.
Judging condition 2:
The adjustment does not complete although the pump proportional valve
current reaches to the specified value.
The P1 and P2 pump pressures usually increase to 33~38MPa.

When the pressure does not increase;
a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
• Check that the pump proportional valve operates normally.
• Check that the pump regulator operates normally.
And so on.
3-6
2) In cases where unloading valve can not be performed; And "ERROR

ERROR UNLOAD
UNLOAD" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
The pump pressure does not increase up to the pressure in the range of the D-1 300mA D-2 300mA
specified adjustment. Or the increased pressure is held as it is.
Judging condition 2:
Pressure sensor of either P1 pump or P2 pump is failed.
Normally the pump pressures of P1 and p2 pumps gradually increase to

10~25MPa.
(It may be affected by operating oil temperature.)
When the pump pressure does not increase;

a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
(4) Other precautions:
1) In the event of a failure, there is case where the adjustment may not be
performed normally.
First serve the machine, and perform the adjustment work.
2) In the condition where large load is constantly applied to engine, the
adjustment could not be performed normally.
3-7
(5) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are
replaced, perform the adjustment of unloading valve only.
Procedure
1) Turn starter switch ON keeping the work mode selector switch on the gauge

cluster pressed, and hold it for 5~10 seconds, and then release it.
(If the engine is started, the following indication is not displayed. Therefore do
not start the engine.)

2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release
it and the screen for selection of adjustment type is displayed. And "ADJUST"
ADJUST
READY
is displayed. FEED
When adjustment data is not entered in mechatro controller, "READY" is
indicated. If the adjustment operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Change the adjusting items with washer switch ( ) and wiper switch ( ), and

select "ADJUST UNLOAD". (See Fig. 3-2)
Like the output adjustment, when adjustment data is not entered in mechatro
controller, "READY" is indicated. If the adjustment operation is once
performed, "FIN" is indicated.
4) Press selector switch on gauge cluster to display "START ENG".

"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration

command voltage) are indicated.

5) After starting engine, press selector switch on gauge cluster and "MEMORY
MEMORY UNLOAD
UNLOAD" is indicated, the engine speed is automatically increased and the ENGINE SPEED
2000rpm
adjustment of unloading valve is performed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" PROPO-VALVE
D-1 300mA D-2 300mA
(acceleration command current) are indicated.
6) When the unloading proportional valve operates to the specified value, the

adjustment of unloading proportional valve automatically completes. "FINISH

UNLOAD" is indicated.

The speed is shifted to the speed corresponding to acceleration potentiometer.

The value of adjusting current is indicated on the display of current of P1 and

P2 unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.)
3-8
3.2 SUMMARY OF MULTI DISPLAY

Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
(1) Controls
GAUGE
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
STARTER SWITCH
ACCEL DIAL
KPSS WORK MODE

RELEASE SWITCH
SWING PARKING
BRAKE RELEASE
SWITCH
ENGINE
FUSE & ECU
MECHATRO RELAY BOX
CONTROLLER
A DETAIL A
(2) Gauge cluster
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)
3-9
(3) KPSS work mode switch

Press the work mode selector switch ( ) in order, and "H" → "B" → "A" → "S" mode can be selected.
Select the effective work mode according to the work condition and working target from the table shown below.
For the selected work mode, refer to the table shown below.
• S mode: For standard excavating work

• H mode: For heavy duty excavating work
• B mode: For works with breaker
• A mode: For demolition works with crusher
(Nibbler)
10:25
S
• The initial setting (default) of work mode had been set
to "S" mode at factory.
As for the work mode after the engine starts, the
mode that was used the last time engine was stopped
is automatically set.
Check that the selected mode conforms to the work
before starting work.
• Check that the attachment in use conforms to the
work mode before starting work. If not conformed,
select proper mode with the work mode select switch.
• The operation under improper work mode may cause
damage to machine.
Work mode Display Contents
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.
3-10
1) Pump flow rate adjustment (A mode /B mode)

No. Switches 1 2 3 4
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 3-3
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 "Q" L/min. The adjustment (increase
or decrease) of flow rate is changeable by 10 L/min step.
Main screen Attachment mode (A mode)
10:25 Flow
rate Q L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
In Breaker mode (B mode)
Flow Flow Flow

rate Q L/m rate 100 L/m rate 100 L/m
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
Note : Initial flow rate on, the double flow rate is displayed.
Flow Flow
rate Q L/m rate Q L/m Model Q (L / min)
SK125SR 130
A B SK135SR-2 130
(b) (c)
1. Turn starter key switch on and display main screen (a).

2. The display on the left lower corner of screen is changed in order of "S" → "H" → "B" → "A" each time the
"MODE" switch (3) is pressed under the condition where main screen (a) is displayed.
3. Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed.
4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and
the screen (d) is displayed. In this condition, press FEED (4)/ (5) and the flow rate value increases or
decreases.
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.
3-11
(4) MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the end of recommended replacement/change interval specified for
filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil
5,000 Hr
(OCE)
Hydraulic oil
2,000 Hr
(S.E ASIA)
This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.
1. Remaining time display to the engine oil change

This display shows the remaining time to the coming engine oil change. 492Hr
ENG OIL
H
2. Remaining time display to the coming fuel filter replacement

This display shows the remaining time to the coming engine fuel filter 492Hr
replacement. FUEL FILTER
H
3. Remaining time display to the coming hydraulic oil filter replacement

This display shows the remaining time to the coming hydraulic oil filter 992Hr
replacement. HYD. FILTER
H
4. Remaining time display to the coming hydraulic oil change

This display shows the remaining time to the coming hydraulic oil 4992Hr
change. HYD. OIL
H
• 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 3.7 SET PROCEDURE OF MAINTENANCE SCHEDULE.
• The display of the alarm appears when the remaining time until replacement becomes 0 hours.
3-12
(5) Gauge cluster display

After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The
display functions of multi display are explained below.
CLOCK DISPLAY
SELF DIAGNOSIS / WARNING
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.
. Warning These descriptions indicate error codes.
SELCTOR VALVE HIGH ENG

FAILURE
W009
WATER TEMP.
W006 LOW FUEL LEVEL
AUTO IDLE STOP DRAIN WATER SEPA W010 WARM AUTO WARMING UP
(OCEANIA ONLY)
WARM FINISH WARM-UP CLOGGED AIR FLTR W008 CHANGE ENG OIL
DATA HYDRAULIC SYSTEM

CPU COMMUNICATION ENGINE STOP CPU BACK UP MODE
ERROR
SWING BRAKE
W001 CHARGE ERROR
DISENGAGED
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
3-13
3.3 SELF DIAGNOSIS DISPLAY

(1) Outline
This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine
operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector
No. and pin No., refer to the section "C-1 Mechatro controller" explained later. Electric circuit diagram or harness
is available to identify wire No. and wire color.
(2) I/O configuration
CONTROL
Pressure sensor, Engine controller SERIAL COMMUNICATION
INPUT Proportional valve, Battery relay
Gauge cluster
Selector valve (SOL) (Buzzer sound)
(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with
the aid of error code.
Alphabet: Decide system failure occurred.
10:25 B 01 3 Last 2nd and 3rd digits: Specifies failed section.
B013
Last 1 digit: Specifies failure type.
This failure symbol is displayed simultaneously with error code during failure diagnosis.
ERROR CODE
A B C D E F G H I K P R
Last 2,3 Controller Low pressure High pressure Proportional Proportional Solenoid Speed sensor Potentiometer Communication Battery relay Engine ECU Relay output
digits memory sensor sensor valve for valves valve for pumps valve etc
Boom up P1 pump P1 unload P1 pump Acceleration Battery relay Wiper ark
01 prevention relay
Torque Boom down P2 pump P2 unload P2 pump Swing parking Boom angle Wiper ark forward
02 adjust data rotation relay
Unload Arm out Boom head Travel straight Travel 1,2 Angle sensor Arm angle Wiper ark reverse
03 adjust data speed for shovel rotation relay
Boom up Arm in Option Angle sensors for Washer motor
04 adjust data selector shovel & ECU
Arm in Bucket Bucket stroke
05 adjust data digging limit
Arm out Bucket Arm 2 spool
06 adjust data dump for arm in
Swing
07
Engine coolant
08 temp. sensor
Travel right Fuel sensor
09
Refer to next page (Engine)
Travel left
10
Selector position CAN
11 detection communication
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
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)
Larger than Larger than

0 normal range normal range
Transistor OFF CAN error
failure / Grounding
1 - short circuit
Wrong output Wrong output Transistor Transistor Over run
2 - ON failure ON failure
Disconnection Disconnection Disconnection Disconnection Transistor ON Disconnection Disconnection Time is over
failure /
3 - Disconnection
Power source Power source Power source Contact point is Power source
4 - short circuit short circuit short circuit melted and adhered short circuit
Wrong value
5
3-14
ECU failure code list

Failure Code Malfunctioned component Content of Failure [Class]/Limitation of output when failure occurs
20081 ADC monitoring ECU failure [1]
20082 Dfp_ADCMon A/D converter is abnormal in ECU. Engine is shut down
20084
20088
00291 Accelerator sensor 1 Analog signal input is defective. [5]
00292 SRC Defective analog input signal from controller is detected. -
Dfp_APP1
03838 Accelerator sensor Accelerator signal mutual comparison is defective. [5]
mutual diagnosis When there is deflection of 20% or more between CAN signal and analog signal, sensor detects it. -
Dfp_APPSync
01081 Atmospheric pressure sensor Atmospheric pressure sensor fails [4]
01082 Dfp_APSCD Defective operation of atmospheric pressure sensor in ECU (Disconnection, short circuit and characteristic defect) is detected. Engine power down
01021 Boost pressure sensor Boost pressure sensor failure [4]
01022 Dfp_BPSCD Defective operation of boost pressure sensor attached to engine (Disconnection, short circuit and characteristic defect) is detected. Engine power down
01101 Coolant temperature sensor Coolant temperature sensor failure [5]
01102 Dfp_CTSCD Defective operation of coolant temperature sensor attached to engine (Disconnection, short circuit and characteristic defect) is detected. Engine power down
05181 Q tune resistance Q tune resistance failure [8]
05182 SRCDfp_EngCD_TrqAdj Input failure of Q tune resistance is detected. -
06351 Cam single operation warning Crank sensor failure [3]
Dfp_EngMBackUp It is detected that crank sensor fails and engine is operated with the cam sensor. Engine power down
06361 Cam sensor Cam sensor failure [5]
06362 Dfp_EngMCaS1 Failure of cam sensor (Disconnection, short circuit, and damaged tooth) is detected. -
06371 Crank sensor Crank sensor failure [3]
06372 Dfp_EngMCrS1 Failure of crank sensor (Disconnection, short circuit, and damaged tooth) is detected. Engine power down
02281 Misalignment between cam and crank Misalignment between cam and crank [3]
Dfp_EngMOfsCaSCrS Misalignment between cam and crank is detected. Engine power down
00914 CAN accelerator CAN communication failure [7]
Dfp_FrmMngCANAPP It is detected that accelerator opening (APPREQ) received with CAN is defective. -
16744 APPREQ message time-out CAN communication failure [7]

Dfp_FrmMngTOAPPREQ Accelerator opening (APPREQ) signal is received by CAN. But it detects that the CAN -
cannot receive the signal.
20284 CAN transmission time-out CAN communication failure [7]
Dfp_FrmMngTxTO The transmission of CAN message is defective. -
06771 Glow relay power stage Glow relay failure [5]
06772 Dfp_GlwCD_Actr Failure of glow relay or wiring harness is detected. -
06774
06778
12311 SPI communication error ECU failure [1]
Dfp_HWEMonCom SPI (Serial peripheral interface): Serial communication malfunction between CPU and each internal IC occurs. Engine is shut down
12352 EEPROM ECU failure [5]
12354 Dfp_HWEMonEEPROM Defective reading and writing to EEPROM are detected. -
12358
16688 Recovery occurrence ECU failure [5]
Dfp_HWEMonRcyLocked Recovery (partial reset) occurred by ECU internal malfunction. -
16698 Recovery generation ECU failure [5]
Dfp_HWEMonRcySuppressed Recovery (partial reset) occurred by ECU internal malfunction. -
16708 Recovery generation ECU failure [5]
Dfp_HWEMonRcyVisible Recovery (partial reset) occurred by ECU internal malfunction. -
15421 CJ940 excessive voltage ECU failure [1]
Dfp_HWEMonUMaxSupply The supply voltage is excessive for power stage control IC. Engine is shut down
15432 CJ940 voltage is too low ECU failure [1]
Dfp_HWEMonUMinSupply The supply voltage is too low for power stage control IC. Engine is shut down
6511 Injector drive bank 1 Injector failure (ECU internal circuit) [1]
6512 Dfp_InjVlvBnk1A The injector drive circuit detected short circuit. Engine is shut down
6518
Dfp_InjVlvBnk1B The injector drive circuit detected disconnection. Engine is shut down
6532 Dfp_InjVlvBnk2A The injector drive circuit detected short circuit. Engine is shut down
6538
Dfp_InjVlvBnk2B The injector drive circuit detected disconnection. Engine is shut down
6551 Injector drive IC ECU failure [1]
6552 Dfp_InjVlvChipA IC which controls injector is malfunctioned. Engine is shut down
6554
6558
6561 Injector drive IC ECU failure [1]
6562 Dfp_InjVlvChipB IC which controls injector is malfunctioned. Engine is shut down
6564
6568
6571 Injector #1 Injector failure [1]
6574 Dfp_InjVlvCyl1A Short circuit is detected in injector or harness. Engine is shut down
6578
Dfp_InjVlvCyl1B Disconnection is detected in injector or harness. -
6598
Note) For detail of engine error code refer to shop manual "Section 51 ENGINE CHAPTER"
3-15
Failure Code Malfunctioned component Content of Failure [Class]/Limitation of output when failure occurs
6618

6638
20004 MPROP power stage MPROP failure [2]
20008 Disconnection and excessive load Disconnection or short circuit of MPROP or harness. Engine power down
Dfp_MeUnCDNoLoad
VB short Battery short circuit of MPROP or harness Engine power down
Dfp_MeUnCDSCBat
GND short circuit GND short circuit of MPROP or harness Engine power down
Dfp_MeUnCDSCGnd
14848 Supervision ECU failure [1]
Dfp_Montr Malfunction judgment by self-diagnosis function in ECU. Engine is shut down
16711 CAN A Pass off CAN communication failure [7]
Dfp_NetMngCANAOff Disconnection and short circuit of CAN communication line -
16731 CAN C Pass off CAN communication failure [7]
Dfp_NetMngCANCOff Disconnection and short circuit of CAN communication line -
198 Oil pressure switch Oil pressure switch failure [8]
Dfp_OPSCDPlaus1 Engine speed is high but sensor is OFF status. LOW IDLE
1008 Oil pressure switch Oil pressure switch failure [1]
Dfp_OPSCDPlaus2 Engine speed is high but sensor is OFF status. Engine is shut down
20051 Engine speed ECU failure [5]
Dfp_OvRMonSigA Recognized engine speed is defective. -
20411 DBV valve opening DBV valve opening [2]
Dfp_PRVMonMax It is recognized that DBV opened. Engine power down
20422 DBV kick off DBV valve is opened forcibly. [2]
Dfp_PRVMonMin Open valve forcible command is ordered for entering into Limp-home mode. Engine power down
20434 DBV valve is seized in closed position DBV valve is seized in closed position [1]
Dfp_PRVMonSig If you try to open valve forcibly, valve doesn't open. Engine is shut down
20441 Holding pressure of DBV Holding pressure of DBV is abnormal [1]
2-step is too high Holding pressure of DBV 2-step is higher than standard level. Engine is shut down
Dfp_PRVPresHi
20452 Holding pressure of DBV Holding pressure of DBV is abnormal [1]
2-step is too low Holding pressure of DBV 2-step is lower than standard level. Engine is shut down
Dfp_PRVPresLo
281 PTO accelerator sensor PTO failure for backup [2]
282 Dfp_PTOCD_APP Disconnection and short circuit of PTO or harness are detected. Engine power down
20111 Rail pressure sensor SRC Rail pressure sensor failure [2]
20112 Dfp_RailCD Disconnection and short circuit of rail pressure sensor or harness are detected. Engine power down
20121 Rail pressure sensor offset Rail pressure sensor failure [2]
20122 monitoring Zero-adjustment failure of rail pressure sensor. Engine power down
Dfp_RailCDOfsTst
20131 Rail pressure governor has deviation Rail pressure control failure [4]
(Nonattainment of target value) Rail pressure doesn't achieve target value. Engine power down
Dfp_RailMeUn0
(Nonattainment of target value & Despite fully pressurized feed of pump, rail pressure doesn't achieve target value. Engine is shut down
Fully pressurized feed of pump)
Dfp_RailMeUn1
(Pressure exceeds target value Despite fully closed pump, rail pressure is higher than target value. Engine power down
& Pump doesn't inject)
Dfp_RailMeUn2
20161 Rail pressure governor Rail pressure control failure [1]
(Real pressure is too low) Rail pressure is lower than standard value. Engine is shut down
Dfp_RailMeUn3
20171 Rail pressure governor Rail pressure control failure [2]
(Real pressure is too high) Rail pressure is higher than standard value. Engine power down
Dfp_RailMeUn4
11102 Shut-off pass test ECU failure [5]
11104 Dfp_SOPTst Emergency injection stop circuit doesn't operate. -
11108
10791 Sensor supply voltage monitor1 ECU failure [5]
10792 Dfp_SSpMon1 Failure of 5V power line which supplies power to sensor. -
10801 Sensor supply voltage monitor 2 ECU failure [5]
6201 Sensor supply voltage monitor 3 ECU failure [5]
20098 TPU monitoring ECU failure [1]
Dfp_TPUMon Failure of TPU in ECU Failure of Engine is shut down
Arithmetic circuit of rotational pulse
20108 SPIDfp_WdCom ECU failure [1]
Judgment of malfunction by self-diagnosis for ECU Error of watch dog Engine is shut down
Note) For detail of engine error code refer to shop manual "Section 51 ENGINE CHAPTER"
3-16
3.4 SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This
section explains the operating procedure and examples of each screen. The values in display changes according to
the conditions like engine speed, attachment position, etc.
(1) Service diagnosis display screen operating procedure
1) Turn starter switch ON keeping buzzer stop switch pressed.

2) After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.
• Mode No.1 : Screen No.1~No.30
• Mode No.2 : Screen No.1, Screen No.31~No.40
• Mode No.3 : Screen No.1, Screen No.41~No.50
3) The screen changes each time each switch is pressed from now on.
Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...)
Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1.
(No.1→No.2→No.3→No.1→...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to
No.3. (No.3→No.2→No.1→No.3→...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.
3-17
(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low
speed and lever to neutral position.)
1) Service diagnosis mode No.1
No. Displays Contents No. Displays Contents
1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YN22E00001F1 P/No. indication K-1 AIS RELAY 2 OFF Indicated value
PROGRAM VERSION K-2 SAFETY RLY OFF Indicated value
1-VER 11.11 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 00.00 MERIT controller program version KEY SWITCH OFF Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER OFF Indicated value
SWITCH OFF Switch
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)
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.
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
3-18
7 NO.7 P.SENSOR PROPO-V 16

NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11 Option selector detect
0.5V 0.3M Sensor voltage / Pressure converted value 0.3V 0.0M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
C-3 BOOM-HEAD (Over load alarm) B-13
C-4 BOOM-ROD
B-14
0.0V 0.0M
PROPO-VALVE Sensor voltage / Pressure converted value 0.0V 0.0M Sensor voltage / Pressure converted value
E-3 OPT RELIEF 1 B-15
COMP. 0mA 0.0M Set value in computer / Converted value from pressure 0.0V 0.0M Sensor voltage / Pressure converted value
MEAS. 0mA 0.0M Measured value / Converted value from pressure B-20
E-4 OPT RELIEF 2 0.0V 0.0M Sensor voltage / Pressure converted value
COMP. 0mA 0.0M Set value in computer / Converted value from pressure
MEAS. 0mA 0.0M 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. 750mA 3.0M Set value in computer / Converted value from pressure DI2 ON ON/OFF indication
MEAS. 750mA 3.0M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 750mA 3.0M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
controller
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
DI13 OFF ON/OFF indication
9 19 NO.19 DIGITAL INPUT
NO.9 PROPO-VALVE
E-1 P1 PUMP DI15 OFF ON/OFF indication
COMP. 417mA 1.0M Set value in computer / Converted value from pressure DI16 ON ON/OFF indication
MEAS. 417mA 1.0M Measured value / Converted value from pressure DI17 ON ON/OFF indication
POWER SHIFT 0mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 20L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 ON ON/OFF indication
POWER SHIFT 0mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 20L Flow rate of pump P2 DI24 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
0.7V 97% Fuel level DI30 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI31 OFF ON/OFF indication
0.0V 0 Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW - Glow switch DI33 ON ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 OFF ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 OFF ON/OFF indication
ENG OIL FILTER - Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 OFF ON/OFF indication
DOUBLE FLOW OFF Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI39 OFF ON/OFF indication
HEATER - Command from air heater DI40 OFF ON/OFF indication
ENG OIL LEVEL OK Engine oil level DI41 OFF ON/OFF indication
COOLANT LEVEL - 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 - Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. - Set value in computer MEAS. OFF Measured value
MEAS. - Measured value DO5 COMP. OFF Set value in computer
F-6 MEAS. OFF Measured value
COMP. - Set value in computer DO6 COMP. OFF Set value in computer
MEAS. - Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
12 22
NO.12 POTENTIO. NO.22 DIGITAL OUTPUT
H-2 BOOM DO8 COMP. ON Set value in computer
2.5V 90 Sent value from sensor / Converted value from angle MEAS. ON Measured value
H-3 ARM DO9 COMP. OFF Set value in computer
2.5V 90 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
3-19

23 27
NO.23 DIGITAL OUTPUT NO.27 MERIT SYSTEM
MEAS. OFF Measured value COMMUNICATION OFF Status of communication in MERIT controller
DO16 COMP. ON Set value in computer 0
MEAS. ON Measured value
DO18 COMP. ON Set value in computer 000000000
DO21 COMP. ON Set value in computer
24 28
NO.24 DIGITAL OUTPUT NO.28 ENG CONT.
DO22 COMP. OFF Set value in computer TRANS.COUNT. 0 Counted number of transmission error
MEAS. OFF Measured value RECEIVE COUNT. 0 Counted number of reception error
DO23 COMP. OFF Set value in computer DIAG STATUS 0 Diagnosis status
MEAS. OFF Measured value NUMBER OF DIAG 0 Numbers of error
DO24 COMP. OFF Set value in computer BOOST PRESS. 0 Boost pressure
MEAS. OFF Measured value BOOST TEMP. 0 Boost temperature
DO25 COMP. OFF Set value in computer BAROMETRIC P. 0 Atmospheric pressure
MEAS. OFF Measured value FUEL TEMP. 0 Fuel temperature
DO26 COMP. OFF Set value in computer FUEL CONS. 0 Fuel consumption
MEAS. OFF Measured value INTAKE TEMP. 0 Intake air temperature
DO27 COMP. OFF Set value in computer ENG PRESS. 0 Engine oil pressure
MEAS. OFF Measured value GLOW - Glow output from ECU
DO28 COMP. OFF Set value in computer ENG STOP - Engine stop command from ECU
MEAS. OFF Measured value TORQUE 500 Calculated torque of ECU
25
NO.25 WIPER SYSTEM
WIPER SW OFF Wiper switch
RISEUP SW OFF Wiper rise-up switch
REVERSE SW OFF Wiper reverse rotation switch
PREVENT ARC OFF Wiper motor ark prevention
CW MOTOR RLY OFF relay
CCW MOTOR RLY OFF Wiper normal rotation relay
WASHER SW OFF Wiper reverse rotation relay
MOTOR RELAY OFF Washer switch
Washer motor relay

1 33
NO.1 NO.33 BUCKET
MAIN CONT. P/N C-1 P1-PRES 0.3M Pump pressure sensor
YY22E00100F1 P/No. indication C-2 P2-PRES 0.3M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 417mA Command current
1-VER 12.34 Program version indication E-2 P2-PSV 417mA Command current
2-VER 11.11 MERIT controller program version D-1 P1-UL(BPC) 750mA Command current
D-2 P2-UL(BPC) 750mA Command current
SERVICE DIAG 2 Service diagnosis mode D-3 S-TRAVEL 350mA Command current
B-5 BUCKET DIG 0.0M Bucket digging pressure sensor
B-6 BUCKET DUMP 0.0M Bucket dump pressure sensor
G-3 ENG SPEED 1000 Engine actual speed
POWER SHIFT 0mA Power shift current
31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 0.3M Pump pressure sensor C-1 P1-PRES 0.3M Pump pressure sensor
E-1 P1-PSV 417mA Command current E-1 P1-PSV 417mA Command current
D-1 P1-UL(BPC) 750mA Command current D-1 P1-UL(BPC) 750mA Command current
B-1 BOOM RAISE 0.0M Boom up pressure sensor D-3 S-TRAVEL 350mA Command current
B-2 BOOM LOWER 0.0M Boom down pressure sensor B-9 TRAVEL(R) 0.0M Travel right pressure sensor
G-3 ENG SPEED 1000 Engine actual speed B-10 TRAVEL(L) 0.0M Travel left pressure sensor
POWER SHIFT 0mA Power shift current Pi-P1 0.0M Pilot pressure at travel straight (P1 side)
Pi-P2 0.0M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
D-3 S-TRAVEL 350mA Command current D-3 S-TRAVEL 350mA Command current
D-6 ARM-IN-2 750mA Command current E-3 OPT RELIEF 0mA Command current
B-3 ARM OUT 0.0M Arm out pressure sensor B-16 P1 OPT 0.0M P1 side option pressure sensor
B-4 ARM IN 0.0M Arm in pressure sensor B-17 P2 OPT 0.0M P2 side option pressure sensor
B-1 BOOM RAISE 0.0M Boom up pressure sensor F-4 OPT SELECT - Optional selector SOL (Nibbler line)
B-7 SWING 0.0M Swing pressure sensor DOUBLE FLOW SW OFF Conflux/ Single selector switch
G-3 ENG SPEED 1000 Engine actual speed G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0mA Power shift current POWER SHIFT 0mA Power shift current
3-20

1 43
NO.1 NO.43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YN22E00001F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 11.11 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 00.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time
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
3-21
(3) Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these data
to decide normal/abnormal status.
• The values in following display are reference values with standard attachment attached machine.
• The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
• The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
• The current value of pump proportional valve is reference value because it varies according to pump
pressure and adjusted torque value.
• The value in display during operation shows the value in steady state, rather than, at start of operation.
• Check on machine after sufficiently warming up machine.
• The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation Operation No.2 : No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 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 1970~2030 G-3 ENG SPEED 1870~1930
POWER SHIFT 0 mA POWER SHIFT 0 mA
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
No.31 BOOM No.31 BOOM

C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 450~550 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
3-22
Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 549 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~16.5 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~16.5 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 550~700 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 550~750 mA
3-23
Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~18.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~18.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 606~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 606~750 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 8.0~13.0 M
E-2 P2-PSV 500~610 mA E-2 P2-PSV 642 mA
3-24

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 750 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 650 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
3-25

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 480~590 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 480~590 mA E-2 P2-PSV 665~750 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
* Conflux switch is ON. Relief set pressure is value of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
3-26
3.5 TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one
of history. And the errors are able to be indicated on the multi display.
The warning content is record partially in "Travel history screen".
The error code for self diagnosis is stored.
(1) How to display

1) Turn starter switch on.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR
Error detected in the past
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)
• Press washer switch ( ), and the item moves upward.
• Press wiper switch ( ), and the item moves downward.

5) Turn starter switch off, and the display is disappeared.
(2) How to delete contents of trouble history

1) Display trouble history screen.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3) When "NO ERROR" is displayed, the deletion is completed.
4) Turn starter switch off.
All the stored items are erased. It is impossible to erase data partially.
3-27
3.6 TROUBLE DIAGNOSIS MODE

The recent control system includes many electrical systems and it makes troubleshooting very difficult.
The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be
detected through the use of self diagnosis function (the failure can be specified through the use of error code) like
disconnection and abnormal output. This is useful to save the time for troubleshooting.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are automatically
actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition
or failed condition of the system.
For details of how to use, refer to the next page "3.6.1 TROUBLE DIAGNOSIS MODE".
3-28
3.6.1 TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be
detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are automatically
actuated, the sensor detects the machine condition and the mechatro controller identifies the normal
condition or failed condition of the system.
(2) How to use and flow chart
The operation is performed through gauge cluster.
No.1 Select service adjustment select screen.
(Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing
buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.
No.1 No.2 No.3

SELECT SWITCH
LANGUAGE/LOGO 8 FAULT DIAG MODE DIAG MODE 1
BUZZER STOP SWITCH
ADJUSTING MODE 1 DIAG MODE 2
PRESET BY FACTORY
FEED SCREEN CHANGE SWITCH
CASE OF DIAG MODE 1
SENSOR CHECK START ENG LOWER BOOM DIAG MODE 1

ENGINE SPEED
RELEASE LOCK In diagnosis
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND LEVER START operation
PROPO-VALVE About 15 minutes
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
For the diagnosing items, see Table 48-1.

When required to stop in diagnosis
Turn engine on operation, press the buzzer stop switch
manually. BACK TO No.3 and the operation is forcedly stopped.
The data at the time of judgment

can be confirmed with the select
RESULT OF DIAGNOSIS RESULT OF DETAIL switch.
When
DIAG MODE 1 not failed, DIAG MODE 1 1 P1 UNLOAD
ENGINE SPEED
0000 rpm
END ENGINE STOP OK O K PRESSURE
C-1 00.0M C-2 00.0M
PROPO-VALVE
E-1 005mA E-2 005mA
DATA END FEED D-1 300mA D-2 300mA
The other judgments can be

Engine stops confirmed with the feed button.
automatically. RESULT OF DIAGNOSIS
When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG 0000 rpm
P1 UN-LOAD SPOOL NG NG PRESSURE

C-1 00.0M C-2 00.0M
PROPO-VALVE
DATA END FEED DATA END FEED E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
The suspected trouble sections are displayed in order of

possibility. The suspected three sections in maximum are
BACK TO No.3 displayed. When desired to see other suspected trouble sections,
press feed " " button. For diagnosis results and corrective
actions to be taken, see Table 48-2.
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death.Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality.
Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis.
The preliminary investigation of electric system makes the time saving and high precision diagnosis possible.
3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a
case no accordance of diagnosis obtained. In this case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
3-29
No.4 CASE OF DIAG MODE 2
SENSOR CHECK START ENG

ENGINE SPEED
LOWER BOOM DIAG MODE 2
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND START
PROPO-VALVE
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP
OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
SEARCHABLE OPERATION
Boom up
Boom down
In the normal condition, OK is
Bucket digging displayed when the control
lever is moved to stroke end.
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P1 side option
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
Table3-1 Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that the flow rate at P1 side is minimum and
1 1 P1 UNLOAD
the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P1
2 2 P1 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P1
3 3 P1 UNLOAD
side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position,
4 1 P2 UNLOAD
and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P2
5 2 P2 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P2
6 3 P2 UNLOAD
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and
7 1 P1 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P1
8 2 P1 PUMP
9 3 P1 PUMP
and P1 side flow rate is maximum?
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and
10 1 P2 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P2
11 2 P2 PUMP
12 3 P2 PUMP
and P2 side flow rate is maximum?
3-30
Table3-1 Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload
13 1 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload
14 2 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little
15 1 P1 ENGINE
when P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little
16 2 P2 ENGINE
when P2 side flow rate is relieved?
Table3-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Check each pressure sensor by
SENSOR CHECK Disconnection of pressure sensor, Short
service diagnosis and replace it if
NG circuit, Abnormal output
necessary
Secondary pressure is excessive high against
the command Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low against and replace it if necessary
the command
Stuck at full-stroke side Check P1 unload spool and replace it
P1 UN-LOAD SPOOL NG
Stuck at neutral side if necessary
the command Check P2 unload proportional valve
P2 UN-LOAD PSV NG
the command
Stuck at full-stroke side Check P2 unload spool and replace it
P2 UN-LOAD SPOOL NG
Stuck at neutral side if necessary
Stuck at closing side Check P1 by-pass cut valve and
P1 B-P CUT NG
Stuck at neutral side replace it if necessary
Stuck at closing side Check P2 by-pass cut valve and
P2 B-P CUT NG
the command Check P1 pump proportional valve
P1 PUMP PSV NG
the command
Delivery rate is excessive large against the Check P1 pump regulator and replace
command it if necessary.
P1 PUMP NG
Delivery rate is excessive small against the Check P1 pump and replace it if
command necessary.
the command Check P2 pump proportional valve
P2 PUMP PSV NG
the command
Delivery rate is excessive large against the Check P2 pump regulator and replace
command it if necessary.
P2 PUMP NG
Delivery rate is excessive small against the Check P2 pump and replace it if
command necessary.
3-31
Table3-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
the command Check travel straight proportional
S-TRAVEL PSV NG
Secondary pressure is excessive low against valve and replace it if necessary
the command
Stuck at full-stroke side Check travel straight spool and
S-TRAVEL SPOOL NG
PUMP 1 PRESS. SENSOR Check P1 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
PUMP 2 PRESS. SENSOR Check P2 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
Set pressure decreases Check main relief valve and replace it
MAIN RELIEF NG
Set pressure increases if necessary
Check engine and replace it if
ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary
3-32
3.7 SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display which makes confirmation of remaining time to the coming replacement/
change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil. When the remaining time reaches to Zero
(0), replace or change them and perform the initial setting in the following order.
Screen change Buzzer stop Work mode

switch switch select switch
Interval of replacement of parts is mentioned below. Washer

switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
• Hydraulic oil : 5,000 Hr (For OCEANIA) switch select switch
• Hydraulic oil : 2,000 Hr (For S.E. ASIA)
Procedure Operating Procedure Display on Multidisplay
After several seconds,

display is changed to 10:25
1 Turn starter key switch on.
clock autmatically.
S
Press " " switch press once display

change switch on the switch panel once. And 10:25 Press screen change 250 Hr
2 ENGINE OIL
the clock display changes to the display of switch once more.
remaining time for coming engine oil change. S S
Press " " switch press once select

switch once and the display for the engine 250 Hr Press select switch 250 Hr
3 ENGINE OIL ENGINE OIL
oil change reverses. once more.
S
When required to adjust the interval to the coming

Replacing interval is
4
change time by 10 hours, press " " switch 250 Hr changed with each 500 Hr
and the time to the coming engine oil change is ENGINE OIL ENGINE OIL
pressing of switch.
added. Press " " switch and the time to the
coming engine oil change is reduced.
When desired to return to the initial set time,

press " " buzzer stop switch once. 500 Hr To set the desired interval, 500 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL
time is stored. S
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.
3-33
3.8 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
1) Auto idling stop (OCEANIA ONLY)

No. Switchs 1 2 3 4
3 Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
7 Auto Accel Switch 5
8 Select Switch 8 7 6
Fig. 3-4
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
FEED FEED FEED
(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.
3-34
2) Clock Adjustment Switches

4 Washer Switch
5 Wiper Switch
7 Auto Accel Switch
5
Main screen (a)

SWITCH STATUS
10:25 CLOCK/CONTRAST 13:15
H H
(a) (b)
(c) (d) (e)

SWITCH STATUS ADJUST CLOCK Y M D H M Enter
CLOCK/CONTRAST ADJ CONTRAST 06 04 01 13 15
Select Year/Month/Day/Hour/Minute Increase/Decrese
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).
3-35
3) Contrast Adjustment Switches

4 Washer Switch
5 Wiper Switch
7 Auto Accel Switch
5
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(c) (d) (a)

SWITCH STATUS ADJUST CLOCK
CLOCK/CONTRAST ADJ CONTRAST 10:25
H
(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).
3-36
(2) Function for service

Following items are provided for adjustment of service function.
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop (OCEANIA ONLY) 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
3-37
3.9 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view
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
CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21
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
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
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
25 DL GND / OPEN(5V
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output GND / OPEN
30 DO 21 - Output GND / OPEN
31 DO 22 Spare Output GND / OPEN
32 DO 23 Rotary light (yellow) Output GND / OPEN
33 DO 24 Rotary light (green) Output GND / OPEN
34 DI 36 - Input GND / OPEN
3-38
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
22 D1 37 Spare Input GND / OPEN
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
16 Reserved
3-39
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
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
12 GA 0V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
24 GA 0V
25 GA 0V
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 - Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload 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
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ - Output +0~800mA
26 D7- -0~800mA
27 D8+ - Output +0~800mA
28 D8- -0~800mA
29 D9+ - Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
3-40
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ - Output +24V 1.5A
4 F1- Output +24V 1.5A
5 F2+ Output +24V 1.5A
6 F2- Output +24V 1.5A
7 OIL - 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
14 D13- -0~800mA
16 D14- -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 - CAN communication
24 CANL2 CAN communication
CN107 1 DI 3 - Input +24V/OPEN
2 DI 8 Water separetor Input GND / OPEN
4 DI 10 Air filter Input GND / OPEN
5 DI 11 Stroke end check Input GND / OPEN
6 DI 12 Spare Input GND / OPEN
10 DI 20 ECU main relay Input GND / OPEN
12 DI 32 Hand control nibbler Input GND / OPEN
13 DI 38 Quick coupler Input GND / OPEN
14 DI 39 Extra pressure Input GND / OPEN
17 Reserved
3-41
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 High reach hoisting at fixed position Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
9 DI 19 Nibbler open check SW Input GND / OPEN
10 DI 21 - 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 High reach (hoist at travel) Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
24 Reserved Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Accel signal 2 0~5V
28 H2- 0V
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 Reserved 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 Extra pressure release Output GND / OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Tranmission RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shiled GND
22 DO 10 - SV 24V/OPEN
3-42
(2) Gauge cluster (symbol C-2)

1) General view
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
BUZZER STOP SWITCH WORK MODE SWIHCH
2) Connector CN-600 (Harness side)
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.
4) Summary of display and drive item
No. Item Remarks

1 Monitar display LCD dot 120×168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 —
4 Buzzer Piezo-electricity type
8 Back light LED
3-43
(3) Relay & fuse box (symbol E-1)

1) General view
(Overhead view of box)

LABEL INSIDE
Note) These circles indicate the parts

which are used in standard specification
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
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF RELAY & FUSE
LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME
3-44
2) Circuit diagram
3-45
3-46
3-47
(4) High pressure sensor : YN52S00048P1
ECONOSEAL SERIES MARK (+)> SPECIFICATION :

3POLES CAP
MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa
POWER SOURCE VOLTAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESISTANCE : 100M OR MORE
HOUSING (BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
PLASTIC POTTING CONDENSER
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
O-RING P14 PIPE

JIS B2401 CLASS1B
THREAD
PF 3/8
Tightening torgue STRUCTURE
73.5N.m (54.2lbf.ft)
(5) Low pressure sensor : YX52S00013P1

Tightening torgue
Vout
29.4 34.3N.m (21.7 25.3lbf.ft)
PF1/4
Vcc GND
ELECTRIC CONNECTING DIAGRAM
(Ex. Construction of internal controller)
SPECIFICATION :
PRESSURE RANGE : 0 3.0 MPa
RATED VOLTAGE : 5.0+0.5V DC
OUTPUT CHARACTERISTIC INSURANCE RESISTANCE : 50M OR MORE
(BETWEEN CASING AND EACH TERMINAL AT
50V DC MEGGER)
3-48
3.10 ELECTRIC EQUIPMENT

3.10.1 ELECTRIC EQUIPMENT LIST (SK125SR, SK135SR-2)
Group Code Name Parts No.

C - 1 Mechatro controller YN22E00214F1
(C) Controller
C - 2 Gauge cluster YN59S00021F3

C - 4 Air-con controler (including panel) YN20M01468P2
C - 8 Engine controller 32G87-01020
D - 4 Diode Accessory of relay box

D - 5 Diode ↑
D - 6 Diode ↑
D - 9 Diode ↑
(D) Diode
D - 10 Diode ↑
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 15 Diode ↑
D - 16 Diode ↑
D - 17 Diode ↑
E - 1 Fuse and Relay box YY24E00008F1
E - 2 Alternator 32G68-00100
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LC53S00001D1
E - 6 Horn low LC53S00001D2
E - 7 Tuner AM / FM (OCEANIA) YN54S0046P1
(E) Electric fittings
E - 8 Speaker left YN54S00050P1

E - 9 Speaker right ↑
E - 10 Receiver dryer YN54S00041P1
E - 11 Air-con compressor YX91V00001F1
E - 12 Battery 2484U171
E - 13 Travel alarm YN53S00004F1
E - 14 Cigaratte lighter YN81S00003P1
E - 15 Fusible link YY73S00003P1
E - 16 One way call amp 2447R145
E - 17 One way call speaker 2479R2098
E - 22 DC-DC converter YN77S00005F1
L - 1 Boom work light (LH) YW80S00001F1
(L) Light
L - 2 Frame work light (RH) YT80S00002F2

L - 3 Swing flasher (LH) YY80S00001F1
L - 4 Swing flasher (RH) ↑
L - 5 Room light YT80S00001P1
3-49

M - 1 Starter motor 32G66-00100
(M) Motor
M - 3 Wiper motor YN53C00012F2

M - 4 Washer motor (Tank assy) YT54C00003F1
M - 8 Grease motor LC71V00001P1
M - 9 Roof wiper motor YN76S00005P1
PSV - A Arm 2 speed inverse propo. valve YN35V00049F1
PSV - B P2 unload propo. valve (YY35V00013F1) YN35V00048F1
PSV - C Travel straight propo. valve Solenoid valve assy ↑
(P) Proportional
solenoid valve
PSV - D P1 unload propo. valve ↑

OPT. Relif adjustment propo.
PSV - E — —
valve 1
OPT. Relif adjustment propo.
PSV - I — —
valve 2
PSV - P1 P1 pump propo. valve (YY10V00013F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump accesory ↑
R - 1 Battery relay YN24S00008F1
R - 2 Starter relay Engine accessory
R - 3 Glow relay 34390-00601
R - 4 Safety relay Accessor of relay box
R - 5 Horn relay YN24S00010P1
R - 6 Working light relay ↑
R - 8 Travel alarm relay ↑
R - 12 Revolution right relay ↑
R - 13 Revolution left relay ↑
R - 15 Nibbler open relay ↑
(R) Reray
R - 16 Nibbler close relay ↑

R - 19 Flasher relay YY24S00001F1
R - 23 Auto idle stop relay 1 YN24S00010P1
R - 24 Auto idle stop relay 2 ↑
R - 25 Engine emergency stop relay ↑
R - 26 Lever lock relay ↑
R - 28 Alternator relay ↑
R - 29 Wiper motor relay (Normal rotation) YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation) ↑
R - 31 Prevent spark relay ↑
R - 32 Washer motor relay ↑
R - 53 Glow relay (ECU) ↑
3-50

SE - 1 Pressure sensor : Bucket digging YX52S00013P1
SE - 2 Pressure sensor : Bucket dump ↑
SE - 3 Pressure sensor : Boom up ↑
SE - 4 Pressure sensor : Boom down ↑
SE - 5 Pressure sensor : Swing ↑
SE - 7 Pressure sensor : Arm in ↑
SE - 8 Pressure sensor : Arm out ↑
(SE) Sensor
SE - 9 Pressure sensor : Travel RH ↑

SE - 10 Pressure sensor : Travel LH ↑
SE - 11 Pressure sensor : P2 OPT. ↑
SE - 13 E/G speed sensor Engine accessory
SE - 15 Fuel sensor YN52S00045F1
SE - 16 Accel potentiometer YN52S00032P1
SE - 20 Pressure sensor : P1 OPT. YX52S00013P1
SE - 22 Pressure sensor : Pump P1 YN52S00048P1
SE - 23 Pressure sensor : Pump P2 ↑
SE - 29 Opt. selector detect sensor YX52X00013P1
SV - 1 Swing parking brake SOL. YN35V00051F1
(SV) Solenoid
SV - 2 — (YY35V00013F1) —
SV - 3 Two speed select SOL Solenoid valve assy YN35V00050F1
SV - 4 Safety lock lever SOL ↑
SW - 1 Key switch YN50S00029F1
SW - 4 Swing parking brake release switch YN50S00047P1
SW - 5 Horn switch (RH) YN50E00017P1
SW - 8 Air filter clogging switch YR11P00008S005
SW - 10 Horn switch (LH) YN50E00017P1
SW - 11 Safety lock lever switch YN50S00041F1
SW - 13 Travel alarm switch YN50S00040DF
SW - 15 Conflux/single select switch YN50S00040DD
(SW) Switch
SW - 17 Skylight wiper switch YN50S00040D9

SW - 19 Wiper interlock switch YT50S00004P1
SW - 22 KPSS release switch YX50S00001F1
SW - 26 Cab work light switch YN50S00040D4
SW - 29 Nibbler open switch 2406P5872
SW - 30 Nibbler close switch ↑
SW - 33 Revolution right switch YN03M01231P3
SW - 34 Revolution left switch ↑
SW - 36 Water separator restrlction switch 32G90-00300
SW - 37 Travel independent switch YN50S00040DB
SW - 55 Boom work light switch YN50S00040D1
3-51
3.10.2 SPECIFICATION OF ELECTRIC EQIUPMENTS
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 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
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 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
3-52
File No.
Name of part
Use
Applicable Machine
C-4
Controller
YN20M01468P2

Air-con Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
C-8
Controller
Weight 700g (711.5g)[1550 lbs]
32G87-01020
ECU Type : EDC16UC40
Engine controller BOSCH part No. : 0 281 B03 233
YV05 - 04501 ~ (978772-0627)
MHI part No. : 32F98-10115
YY05 - 12001 ~
YH05 - 07001 ~
(7.99")
(6.56")
E-1
Fuse capacity and circuit
Fuse & Relay box
YY24E00008F1
Fuse & Relay
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
Front side of machine
3-53
File No.
Name of part
Use
Applicable Machine
E-2
Alternator
32G68-00100
Generator
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E-3
Hour meter Movement Quarts
Operating voltage 10~80VC
YT58S00006P1 GM terminal : 2962447
GM connector : 2962448
Service meter
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 5, 6
Type Bottom L : Low sound
Horn H : High sound
Rated voltage DC24V
LC53S0001D1 (High) STAMP
Operating voltage range DC20~30V
LC53S0001D2 (Low)
Sound level 113+5dB(A)/2m
Warning sound
420+20Hz high sound
LC10 - 07001 ~ Basic frequency 350+20Hz low sound
YC10 - 03501 ~ Insulation resistance More than 3M /DC500V
YF05 - 02001 ~
YU05 - 02001 ~ o 8.5
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
3-54
File No.
Name of part
Use
Applicable Machine
E-7
Maker SOKEN Co,.Ltd.
Tuner
Part name AM/FM radio
YN54S00046P1
Radio (AM & FM)
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 8, 9
Speaker (L/R) Maker SOKEN Co,.Ltd.
Model SOK104A004
YN54S00050P1
Rated input 10W
Radio
Impedance 8
LY01 - 00101 ~
Frequency 33.3Hz
LV02 - 00201 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
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)
LC10 - 07001 ~ 17% or over than the
Desiccant moisture
YC10 - 03501 ~ adsorption capability weight of desiccant
(Include initial absorption 2%)
YF05 - 02001 ~ Refrigerant HFC-134a
YU05 - 02001 ~
Inner volume/Desiccant 578cm3/300g Inlet (From condenser)
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
3-55
File No.
Name of part
Use
Applicable Machine
E - 11
Air-con compressor
!"#$"###
YX91V00001F1

%&'
Air-con

'### (
YX03 - 01601 ~

)* +
YX04 - 01773 ~

$,!'
YX05 - 02001 ~
-.$&#/,!0
YN11 - 45001 ~

YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 12
Type 95E41R-N100
Battery
Voltage 12V
2484U171
5 HR 80Ah
Power Capacity
20 HR 100Ah
YV03 - 02150 ~
Weight 26kg (57lbs)
LD03 - 01105 ~
YY03 - 04299 ~
YH03 - 02013 ~
YV04 - 03001 ~
LD04 - 01200 ~
YY04 - 06001 ~
YH04 - 03001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
407L 175W 250H

(16.02" 6.89" 9.84")
3-56
File No.
Name of part
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
Travel alarm AMP Econoseal J series Mark II water-proof

Housing : 174354-2 Harness seal : 172888-2
YN11 - 45001 ~ Terminal : 171661-1 Retainer : 1-174355-1
YQ11 - 06001 ~ VIEW A
LC10 - 07001 ~
YC10 - 03501 ~
Vinyl tube
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 14
Cigarette lighter !

"# $%
YN81S00003P1
&! - +
Cigarette lighter ./
YN11 - 45001 ~

' (
YQ11 - 06001 ~
)&%
LC10 - 07001 ~ * + (,$&
YC10 - 03501 ~
YF05 - 02001 ~
01 +
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
E - 15
Type Slow blow fuse
Fusible link
Allowable current 80A
YY73S00003P1
Fuse
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
3-57
File No.
Name of part
Use
Applicable Machine
L-1
Light (Halogen)

YW80S00001F1
Boom work light (LH)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
L-2
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effective area of lens 71cm2
Frame work light (RH)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
L - 3, 4
Light Bulb 24V,6W
VINYL TUBE
YY80S00001F1 (BLACK)
Swing flasher
(Right, left)
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~ DRAIN HOLE
YAZAKI Part No.
YY05 - 12001 ~ 7322-2228
YH05 - 07001 ~
AV0.5B AV0.5B
3-58
File No.
Name of part
Use
Applicable Machine
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens
YT80S00001P1
Room light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
Bulb
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
SECTION A-A Door
YV05 - 04501 ~ Switch
YY05 - 12001 ~
YH05 - 07001 ~
M-1
Motor
32G66-00100
Starter motor
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
LC10 - 07001 ~ Controller
YC10 - 03501 ~ Wiper motor 24V

YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~ Wiper sw
OFF-Stop
YY05 - 12001 ~ Stop signal ON-Start
YH05 - 07001 ~ Reverse signal

Electric diagram
M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 1.2L (0.32 gal) / min or more
YT54C00003F1
Capacity 1.5L (0.4 gal)
Window washer
Time rated Max. continuous 60 sec.
YF05 - 02001 ~
Injection nozzle 1 X 2 pcs.
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
PUMP
3-59
File No.
Name of part
Use
Applicable Machine
M-8 "'() " $
Motor

!
LC71V00001P1

"
#$
Auto greasing

"%%%
&
YN11 - 45001 ~ *.5
%
YQ11 - 06001 ~
$
YF05 - 02001 ~
. &

YU05 - 02001 ~ / &

)40&
YV05 - 04501 ~
0!
1,*22 .312
YY05 - 12001 ~ 00 3 "'() "
YH05 - 07001 ~ *+,* * -+
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 HOUSING AMP
GND terminal
LC10 - 07001 ~
174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
YC10 - 03501 ~ TERMINAL AMP
171661-1
YF05 - 02001 ~ WIRE PROOF PLUG AMP
172888-2
YU05 - 02001 ~ VIEW Z Terminal L

YV05 - 04501 ~ Flowing direction of
main current
o 9 X 30L F HOUSING YAZAKI
YY05 - 12001 ~ Terminal A Terminal B Terminal B AVS 1.25G
Heart shrinkage tube 7123-4210-30
F TERMINAL YAZAKI
YH05 - 07001 ~ z
AVS 1.25B 7116-3251*
GND wire
WIRE PROOF PLUG
I Terminal B Terminal L 7157-3580-60
F HOUSING YAZAKI AVS 1.25L Terminal B
7123-4220-30
F TERMINAL YAZAKI
P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60
Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)
Fusible link assy B o 7.0 X 150L

Fusible link assy A Corrugete tube (Black)
3-60
File No.
Name of part
Use
Applicable Machine
R-3
Relay
34390-00601
Glow relay
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
Specifications
Rated voltage DC24V
Exciting current 2.3A (AT 24V 20 )
Rated time 75 sec
Closing circuit volt. 16V MIN. Electric diagram
Opening circuit volt. 4V MAX.
Max. Permissible
200A
current
Weight 0.26kg (0.57lb)
Tightening torque M6NUT 2.45~3.43N.m (1.81~2.53lbf.ft)
for terminal M4BOLT 1.13~2.35N.m (0.83~1.73lbf.ft)
R - 5,6,8,12,13,15,
16,23,24,25,26,28 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
YN24S00010P1
Horn realy
Work light relay Contact 1C
Travel alarm relay * Accessory of relay box
Revolution right relay
Revolution left relay
Nibbler open relay
Nibbler close relay Pin assignment
Auto idle stop relay 1, 2
Engine emergency stop relay
Lever lock relay
Alternator relay
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
Terminal arrangement
YY05 - 12001 ~
YH05 - 07001 ~
3-61
File No.
Name of part
Use
Applicable Machine
R - 29,30,31,32,55
Maker Tyco Electronics
Relay
Maker's p/No. V23134-A0053-C643
YN24S00012P2
Type Relay
Wiper motor relay
Wiper motor reveing relay Rated voltage DC 24V
Prevent spark relay Contact 1C
Washer motor relay
* Accessory of relay box
Glow relay (ECU)
YN11 - 45001 ~
YQ11 - 06001 ~
Pin assignment
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
30 85 86 87 87a 30
87a
85 86
87
SE - 1 ~ 5, 7 ~ 11,20,29
Pressure range 0~3MPa (435 psi)
Pressure sensor
Allowable max. pressure 7.0MPa (1010 psi) O-ring
(Low pressure) (P11 1B)
Rated voltage 5+0.5V DC
YX52S00013P1 Vout
50M or more /DC50V megger HEX24
Bucket dig and dump, Insulation resistance
(Between Body terminal)
Boom up and down,
Swing,
Connection (Arrangement)
Arm in and out,
Travel RH and LH and other
Vcc GND
Opt. selector detect PF1/4
.
Tightening torque 29.4~34.3 N m
YF05 - 02001 ~
(21.7~25.3 lbf.ft)
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
3-62
File No.
Name of part
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 ~
1/2 32+5
YQ11 - 06001 ~
1/4 (49.5)
LC10 - 07001 ~
EMPTY 85 +10
0
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~ Machine side controller
Float
Electric diagram VIEW A
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 ~
Potentio
YC10 - 03501 ~
3MA JM II + AMP
YF05 - 02001 ~ Bracket
HOUSING : 174359-2
YU05 - 02001 ~ TERMINAL : 171661-1
YV05 - 04501 ~ Dial

YY05 - 12001 ~
YH05 - 07001 ~
3-63
File No.
Name of part
Use
Applicable Machine
SE - 22, 23 Electric diagram (Arrangement)
Pressure range 0~50MPa (7250 psi)
Pressure sensor
Max. allowable press. 120MPa (17400 psi)
(High pressure)
Operating source voltage 5+0.5V DC
YN52S00048P1
100M or more/DC50V megger
P1 pump Insulation resistance
(Between casing and terminal)
P2 pump
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
P3/8 Source (+)
YC10 - 03501 ~ Tightening torque Output (+) Econo seal J series
YF05 - 02001 ~ : 73.5 N.m O ring P14 Common (+) (Mark II (+)
(54.2 lbf.ft) JIS B2401 3 pole
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
PSV - A, B, C, D
Proportional solenoid valve YN35V00049F1 YN35V00048F1 YN35V00050F1 YN35V00050F1
YN35V00051F1
Hydraulic solenoid valve
T=7N.m
Hydraulic symbol A5 to A8
(YY35V00013F1)
YN35V00048F1
YN35V00049F1
YV05 - 04501 ~
YY05 - 12001 ~ T2
YH05 - 07001 ~ A1
A8 A7 A6 A5 A4 A3 A2 A1
P2
P1
PSV-A PSV-B PSV-C PSV-B SV-3 SV-1 SV-4

T2
HYDRAULIC SYMBOL P1
P2
A8 A7 A6 A5 A4 A3 A2 A1
Arm 2 speed
P1 unload
Travel straight
P2 unload
Travel 1,2 speed
Swing parling
Lever lock
3-64
File No.
Name of part
Use
Applicable Machine
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)
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
Sleeve O-ring Solenoid Seal nut
YH05 - 07001 ~ 1B P20
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
valve (7 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 A3 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YY35V00013F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 1 Auto return
Switch
Connection
YN50S00029F1 Terminal
Position
Starter switch
Auto return
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~ VIEW A Terminal
YY05 - 12001 ~ arrangement
YH05 - 07001 ~
SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
YN50S00047P1 Rated DC30V, 10A
Swing parking brake Insulation resistance
release
Vinyl tube
YF05 - 02001 ~ YAZAKI
T No.
YU05 - 02001 ~ Contact construction : Position Red (2) 7122-2237
7114-2020
YV05 - 04501 ~ Swing parking release
YY05 - 12001 ~ Normal
YH05 - 07001 ~
White (3) Blue (1)
3-65
File No.
Name of part
Use
Applicable Machine
SW - 5, 10
*+ ,-
Switch -

).

YN03M01861F1
(Right grip)
!" #$ $%
&
& '
YN03M01862F1 (%" )
(Left grip)
Horn
YF05 - 02001 ~
YU05 - 02001 ~ )) ) - /012-, 34+# 5! )6
YV05 - 04501 ~ )) ) - &$7-, 8!#+9!8!
7 5)) ) : ( #6
YY05 - 12001 ~
YH05 - 07001 ~
SW - 8
Switch

YR11P00008S005

Air cleaner
Clogging switch !
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 11
Switch

YN50S00041F1

Lock lever
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~ ! "
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~ ! "
#$
SW - 13
Switch
Single pole single throw
YN50S00040DF Type (alternate)
Travel alarm More than 1M /
Insulation resistance DC500V megger UP
LC10 - 07001 ~
YC10 - 03501 ~
Terminal connector
YF05 - 02001 ~ Connector
Position
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
3-66
File No.
Name of part
Use
Applicable Machine
SW - 15
Switch
YN50S00040D3 Type (alternate)
Conflux / single flow More than 1M /
switching
LC10 - 07001 ~ Terminal connector
YC10 - 03501 ~ Connector
Position
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 17
Switch
Roof window wiper More than 1M /
switch
LC10 - 07001 ~ Terminal connector
YC10 - 03501 ~ Connector
Position
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 19
Switch
YT50S00004P1
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
Insulation resistance 5M or more
LC10 - 07001 ~
YC10 - 03501 ~
Operation force Initial motion 0.8+0.3
0 kg
YF05 - 02001 ~
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~ Max. stroke
SW - 22
HOUSING : 6098-0258
Maker's part No. ET610N13
Switch TERMINAL : 8230-4282
YX50S00001F1 Rated DC 30V
KPSS release More than 100M /

Insulation resistance 500V megger
YF05 - 02001 ~ After fixing the wires by soldering,
insulate them with insulation tape. VIEW I
YU05 - 02001 ~ (all terminals)
YV05 - 04501 ~ Bundle with vinyl tape
YY05 - 12001 ~ or tape.
YH05 - 07001 ~
I
3-67
File No.
Name of part
Use
Applicable Machine
SW - 26
Switch
Cab work light switch More than 1M /
LC10 - 07001 ~
YC10 - 03501 ~
Terminal connector
YF05 - 02001 ~ Connector
Position
YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 36
Switch
32G90-00300
Water separator
restrlction
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
SW - 37
Switch
YN50S00040DB Type (alternate)
Travel independent More than 1M /
YF05 - 02001 ~
YU05 - 02001 ~ Terminal connector
YV05 - 04501 ~ Position
Connector
YY05 - 12001 ~
YH05 - 07001 ~
3-68
File No.
Name of part
Use
Applicable Machine
SW - 55
Switch

YN50S00040D1
Boom work light switch !
"## &%
$

LC10 - 07001 ~
YC10 - 03501 ~ $
YF05 - 02001 ~ %

YU05 - 02001 ~
YV05 - 04501 ~
YY05 - 12001 ~
YH05 - 07001 ~
3-69
[MEMO]
3-70
4. ENGINE
4-1
4. ENGINE
4-2
4. ENGINE
4.1 ENGINE SPECIFICATIONS

4.1.1 SPECIFICATIONS (SK125SR, SK135SR-2)
Applicable machine SK125SR / SK135SR-2 / SK135SRLC-2

Engine model MITSUBISHI D04FR-74kW
Water-cooled, 4 cycle 4 cylinder direct injection type
Type
diesel engine with inter cooler turbo-charger
Number of cylinder×Bore×Stroke mm (in) 4 × 102 × 130 (4.02 × 5.12)
Total displacement cc (cu•in) 4,249 (259.27)
Compression ratio 17.8
Rated output kW (PS) at min -1
69.2 (94) at 2,000
N•m (lb•ft) at
Maximum torque 375 (277) at 1,600
min-1
High idling min-1 2,240 ± 20
Low idling min -1
1,015 ± 20
Injection starting pressure MPa (psi) —
Start/Full open
Thermostat action 344 (160) / 358 (185)
K (°F)
Firing order 1-3-4-2
Starter capacity V × kW 24 × 5.0
Generator capacity (Alternator) V×A 24 × 50
ø600 (23.6") × suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.9
Full level 17.5 (4.62)
Engine oil quantity L (gal) Low level 14.5 (3.83)
Total 18.5 (4.89)
Dry weight kg (lbs) 395 (871)
Fuel consumption ratio
g/kW•h (g/ps•h) 233 (171)
(At rated output)
Allowable inclination Front / Rear and Right / Left : 35°
Dimension (L×W×H) mm (in) 911 × 719 × 940 (35.9in × 28.3in × 37.0in)
Rotating direction Counterclockwise seeing from flywheel side
4-3
4. ENGINE
4.1.2 ENGINE CHARACTERISTIC CURVE (SK125SR, SK135SR-2)
Condition to be measured: The net value is indicated, measuring without cooling fan.
TORQUE Nm
OUTPUT kW
ENGINE SPEED (min-1)
Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
233g/kW.h
X 74kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
20.65
Fuel consumption in regular operation
(load factor 0.70~0.80)
14.5 L/h~16.5 L/h
4-4
4. ENGINE
4.2 ENGINE OUTSIDE VIEW

4.2.1 GENERAL VIEW (SK125SR, SK135SR-2)
FUEL FILTER
OIL-FILTER
ELEMENT WATER SENSOR
ENGINE
AIR HEATER THERMOSTAT

STARTER
RELAY
V-BELT
(AIR CONDITIONER) V-BELT
ALTERNATOR
WATER TEMP
SENSOR
PICK UP
Fig. 4-1 General view of engine
4-5
4. ENGINE
4.3 ENGINE MOUNTING

4.3.1 SK125SR, SK135SR-2
9
10
9
7 10
7
2
6 4
5
3
4
4 A
8
8
A
9
11
A
9 9
10 10
7
7
4
4
1
2
5
4 6
4
8
8
Fig. 4-2 Engine mounting
4-6
4. ENGINE
4.4 SYSTEM FLOW DIAGRAMS

4.4.1 FUEL SYSTEM - FLOW DIAGRAM

4.4.2 LUBRICATION SYSTEM - FLOW DIAGRAM

4-7
4. ENGINE
4.4.3 COOLING SYSTEM - FLOW DIAGRAM

4.4.4 INLET AND EXHAUST SYSTEM - FLOW DIAGRAM

4-8
4. ENGINE
4.4.5 ELECTRICAL SYSTEM - WIRING DIAGRAM

INJECTOR POWER SUPPLY
INLET MANIFOLD AIR HEATER RELAY
PRESSURE SENSOR
WATER TEMPERATURE
SENSOR
COMMON RAIL
COMMON RAIL
PRESSURE SENSOR
SPEED / TIMING SENSOR
SPEED / TIMING SENSOR (CAMSHAFT SIDE)
(CRANKSHAFT SIDE)
FUEL PUMP
HIGH PRESSURE PUMP

ENGINE OIL SOLENOID SENSOR
PRESSURE SWITCH (MPROP)
CONNECTOR
ELECTRONIC
CONTROL UNIT (ECU)
ELECTRICAL SYSTEM - WIRING DIAGRAM
4-9
4. ENGINE
4.5 ENGINE SERIAL NUMBER LOCATION

The engine serial number is stamped on the side of the crankcase.

4-10
4. ENGINE
4.6 REMOVING FUEL SYSTEM
1. Keep open flame or heat away from fuel system before conducting the removal work. It could cause a fire.
2. Wipe off any spilled fuel. Spilled fuel could cause a fire.
3. Cover or plug any inlet and outlet openings to prevent dust from entering the fuel system.
4. For fuel pump, common rail, and injector, have a specialized maintenance shop do the maintenance work.
4.6.1 REMOVING FUEL SYSTEM (PART 1)
4-11
4. ENGINE
4.7 FUEL INJECTION SYSTEM (COMMON RAIL SYSTEM)

4.7.1 OUTLINE
LEAKAGE PIPE INJECTOR ASSEMBLY
ECU (ELECTRONIC CONTROL UNIT)
RAIL PRESSURE SENSOR
COMMON RAIL ASSEMBLY
PRESSURE LIMITER VALVE FEED PUMP

FUEL METERING UNIT (MPROP)
HIGH PRESSURE PUMP ASSEMBLY
The common rail system is developed aiming at high reliable operation performance, low fuel consumption, low
noise, high power output and clean emission gas which are required for the present engine with the optimum fuel
injection quantity and injection timing.
This system is used to operate the engine in most suitable condition for the engine operating condition (engine
speed, acceleration condition, coolant temperature, etc.) with provided each sensor by inclusively controlling the fuel
injection quantity, fuel injection timing, injection pressure and so on to the operating condition with ECU (electronic
control unit).
The ECU self-diagnoses the main parts, and is equipped with diagnosis and alarm functions which are helpful in
informing operator about the detected abnormality.
The common rail system is made up of electronically-controlled high pressure pump assembly, injector assembly,
common rail assembly, and ECU and sensors which are used to control the said assemblies.
4-12
4. ENGINE
4.7.2 FEATURES
(1) High pressured fuel injection
The common rail type fuel injection system can produce high pressure of 110MPa (1122kgf/cm2), and can
respond to compact, medium and large size high-speed direct injection diesel engines in low fuel consumption
and high power output.
(2) Small and high pressure injection nozzle was adopted
By adopting high pressure fuel injection nozzle and small and high pressure injection nozzle, the injector
assembly boosts the fine mist spray of fuel injection through nozzle, increases in fine mist fuel spray travel,
enhances the distributing action and improves the mixing ability with air. Consequently the exhaust emission gas
is cleaned.
(3) Optimum fuel injection system
The low fuel consumption and high power output are obtained by controlling the fuel injection quantity and
injection timing to those most suitable for the engine in use at high speed with ECU (electronic control unit).
(4) Improvement of durability
The parts which are used for the common rail type fuel injection system are of high pressure proof parts to
improve the durability.
(5) Improvement of adaptability to engine
The fuel injection to engine can be controlled for each cylinder and the adaptability to the engine was improved.
(6) Improvement of power performance
As fuel injection pressure to the acceleration gate opening is controlled to optimum pressure by ECU, the torque
can be increased by controlling the low acceleration gate opening and consequently the power performance is
improved.
(7) Drop of combustion temperature and shortening of combustion time
Compared to the previous fuel injection system, NOx (nitrogen oxides) rate is reduced due to the drop of
combustion temperature. And the particulate matter is reduced due to the shortening of combustible time.
(8) Reduction of smoke at acceleration
Smoke might be produced by excess fuel quantity when increasing the fuel injection to raise the engine power.
The common rail fuel injection system is helpful in accurately controlling the fuel injection quantity, preventing
the production of smoke without reducing the acceleration performance.
(9) Additional equipments are not required
The common rail fuel injection system does not require additional equipments like boost compensator, aneroid
compensator and so on to be installed on the common rail, because ECU compensates it according to signals
transmitted by each sensor. Consequently, this system saves the space and makes the engine weight light.
(10)The self diagnosis function is built in the system
The self diagnosis function is built in the system, and the function finds the troubled parts and indicates the error
codes of troubles.
4-13
4. ENGINE
4.7.3 SPECIFICATIONS
4-14
4. ENGINE
4.7.4 FUEL SYSTEM
RAIL PRESSURE SENSOR COMMON RAIL ASSEMBLY PRESSURE LIMITER VALVE

FEED PUMP
FUEL METERING UNIT

(MPROP)
INJECTOR ASSEMBLY
FUEL FILTER
COOLANT SENSOR
SEGMENT SENSOR BOOST PRESSURE SENSOR

FUEL TANK
ACCEL POSITION SENSOR
ECU INCREMENT SENSOR
(ELECTORONIC CONTROL UNIT)
(1) Fuel piping system

The fuel piping system is made up of fuel tank, fuel filter, high pressure pump assembly (supply pump – MPROP:
fuel metering unit), common rail assembly, pressure limiter, injector assembly and pipes which are used to
connect these equipments.
(2) Fuel oil feed line
The fuel oil in the tank is fed from MRROP of high pressure pump assembly into plunger through fuel filter by
supply pump installed on the high pressure pump assembly after cranking up the engine by turning the starter
switch key on.
The fuel oil is pressurized inside of plunger and fed to the common rail assembly.
(3) Fuel oil abnormal pressure rise prevention
The fuel oil delivered by high pressure pump assembly is returned to fuel tank by pressure limiter when abnormal
pressure was generated in the common rail to prevent abnormal pressure rise. When the valve piston is once
opened due to detection of abnormality, the overflowing oil quantity to the fuel tank is automatically controlled.
Consequently the pressure in the common rail is kept constant and the quick-fix traveling of machine is available.
(4) Decision of optimum injection timing and fuel injection quantity
The ECU (Electronic Control Unit) controls a plunger. And the fuel oil pressurized by plunger in the common rail
of engine is injected into the cylinder of engine by injector in optimum fuel injection quantity and injection timing.
(5) Return of excess fuel oil
The excess fuel oil generated in high pressure pump assembly and injector assembly returns to fuel tank.
4-15
4. ENGINE
4.7.5 SYSTEM DIAGRAM
ECU (ELECTRIC CONTROL UNIT)
PRESSURE LIMITER COMMON RAIL ASSEMBLY RAIL PRESSURE

VALVE SENSOR
INLET VALVE
OUTLET VALVE ZERO DELIVERY

THROTTLE
INJECTOR ASSEMBLY
TAPPET
OVERFLOW VALVE
PLUNGER
POLYGON RING
FEED PUMP
FUEL FILTER
HIGH PRESSURE PUMP

FUEL METERING UNIT (MPROP) PRIMING
ASSEMBLY
PUMP
FUEL TANK
4-16
4. ENGINE
4.7.6 LAYOUT EXAMPLE
INJECTOR ASSENBLY
FUEL FILTER
COMMON RAIL ASSEMBLY
FUEL TANK
FUEL LINE
RETURN LINE
This figure shows the "Example layout of common rail system". Refer to the maintenance manual of the engine
manufacturer for an actual arrangement.
4-17
4. ENGINE
4.7.7 CONTROL UNIT SYSTEM DIAGRAM
4-18
4. ENGINE
4.8 HIGH PRESSURE PUMP ASSEMBLY

4.8.1 STRUCTURAL DRAWING
INLET VALVE
PLUNGER OUTLET VALVE

TAPPET
BUSHING
ECCENTRIC DRIVE SHAFT
POLYGON RING
FEED PUMP
FUEL METERING UNIT (MPROP) HIGH PRESSURE PUMP
Pump assembly is composed of the following parts.

• Supply pump
• Fuel metering unit (MPROP)
• High pressure pump
As the high pressure pump is connected to the common rail with injection pipe, the fuel oil pressurized by plunger
in the pump is fed to the common rail.
The high pressure pump assembly is installed on the engine with bracket and is driven by gear.
4-19
4. ENGINE
4.9 INSTALLING LUBRICATION SYSTEM

4.9.1 INSTALLING OIL FILTER AND OIL COOLER
To install the lubrication system, follow the removal procedure in reverse order, observing the followings:
(1) Use new gaskets and O-rings when reinstalling.
(2) Clean oil passage of each part thoroughly in wash oil, and dry it completely using compressed air.
(3) Install the bracket first, then install the oil filter.
4-20
4. ENGINE
4.10 REMOVING INLET AND EXHAUST SYSTEM

4.10.1 REMOVING INLET SYSTEM
4-21
4. ENGINE
4.11 REMOVING ELECTRICAL SYSTEM

4.11.1 REMOVING STARTER
4-22
4. ENGINE
4.11.2 REMOVING ALTERNATOR
4-23
4. ENGINE
4.12 TROUBLESHOOTING BY DIAGNOSIS CODES

4.12.1 OUTLINE OF CONTROL SYSTEM
This engine is controlled by electronic control unit (ECU).
The engine has the control parts and the sensors that monitors the engine operation.
The ECU monitors the engine operation using the inputs from various sensors, and controls the injectors and the
fuel injection pump.
This control system can provide appropriate engine control for operating condition.
4.12.2 DIAGNOSIS CODES

When the ECU detects the abnormal engine operation receiving signal input from the sensors, the ECU generates
an error code which is called a diagnosis code.
The diagnosis code includes the one which warns the critical failure, and also the one which warns the light fault.
The diagnosis code can be seen on the monitor located on the vehicle. It also can be seen by connecting the scan
tester (32G91-00600) to the ECU directly.
4.12.3 CONNECTING SCAN TESTER AND ECU

To see the diagnosis code, connect the scan tester to the ECU.
(1) Turn the ignition switch to OFF position.
(2) Connect the scan tester connector to the service connector which is located on the vehicle.
(3) Turn the ignition switch to ON position.
4.12.4 WHEN ECU DOES NOT RESPOND

If the scan tester does not display with connecting to the service connector, following conditions can be concerned.
• The harness and/or the connector between the service connector and the ECU are faulty.
• The ECU is faulty.
At first, inspect the harness and connectors between the service connector and the ECU.
If the harness and the connectors are not faulty, replace the ECU.
The engine may operates even if the ECU does not respond with the scan tester. In this case, it is possible that there
are faults on the CAN circuit (communication circuit connecting the ECU and vehicle control unit) inside the ECU.
Do not operate the engine except emergency situation, replace the ECU.
4-24
4. ENGINE
4.13 SCAN TESTER
4.13.1 OPERATION OF SCAN TESTER

Use scan tester to check the engine status and the diagnosis codes.
4.13.1.1 BASIC OPERATION OF SCAN TESTER

(1) Make sure that ignition key is OFF position.
(2) Connect the scan tester to the service connector on the vehicle.
(3) Turn the ignition key to ON position to energize the ECU.
(4) Press ON key located on the lower right section of scan tester to energize the scan tester. When the scan tester
is energized, startup screen is displayed.
(5) Press "ENTER" key.
(6) "FUNCTION MENU" is dispalyed. Select "SCAN TEST" and press "ENTER" key.
(7) "SELECT PROGRAM" is displayed. Select "GLOBAL OBD II" and press "ENTER" key.
(8) "OBD II TEST MENU" is dispalyed. Select "OBD II FUNCTIONS" and press "ENTER" key.
(9) The menu screen of "OBD II FUNCTIONS" is displayed.
(10)Press "EXIT" key to return the previous screen.
(11)With pressing ON key, press "EXIT" key to turn off the scan tester.
(12)Turn the ignition key to OFF position to turn off the ECU.
4-25
4. ENGINE
4.13.2 CHECK ENGINE STATUS

(1) Select "DATA LIST" from the "OBD II FUNCTIONS"
menu and press "ENTER" key.
(2) Select "All Data" from the "PARAMETER
SELECTION" menu and press "ENTER" key.
(3) The engine status is displayed. Check the engine
status.
ENGINE STATUS DISPLAYS

ECU ID $10
ENGINE SPD Engine speed (rpm) PARAMETER SELECTION SCREEN
ECT( ) Coolant temperature (degree C)
Engine load (%)
ENGINE LOAD
(Proportion to maximum injection quantity)
MAP Boost pressure (kPa (abs))
Error status (ON-OFF)
MIL STATUS
(Failure or not)
STORED DTCs Numbers of failure diagnosis
FRP(G) Rail pressure (MPa)
WARM-UPS Rank of Q adjustment (1-8)
BARO Barometric pressure (kPaA) ENGINE STATUS SCREEEN
CTRL MOD(V) Battery voltage (V)
APP-D CAN acceleration opening (%)
APP-E Analog acceleration opening (%)
4-26
4. ENGINE
4.13.3 DTC MENU DISPLAY

(1) Select "DTCs" from the "OBD II FUNCTIONS"
(2) "DTC MENU" is displayed.
DTC MENU SCREEN
4.13.3.1 CHECK DIAGNOSIS CODES

(1) Select "Confirmed DTCs" from the "DTC MENU"
(2) The diagnosis codes are displayed. The diagnosis
codes are displayed in the order of generating. To
display the previous generated codes, press down
key.
DIAGNOSIS CODES CHECK SCREEN
4.13.3.2 CHECK FREEZE DATA

(1) Select "Freeze Data" from the "DTC MENU" menu
and press "ENTER" key.
(2) The FREEZE DATA is displayed. The FREEZE
DATA is a backup data saving the engine status
screen of when the diagnosis code is generated.
FREEZE DATA CHECKING SCREEN
4.13.3.3 CLEAR DIAGNOSIS CODES

(1) Select "CLEAR DIAG INFO" from the "DTC MENU"
menu and press ENTER key.
(2) The "CLEAR" screen is displayed. Press YES key,
and press ENTER key to delete the diagnosis
codes. However, the diagnosis codes cannot be
deleted until the recovery was completed.
DIAGNOSIS CODES CLEAR SCREEN
4-27
4. ENGINE
4.14 DIAGNOSIS CODE CROSS REFERENCE

The P code shown in the chart below is display by connecting the scan tester to the service connector.
The vehicle side code is displayed on the vehicle monitor. Check the correspoding codes by following chart.
For the detail and treatment of diagnosis codes, refer to "Troubleshooting reference chart".
4-28
4. ENGINE
4-29
4. ENGINE
4.15 INSPECTING SENSORS

4.15.1 SPEED/TIMING SENSOR (CRANK, CAM)
Measure the resistance between terminal A-B.
Standard value : 946 to 774 ohms
If measured value is out of standard, replace the sensor
with a new one.
Speed / timing sensor

(Crank, cam)
4.15.2 INLET MANIFOLD PRESSURE SENSOR

With applying pressure using an air compressor,
measure the voltage between terminal B-C.
Standard value
• at 0MPa{0 kgf/cm2} : 0.5V
• at 0.34MPa{3.5 kgf/cm2} : 4.5V
with a new one.
AIR COMPRESSOR
Inspecting inlet manifold pressure sensor (1)

Air pressure MPa
Output voltage Vdc

Inspecting inlet manifold pressure sensor (2)
4.15.3 WATER TEMPERATURE SENSOR

Put the water temperature sensor to the container filled
with water, measure the output resistance between
terminal 1-2.
Standard value
• 20°C : 2.38 to 2.63 Kilo-ohms
• 20°C : 0.30 to 0.34 Kilo-ohms
If the sensor is an open circuit, its resistance is infinity.
with a new one.
Inspecting water pemperature sensor
4-30
4. ENGINE
4.15.4 ENGINE OIL PRESSURE SWITCH

Apply 60 to 40kPa {0.6 to 0.4kgf/cm2} [8.53 to 5.69 psi]
pressure to the sensor using an air compressor.
Check that the micro switch is in OFF position.
Air compressor
If the switch is not operate, replace the engine oil 60 to 40 kPa
pressure switch with a new one. {0.6 to 0.4 kgf/cm2}
[8.53 to 5.69 psi]
On-Off differences
30 kPa
{0.3 kgf/cm2}
[4.27 psi]
Inspecting oil pressure switch
4.15.5 COMMON RAIL PRESSURE SENSOR

Apply 5V between terminal A-C, and measure the
voltage at terminal B.
Standard value : Approx. 0.5V
If measured value is out of standard, replace the
common rail with a new one.
Inspecting common rail pressure sensor
4.15.6 INJECTOR SOLENOID

Measure the resistance between terminal 1-2.
Standard (at 20 to 70°C [68 to 158°F])
: 0.215 to 0.295 ohms
If measured value is out of standard, replace the
injector with a new one.
Inspecting injector solenoid
4.15.7 HIGH PRESSURE PUMP SOLENOID SENSOR (MPROP)

Measure the resistance between terminal 1-2.
Standard (at 20°C [68°F]) : 2.6 to 3.15 ohms
If measured value is out of standard, replace the fuel
pump with a new one.
Inspecting high pressure pump solenoid sensor

(MPROP)
4-31
4. ENGINE
[MEMO]
4-32
5-1
5-2
5.1 BOOM
5.1.1 BOOM DIMENSIONAL DRAWING (SK125SR, SK135SR-2)
d2
J
X-X
Fig. 5-1 Boom dimensional drawing
Unit : mm (ft-in)
SK125SR SK135SR-2
4.68M (15ft-4in) BOOM
YY02B00287F1 YY02B00273F1
No NAME DIMENSION
A Boom length 4,680 (15'4") ←
B Boom foot width 575 (22.6") ←
C Boom end inner width 274 (10.8") ←
D Boom end outer width 386 (15.2") ←
E Height of boom cylinder rod pin 952 (37.5") ←
F Height of arm cylinder (head side) pin 1,079 (3'6") ←
G Distance between pins of boss R2,110 (6'11") ←
H Distance between pins of bracket R2,293 (7'6") ←
I Arm cylinder (head side) inner width 111 (4.4") ←
J Outer width of bracket on the arm cylinder (rod side) 399 (15.7") ←
mounting
d1 Boom foot pin dia. ø 70 (2.76") ←
d2 Boom cylinder (rod side) pin dia. ø 80 (3.15") ←
d3 Pin dia. of boom end. ø 70 (2.76") ←
d4 Arm cylinder (head side) pin dia. ø 70 (2.76") ←
5-3
5.1.2 BOOM MAINTENANCE STANDARD (SK125SR, SK135SR-2)

(1) Clearance of pin and bushing on boom section
A
C
Fig. 5-2 Clearance of pin and bushing on boom section
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
+ 0.223 + 0.243
(+0.0088) (+0.0096)
A Boom foot YY02B01521P1
+ 0.081 + 0.061
ø 70 (+0.0032) (+0.0024)
(2.7559) + 0.237 + 0.257
Boom cylinder (+0.0093) (0.0101)
B YY02B01174P1
(Head side) + 0.020 + 0.101 + 0.081 More
Replace
(+0.0008) (+0.0040) (+0.0032) than 2.0
bushing
- 0.020 + 0.229 + 0.249 1.2 (0.079)
or pin
Boom cylinder ø 80 (-0.0008) (+0.0090) (+0.0098) (0.047)
C YY02B01177P1
(Rod side) (3.1496) + 0.089 + 0.069
(+0.0035) (+0.0027)
+ 0.231 + 0.251
Arm cylinder ø 70 (+0.0091) (+0.0099)
D YY12B01435P1
(Head side) (2.7559) + 0.091 + 0.071
(+0.0036) (+0.0028)
5-4
(2) Clearance in thrust direction on the boom cylinder installation section
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
Fig. 5-3 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
575
Boom
(22.6) 0.5 (0.02) 1.0 1.5 732
A-A Boom foot L1 PL1
581 or less (0.04) (0.06) (28.8)
Upper frame
(22.9)
90
Boom cylinder
Boom cylinder (3.54) 0.6~1.0 2.0 2.5 185
B-B L2 PL2
(Head side) 96 (0.02~0.04) (0.08) (0.10) (7.28)
Upper frame Shim
(3.78)
adjust
80
Boom cylinder L3 ment
Boom cylinder (3.15) 0.6~2.0 2.5 3.0 597
C-C PL3
(Rod side) 399 (0.02~0.08) (0.10) (0.12) (23.5)
Boom L3'
(15.7)
105
Arm cylinder
Arm cylinder (4.13) 0.6~1.0 2.0 2.5 222
D-D L4 PL4
(Head side) 111 (0.02~0.04) (0.08) (0.10) (8.74)
Boom
(4.37)
5-5
5.2 ARM
5.2.1 ARM DIMENSIONAL DRAWING (SK125SR, SK135SR-2)

Fig. 5-4 ARM DIMENSIONAL DRAWING
2.38m (7ft-10in) ARM YY12B00433F1 Unit : mm (ft-in)

Code NAME DIMENSION Code NAME DIMENSION
C Arm length 2,380 (7'10") N Bracket inner width 110 (4.33")
Distance between pins of boss
D R625 (24.6") O Bracket inner width 91 (3.58")
and bracket
D1 I.D of boss ø95 (3.74") P Idler link dimension 514 (20.2")
D2 I.D of boss ø75 (2.95") Q Bucket link dimension 492 (19.4")
Height between pins of boss and
D4 I.D of boss ø85 (3.35") R 20 (0.79")
center
E R1,862.8 (6'1") d1 Pin dia. ø65 (2.56")
and bracket
F R350 (13.8") d2 Pin dia. ø60 (2.36")
and boss
G 462.3 (18.2") d3 Pin dia. ø70 (2.76")
bracket
H 200 (7.9") d4 Pin dia. ø70 (2.76")
bracket
K Arm top end boss width 249 (9.8") d5 Pin dia. ø60 (2.36")
L Arm link section boss width 254 (10.0")
M Boss width 269 (10.6")
5-6
5.2.2 ARM MAINTENANCE STANDARD (SK125SR, SK135SR-2)

(1) Clearance of pin and bushing
E F
D, D'
B
C
G
Fig. 5-5 Clearance of pin and bushing on arm section
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
+0.267 +0.327
(+0.0105) (+0.0129)
A Arm point
–0.020 +0.090 +0.110
ø65 (-0.0008) (+0.0035) (+0.0043)
YY12B01427P1
(2.5591) –0.060 +0.225 +0.258
Bucket link (-0.0024) (+0.0089) (+0.0102)
B
(Bucket side) +0.089 +0.105
(+0.0035) (+0.0041)
+0.203 +0.243
Idler link
ø60 (+0.0080) (+0.0096)
C (Connected part YY12B01428P1
(2.3622) +0.093 +0.093
of arm) (+0.0037) (+0.0037)
0 +0.198 +0.238
Bucket link (0) (+0.0078) (+0.0094)
D
(Idler link side) –0.040 +0.085 +0.085
Replace
ø65 (-0.0016) (+0.0033) (+0.0033) 1.2 2.0
YY12B01429P1 bushing
(2.5591) +0.198 +0.238 (0.05) (0.008)
or pin
Bucket cylinder (+0.0078) (+0.0094)
D'
(Rod side) +0.085 +0.085
(+0.0033) (+0.0033)
+0.195 +0.215
Bucket cylinder ø60 (+0.0077) (+0.0085)
E YY12B01436P1
(Head side) (2.3622) +0.081 +0.061
(+0.0032) (+0.0024)
+0.020 +0.231 +0.251
Arm cylinder (+0.0008) (+0.0091) (+0.0085)
F YY12B01435P1
(Rod side) –0.020 +0.091 +0.071
ø70 (-0.0008) (+0.0036) (+0.0024)
(2.7559) +0.226 +0.246
Arm foot
(+0.0089) (+0.0097)
G (Connected part YY12B01432P1
+0.085 +0.065
of boom)
(+0.0033) (+0.0026)
5-7
(2) Clearance of arm and cylinder installing sections in thrust direction
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X L3 PL5
X L6
X L5
PL1 PL3 PL6

SECTION A-A SECTION C-C SECTION E-E SECTION F-F
PL7
X2 L2 X7 L7
X L4
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D
SECTION G-G
Fig. 5-6 Clearance of arm and cylinder installing sections in thrust direction
BUSHING
BUSHING
BUSHING
BUSHING
BUSHING
BUSHING
Fig. 5-7 Exploded view of arm top bushing
5-8
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
294
Arm
(11.6)
A-A Arm point L1 PL1
251
Bucket
(9.88) 0.6~1.0 1.2 391
250 (0.024~0.04) (0.05) (15.4)
Link side
(9.84)
B-B Bucket link L2 PL2
252
Bucket
(9.92)
254 0.5 2.0
Idler link Arm 1.0
C-C L3 (10.0) (0.02) (0.08) PL3
(Arm connection) (0.04)
Link side - or less
Bucket link Rod side -
D-D (Idler link L4 254 336
Link side
connection) (10.0) (13.2)
0.6~1.0 1.2 Shim
85 PL4
Rod side (0.024~0.04) (0.05) adjust
Bucket link (3.35)
D’-D’ L4’ -ment
(Rod side) 90
Link side
(3.54)
85
Head side
Bucket cylinder (3.35) 190
E-E L5 PL5
(Head side) 91 (7.48)
Arm
(3.58) 0.6~2.0 2.0 2.5
105 (0.024~0.08) (0.08) (0.10)
Rod side
Arm cylinder (4.13) 222
F-F L6 PL6
(Rod side) 110 (8.74)
Arm
(4.33)
269
Arm 0.5
(10.59) 1.0 2.0 399
G-G Arm foot L7 (0.02) PL7
274 (0.04) (0.08) (15.7)
Boom or less
(10.79)
5-9
5.3 BUCKET
5.3.1 BUCKET DIMENSIONAL DRAWING (SK125SR, SK135SR-2)
(1) Hoe bucket
Fig. 5-8 Bucket dimensional drawing
No. NAME No. NAME

A Distance between pin and bracket G Inner width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of bracket Io Pitch between teeth
E Inner width of lug d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.
5.3.2 BUCKET DIMENSIONAL TABLE
Unit : mm (ft-in)
Type Normal digging
SK125SR SK135SR-2
0.24 0.31 0.38 [STD] [STD] 0.57 0.70
Capacity
(0.20) m3 (0.23) m3 (0.28) m3 0.45 0.50 (0.43) m3 (0.50) m3
(0.35) m3 (0.38) m3
Part No. YY61B00079F1 YY61B00080F1 YY61B00081F1 YY61B00075F1 YY61B00072F1 YY61B00082F1 YY61B00083F1
A R376 (14.8") ← ← ← ← ← ←
B R1,225 (4'0.23") ← ← ← ← ← ←
C 462 (18.2") 562 (22.1") 662 (26.1") 772 (30.4") 863 (34.0") 962 (37.9") 1,112 (3'7.8")
D 324 (12.8") ← ← ← ← ← ←
E 252 (9.9") ← ← ← ← ← ←
F 593 (23.3") 700 (27.6") 800 (31.5") 910 (35.8") 1,000 (3'3.37") 1,100 (3'3.7") —
G 383 (15.1") 439 (17.3") 539 (21.2") 649 (25.6") 739 (29.1") 839 (33.0") 989 (39.0")
H 500 (19.7") 600 (23.6") 700 (27.6") 772 (30.4") 903 (35.6") 1,000 (3'3.37") 1,150 (3'9.3")
I 187 (7.4") 237 (9.3") 191 (7.5") 228 (9.0") 192.5 (7.6") 218.5 (8.6") 256 (10.1")
IO 187 (7.4") 237 (9.3") 191 (7.5") 228 (9.0") 192.5 (7.6") 218.5 (8.6") 256 (10.1")
d1 ø 80 (3.2") ← ← ← ← ← ←
d2 ø 65 (2.6") ← ← ← ← ← ←
Bucket capacity : SAE heaped (Stuck)
5-10
5.3.3 LUG SECTION DIMENSIONAL DRAWING
X B
J
A
Roughness of counterbore bottom X

surface is to be 100S or less in
range of diameter 39mm. BOSS
And M16 bolt is to be installed. (3 places) M
28 2418P26832
(1.10) Apply rust prevention oil
19
(0.748)
3-G
B
F
N
D E
H
BOSS
SHIM 1 Insert this pin flush with surface YY61B01005P1
Five shims are installed
at shipping SECTION X-X
DETAIL B
Fig. 5-9 Dimension of lug section
Unit : mm (ft-in)
Lug plate thickness
Screw hole P.C.D

Boss outer dia.
Boss outer dia.

Spring pin dia.
Pin hole dia.
Boss width.
Boss width.
Capacity of
Screw dia.
bucket
Hole dia.
Type of Part No. of

bucket (SAE heaped) bucket
m3
A B D E F G H J M N
0.24 (0.20) YY61B00079F1
0.31 (0.23) YY61B00080F1
0.38 (0.28) YY61B00081F1
SK125SR [STD]
Normal 65 22 80 10 146 22 138 36 115
digging 0.45 (0.35) YY61B00075F1 (2.56") (0.866") (3.14") (0.394") (5.75") M14 (0.866") (5.43") (1.42") (4.53")
SK135SR-2 [STD]
0.50 (0.38) YY61B00072F1
0.57 (0.43) YY61B00082F1
0.70 (0.50) YY61B00083F1
Bucket capacity : SAE heaped (Struck)
5-11
5.3.4 BOSS SECTION DIMENSIONAL DRAWING
H 5
(0.197")
oG
oC
oD
oA
oB
15 (0.591")
DETAIL A
E
Fig. 5-10 Dimension of boss section
Unit : mm (ft-in)
Capacity of
Type of Part No. of Part No.
bucket øA øB øC øD E F øG H I
bucket bucket of boss
m3
0.24 (0.20) YY61B00079F1
101.6 69 94.5 99.5 15 30 15 13 2.5
0.31 (0.23) YY61B00080F1 YY61B01005P1
(4.0") (2.72") (3.72") (3.92") (0.591") (1.18") (0.591") (0.512") (0.098")
0.38 (0.28) YY61B00081F1
SK125SR [STD]
Normal
0.45 (0.35) YY61B00075F1
digging
SK135SR-2 [STD] 101.6 69 94.5 99.5 19 34 15 13 2.5
2418P26832
0.50 (0.38) YY61B00072F1 (4.0") (2.72") (3.72") (3.92") (0.748") (1.34") (0.591") (0.512") (0.098")
0.57 (0.43) YY61B00082F1
0.70 (0.50) YY61B00083F1
Bucket capacity : SAE heaped (Struck)
5-12
5.4 LOWER PARTS

5.4.1 CRAWLER
5.4.1.1 CONSTRUCTION (SK125SR, SK135SR-2)
FLAT SHOE
2
1-6
1-1
1-8
1-4
1-3
1-8 TRAIANGLE SHOE
2 GROUSER SHOE 7
1-7 2
1-1
9
1-5 7
1-2 1-7 7
1-2
Fig. 5-11 Track link assy and shoe plate
SK125SR / SK135SR-2 SK135SRLC-2

YY60D00028F1 YY60D00029F1
Shoe assy
Shoe assy
YY60D00028F2 YY60D00029F2
YY60D00028F3 YY60D00029F3
YY60D00028F4 YY60D00029F4
YY60D00028F5 YY60D00029F5
No. NAME Q'TY No. NAME Q'TY
.
1 LINK ASSY YY62D00015F1 1 1 1 1 1 .
1 LINK ASSY YY62D00015F2 1 1 1 1 1
1-1 .. TRACK LINK R 44 44 44 44 44 1-1 .. TRACK LINK R 46 46 46 46 46
1-2 .. TRACK LINK L 44 44 44 44 44 1-2 .. TRACK LINK L 46 46 46 46 46
1-3 .. BUSHING 43 43 43 43 43 1-3 .. BUSHING 45 45 45 45 45
1-4 .. PIN 43 43 43 43 43 1-4 .. PIN 45 45 45 45 45
1-5 .. MASTER BUSHING 1 1 1 1 1 1-5 .. MASTER BUSHING 1 1 1 1 1
1-6 .. MASTER PIN 1 1 1 1 1 1-6 .. MASTER PIN 1 1 1 1 1
1-7 .. COLLAR 2 2 2 2 2 1-7 .. COLLAR 2 2 2 2 2
1-8 .. SEAL 86 86 86 86 86 1-8 .. SEAL 90 90 90 90 90
2 . SHOE 500mm 44 2 . SHOE 500mm 46
. SHOE 600mm 44 . SHOE 600mm 46
. SHOE 700mm 44 . SHOE 700mm 46
. SHOE 500mm 44 . SHOE 500mm 46
. SHOE 800mm 44 . SHOE 800mm 46
7 . BOLT YY60D01004P1 176 176 176 7 . BOLT YY60D01004P1 184 184 184
. BOLT YY60D01008P1 176 176 . BOLT YY60D01008P1 184 184
9 . NUT LP60D01002P1 176 176 176 176 176 9 . NUT LP60D01002P1 184 184 184 184 184
5-13
5.4.1.2 MAINTENANCE STANDARD (SK125SR, SK135SR-2)
F E
D D G
B
Fig. 5-12
Unit : mm (in)
REPAIRAB SERVICE
No. ITEM STANDARD VALUE REMEDY
LE LEVEL LIMIT
A Link pitch 171.45 ± 0.1 (6.750 ± 0.0039) 175 (6.89) 179 (7.05) Replace the link
B O.D. of bushing ø 50.65 ± 0.05 (1.994 ± 0.002) ø 47 (1.85) ø 45 (1.77) assy if the service
C Height of link 89 ± 0.3 (3.504 ± 0.012) 84 (3.31) 82 (3.23) limit is exceeded
Basic
Tolerance Fit Fit
dimension
Interference between bushing + 0.11
D Interference
and link ø 50.67 (+0.004) Interference
Shaft 0.05
(1.995) + 0.05 0
(0.0020) Replace
(+0.002)
+ 0.1
Interference
Interference between track pin ø 33.50 (+0.004) Interference
E Shaft 0.05
and link (1.319) - 0.05 0
(0.0020)
(-0.002)
+ 0.03
Interference
Interference between master ø 33.30 (+0.001) Interference
F Shaft 0.05 Replace Link
pin and link (1.311) + 0.088 0
(0.0020)
(+0.003)
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 412 ± 39 N•m (304 ± 28.8 lbf•ft) Reassembly
5.4.1.3 TOOLS AND JIGS

(1) Tightening tools
Unit : mm (in)
NAME OPPOSING FLATS
24 (0.945)
Socket
(2) Jig
NAME SHAPE
Master pin fixing jig for iron

crawler
5-14
5.4.2 UPPER ROLLER
5.4.2.1 UPPER ROLLER ASSY (SK125SR, SK135SR-2)
ASSY YY64D00004F1 (LC) (01)
No. YY64D00016F1 (STD) (01)
ITEM NAME Q'ty REMARKS

1 ROLLER ASSY 2 4 YY64D01002F1
CAPSCREW (SEMS
2 2 4 M20×P2.5×110
SCREW)
3 NUT 2 4
4 WASHER 4 8
5.4.2.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
3 4 3 4
(2) Removing upper roller (1)
1) Remove nuts on support tightening section, and 1
also remove capscrew (2) M20×110. 1
: 30 mm 2
2
(STD SPEC.) (LC SPEC.)
Fig. 5-13 Removing upper roller
5.4.2.3 INSTALLING
Installing is done in the reverse order of removing.
(1) Inspection
Before reassembling, check it that it rotates smooth COUNTER-
manually and for leak. SINKING
(2) Installing upper roller (1)

1) To install the upper roller, turn up socket bolts (2)
toward the center of machine.
2) Insert it until collar comes in contact with support.
3) Fit it directing the countersinking mark of shaft

CENTER OF MACHINE
end upward.
4) Apply Loctite #262 on capscrew M20×110, and

tighten it to the specified torque.
: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
2 1 3,4
Fig. 5-14 Installing upper roller
5-15
5.4.2.4 MAINTENANCE STANDARD
2(0.079")
D
A
E
F
B C
Fig. 5-15 Upper roller assy
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A Dia. ø 99 (3.9) ø 94 (3.7) ø 90.5 (3.56)
B Width 140 (5.51) — —
C Installing length 60 (2.36) — — Replace
D Shaft dia. ø 40 (1.576 ) — —

Basic
Tolerance Fit Fit
dimension
Clearance between - 0.025
E
shaft and bushing (-0.00098) Clearance Clearance
ø 38 (1.496) Shaft
- 0.050 0.7 (0.028) 1.0 (0.039) Replace bushing
(-0.0020)
+ 0.025
Interference between Interference Clearance
F ø 42 (1.654) Hole (+0.00098)
roller and bushing 0 0.01 (0.0004)
0
Tightening torque of
G 65.7 N•m (48 lbf•ft)
socket bolt
Oil Engine oil API grade CD #30, 20cc (1.22cu•in) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly
5-16
5.4.3 LOWER ROLLER
5.4.3.1 LOWER ROLLER ASSY (SK125SR, SK135SR-2)
ROLLER STD YY64D00026F1

ASSY LC(HD) YY64D00028F1
ITEM NAME Q'TY REMARKS
1 LOW ROLLER 14 12 YY64D00027F1
2 CAPSCREW 56 48 M16X75 (P=2.0)
2
Apply Loctite #262 1
T=279N.m (206 lbf.ft)
Fig. 5-16 Lower roller assy and track guide
5.4.3.2 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. SAFETY BLOCK
(WOOD BLOCK)
(2) Remove lower roller
Remove capscrews (2) and remove lower roller (1). Fig. 5-17 Preparation for removal
: 24 mm,
Weight of lower roller : Approx. 25kg (55 lbs)
Fig. 5-18 Installing lower roller
(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.
: 24 mm,
Tightening torque : 279N•m (206 lbf•ft)
(2) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
: 19 mm,
Tightening torque : 59N•m (43 lbf•ft)
5-17
5.4.3.4 MAINTENANCE STANDARD (SK125SR, SK135SR-2)
C C H
-0.5
+
ce 2.5
Clearan 0.020)
(0.09 8
D
B
E
A
Fig. 5-19 Lower roller (Track roller)
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A O.D. of flange ø 170 (6.70) — — Reinforcement weld,
B Tread dia. ø 140 (5.51) ø 132 (5.20) ø 126 (4.96) repair or replace
C Flange width 19 (0.748) 14 (0.551) 11 (0.433)
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 50 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft Replace bushing
(1.96850) - 0.090 0.7 (0.276) 1.0 (0.394)
(-0.00354)
+ 0.030
Interference between ø 57 Interference Clearance
E Hole (+0.00118)
roller and bushing (2.24409) 0 0.01 (0.0004)
0
F Oil Engine oil API grade CD #30, 150cc (9.2 cu•in) Refill
Execute air leak test at 0.2MPa (28psi)
H Plug (8)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
5-18
5.4.4 IDLER ASSY
IDLER ASSY YY52D00007F1 1

No. NAME Q'TY REMARKS 8
1 YY52D00006P1 4
1 IDLER 6
2 SHAFT 1 5
3 BUSHING 2
4 COLLAR 2 LP52D01009P1
5 PIN 2
7
6 FLOATING SEAL 2 2
7 O-RING 2 1A G55 3
8 PLUG 2 PT1/8
Fig. 5-20 Idler assy
132 1.5(5.20 0.059)

C
F
D
E
B
A
Fig. 5-21 Front idler
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A Dia. of idler projection ø 496 (19.5) — —
B Tread dia. ø 456 (18.0) ø 450 (17.7) ø 448 (17.6) Replace
C Flange width 68 ± 1 (2.677±0.04) 63 (2.48) 60 (2.36)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 60 (-0.00118) Clearance Clearance
Shaft Replace
(2.36220) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
- 0.03 Clearance
Interference between idler and ø 64 Interference
E Hole (-0.00118) 0.01
bushing (2.51969) 0
0 (0.0004)
F Oil Engine oil API grade CD #30, 200cc (12.2cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble
5-19
5.4.5 IDLER ADJUSTER ASSY
IDLER ADJUSTER ASSY YY54D00003F1 2 4 3 5 1 8 7 6 9
No. NAME Q'TY REMARKS

1 GREASE CYLINDER 1
2 BRACKET 1
3 NUT 1
4 SPRING PIN 1 6X63
5 SPRING 1
10 Apply grease to bleed air.
6 PISTON 1
7 O-RING 1 1B G90
Fig. 5-22 Idler adjuster assy
8 U-PACKING 1
9 PIN 2
10 COVER 1
No. ITEM STANDARD VALUE

A Installed length of spring 354.8mm (14.0 in)
B Free length of spring Approx. 427mm 16.8 in)
C Stroke 39.4mm (1.55in)
D Set length 686mm (27.0in)
E Outside view of piston Nor scoring and rusting
Tightening torque of
F 59N•m (43 lbf•ft)
grease nipple
X E
aa F
C Apply grease to bleed air
A,B
D
X
INSTALL A SPRING WHOSE STARTING POINT AT BRACKET SIDE TO BE 35 DEGREE.
U-PACKING
8 O-RING 35
7 BRACKET
DETAIL aa
SECTION XX
Fig. 5-23 Idler adjuster assy
5-20
5.4.6 SPROCKET
5.4.6.1 MAINTENANCE STANDARD (YY51D01006P1) (SK125SR, SK135SR-2)
86.69mm NUMBER OF
PITCH 21
(3.4130in) TEETH
SPECIFICATION
ø50.67mm 581.669
ROLLER DIA. PITCH DIA.
(1.9950in) (22.9in)
Unit : mm (in)
171.45 -+1 (6.750 +-0.039 ) B

86.69 62 +
-0.5
)
(3.4130 8.4(0.3307)
97)
(0.
(0.1 5
R5 7)
R
19
R
..55 39) R225
2255(1.00 (1.00 .5
R 39
)
R5
R5 97) (0.1
(0.1 97)
R5 .197
(0.1 R5
C
(0
97)
(22.9 81.669
)
34
(1.3386)
)
D5
P.C.
Fig. 5-24 Sprocket
Unit:mm (in)
REPAIRABLE SERVICE
No. NAME STANDARD VALUE REMEDY
LEVEL LIMIT
ø 594±3 Reinforcement weld,
A O.D. of sprocket ø 586 (23.1) ø 584 (23.0)
(23.4±0.118) repair or replace.
B Width of sprocket teeth 60 (2.36 ) 54 (2.13) 52 (2.05) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 510 (20.1) ø 502 (19.8) ø 500 (19.7)
repair or replace.
5.4.6.2 TOOLS AND JIGS

(1) Tools
Unit : mm
NAME OPPOSING FLATS
24
Socket
5-21
5.5 REMOVING AND INSTALLING PROCEDURE OF ASSY

(RELEVANT UPPER FRAME)
5.5.1 OPERATOR SEAT (SK125SR, SK135SR-2)
5.5.1.1 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.
B2
4) Incline the reclining seat as forward as possible.
C1
(2) Remove operator’s seat. (Include upper rail.)
C2
1) With the above-mentioned condition, remove C1
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.
: 6 mm
2) Remove the operator’s seat. [about 28kg (62 1
lbs).] 7
Carry out the following operations as required. 13
10
3) Remove seat belt (C1).
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (7).
Fig. 5-25 Disassembling and Assembling seat
Install it in reverse procedure of removing according to A4
the tightening torque table.
A5
Allen
Tightening position wrench Tightening torque
HEX (mm) N·m (lbf·ft)
A6
Capscrew (B2) 6 23.5 (17.3) A1
Sems bolt (C2) 17 46.1 (34) A3 A2
Capscrew (A5) 13 23 (17)
Sems bolt (A6) 13 23 (17) A5
Reference : Movement on rail

Upper rail …… Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm (0.26in)]
Lower rail …… Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm (0.19in)]
Amount of adjustment of seat height Fig. 5-26 Disassembling and Assembling armrest
[Up; 23mm (0.07in), down; 37mm (0.16in)]
Suspension stroke
[Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]
5-22
5.5.2 CAB (SK125SR, SK135SR-2)
5.5.2.1 REMOVAL
(1) Remove floor mat.

(2) Remove cover (1A-2)

Lift cover (1A-2) 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).
(4) Remove the harness connector (See Chapter 23)
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. 5-27 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.
A3
(6) Remove the right panel of cab A14
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6×30 and 1 sems bolt (A39) M6×16. And right
panels (A4) and (A4-3) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed A40 A22
with 3 clows and 2 clips) A29

3) Unfix 3 harness clips of inside on right panel (A4-
3). And free the harnesses connected to key A40
switch. A29
4) With harnesses are connected condition, install
key switch cover (A3) to bracket (A1) of rear cab
temporally. (See Fig. 5-29) A39 A4
A4-3
5) Disconnect harness connectors of work light
switch on right panel (A4), air conditioner panel A22
and cigarette lighter, and remove right panel (A4)
and (A4-3). (See Chapter 23)
6) Loosen sems bolts (A22) M6×16 and (A23)
M6×45 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver A5-2
A23
Fig. 5-28 Disassembly and assembly of right panels

(A4-3), (A3) and (A5-2)
5-23
FUSE & A3
RELAY BOX Front
ASSY
A1
Fig. 5-29 Move switch cover assy

(7) Remove cab attaching bolt
1) 5 capscrews (A1) M12×65 and 1 capscrew (A3)
B4
M12×30. (Mark )
2) 4 nuts (B3) M16 (Mark )
(8) Slinging cab
1) Remove two plastic plugs at the front of the
ceiling of the cab. Then place a wire sling with A3
eye rings and a hook around the cab, as shown
in Fig. 5-31.
A1
2) Then lift up slowly avoiding interference with
surroundings.
Fig. 5-30 Removing and installing cab mounting
Wire with hook ; bolts.
Length 1.5m (4ft 11in)×Dia. 8mm
(0.315in)×3pcs.
Weight of cab ; Approx. 250kg (550 lbs)
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(mm)
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 80 (66)
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)
Fig. 5-31 Slinging cab
5-24
5.5.3 BATTERY (SK125SR, SK135SR-2)
5.5.3.1 REMOVING
(1) Open panel assy (1).
1) Unlock with starter switch key.
2) Open panel assy (1).
3) Keep panel assy open with stay.
(2) Remove battery cable
1) Remove cable (A4) [between the earth and
battery (–)].
(Always remove (-) terminal first and install it at
last.)
2) Remove cable (A2) [between battery (+) and (-)] 1
3) Remove cable (A3) [between battery (+) and Fig. 5-32 Opening and closing of panel assy (1)
battery relay]
A2
: 13 mm
A3
Follow the battery removal order.

Start removing battery from grounding side, and finish
attaching to grounding side. If this order is missed,
short-circuits may occur. A4
(3) Remove battery (B1) Fig. 5-33 Removing and installing battery cable
1) Loosen nut (A6) M10 and remove cover (A1) and
spacer (A5).
2) Loosen 2 capscrews (A3) M12×200.
: 17 mm
3) Remove plate (A2).
4) Remove battery (B1).
5.5.3.2 INSTALL
(1) Install the battery in the reverse order of removing. A1 A6
Hold down plate (A2) against battery (B1), and
tighten capscrew (A3).
: 19 mm,
Tightening torque : 10.8N•m (8.0 lbf•ft) A5
(2) Installing grounding cable A2

Install grounding cable (A4) last. Especially care A3
must be taken that the grounding face is free from B1
painting, rust, etc.
: 13 mm
Fig. 5-34 Removing battery
5-25
5.5.4 GUARD (SK125SR, SK135SR-2)

(1) Remove guard in the following procedure
Remove the guards in the order of (H1) → (H3) → (H2) → (5) → (Set of 3) → (Set of 1) → (20) → (22) → (21)
→ (A1) → (B1) → (33),(34) → (C4) → (C1) → (C3) → (D1) → (C2) → (A12) → (29) → (27) → (E1,E2) → (36)
→ (F1).
34 D1
A1 33
36
C3 H3
E2
H1
5
B1
C2
C4 H2
C1 E1
Fig. 5-35 Arrangement of guard assy
5.5.4.2 REMOVE GUARD

(1) Remove bonnet assy (H1)
H1
1) Open bonnet (H1).
2) Remove snap pin (13) from head side of gas
cylinder (11) which is installed reverse side of
bonnet. And remove gas cylinder from bonnet
(H1). (See Fig. 5-39)
3) Remove 2 sems bolts (H5) M12X25.
4) Remove bonnet (H1).
H5
: 19 mm
Weight : 28kg (62 lbs)
Fig. 5-36 Removing bonnet assy (H1)

(2) Remove bonnet assy (H3)
H10
1) Remove 1 sems bolt (H9) M12X30.
2) Remove 2 sems bolts (H10) M12×25.
3) Remove bonnet assy (H3) together with duct H9
assy (H3-2). H3
: 19 mm
H10
5-26
(3) Remove bonnet assy (H2) H5

1) Remove 3 sems bolts (H5) M12×25. H2
2) Remove bonnet assy (H2).

H5
: 19 mm

(4) Remove bracket (5)
1) Remove 2 capscrews (16) M12×30.
2) Remove bracket (5). 16 10
: 19 mm
13 5
14
13
11
13
Fig. 5-39 Removing bracket (5)
(5) Remove bracket assy (3)
3
1) Remove 3 sems bolts (17) M12×25.
2) Remove bracket assy (3). 7
1
: 19 mm
5
8
17
17
4
2
17 3 9
Fig. 5-40 Removing bracket assy (3)
5-27
(6) Remove cover assy (1) (2) (4) (9), brackt assy (7)
and bracket (8). 17 17
2 1
1) Remove all tightened sems bolts (17) M12X25, 7
X
and remove cover assy, guard assy and bracket 7-2
22
in order of following. X
: 19 mm 17 17
4 17 17
a. Remove cover assy (2).
17 17 17 21
b. Remove cover assy (1).
c. Remove guard assy (4). 8 17
17
20
d. Remove cover assy (9).
e. Remove bracket (7).
9
f. Remove bracket (8).
(7) Removing bracket (20), (22) and cover assy (21)
1) Loosen 2 sems bolts (17) M12X25 which fasten
brackets (20) (22). And remove bracket (20),
(22) and cover assy (21) as assembled parts.
: 19 mm
Fig. 5-41 Removing cover assy (1),(2),(4),(9),

bracket assy (7) and bracket (8).
(8) Removing cover assy (A1), (A3), (A4)
1) Loosen all fastened sems bolts (A2) M12X20,
and remove cover assy in the following order.
A1
A2
: 19 mm
a. Remove cover assy (A1).
b. Remove covers (A3) and (A4) as assembled
parts.
A3 A2
A5
A2
A4
Fig. 5-42 Removing cover assy (A1),(A3),(A4)
5-28
(9) Remove panel assy (B1).

B3
B3
1) Remove 6 sems bolts (B3) M12×25. B3
2) Remove panel assy (B1). B1
: 19 mm
(10)Remove guard assy (33) and (34).
39
1) Remove 3 capscrews (39) M12×20.
2) Remove 3 sems bolts (17) M12×25. 33
39
3) Remove guard assy (33).
4) Remove 3capscrews (25) M12×20. 17
5) Remove guard assy (34).
: 19 mm 34
Fig. 5-43 Removing panel assy (B1) and guard assy

(33),(34)
(11)Remove cover assy (C4) and panel assy (C1) C15
C4
1) Remove 3 sems bolts (C15) M8×25.
2) Remove cover assy (C4). C8
C15
C1
3) Remove 2 sems bolts (C8) M12×30
C8
4) Remove a sems bolt (C14) M12×35.
6) Remove panel assy (C1).
: 13 mm, 19 mm
C14
C9
Fig. 5-44 Removing cover assy (C4) and panel assy

(C1)
(12)Remove fuel tank side panel assy (C3)
C3
C10
C10
Weight : 11.5kg (25 lbs)
: 19 mm
C9
Fig. 5-45 Removing panel assy (C3)
5-29
(13)Remove stay (D1)

D1
1) Remove 4 capscrews (D3) M12×55, (D4)
M12×75, (D8) M10×65 and (D9) M16×85. D9
2) Remove stay (D1).
: 17 mm, 19 mm, 24 mm
D8
D4
D3
Fig. 5-46 Removing stay (D1)
(14)Remove panel assy (C2) and bracket (32)
31 17
1) Remove 2 nuts (C13) M12.
Weight : 16kg (35 lbs) 32
17
3) Remove 2 sems bolts (17) M12×25. 18
28
4) Remove bracket (32) together with bracket (31). 17 17 C13
29
Weight : 10kg (22 lbs) C2
17
: 19 mm
16 27
(15)Remove box (29) and bracket assy (27)

1) Remove 2 sems bolts (17) M12×25. 18 16
17
2) Remove box (29).
3) Remove a sems bolt (17) M12×25. Fig. 5-47 Removing panel assy (C2), box (29),
4) Remove bracket assy (27) and bracket (28) as bracket assy (27)
assembled parts.
: 19 mm
5-30
(16)Remove cover assy (E1), (E2) E1

1) Remove 2 sems bolts (E4) M12×25 for attaching L/H
cover assy (E1), (E2).
2) Remove cover assy (E1). 4
3) Remove cover assy (E2).
: 19 mm 4
E2
R/H
E2
4
E1
Fig. 5-48 Removing cover assy (E1), (E2)
(17)Remove cover assy (36) 17
36
2) Remove cover assy (36).
: 19 mm
17
Fig. 5-49 Removing cover assy (36)
5-31
(18)Duct (F1) removal G12

1) Preparation
a. Remove counterweight.
G15
b. Remove hydraulic oil hose which connects to
top of radiator oil cooler.
2) Push filter assemblies (G15) in the direction of
24
arrow, and remove them.
3) Remove air cleaner hose (2) (7) and air cleaner
assy (1).
4) Remove battery relay from battery cover. In this
time, disconnect battery relay which has
remained harness connection with the battery
relay.
5) Remove clip at side of radiator cap and remove
hose (G12) of sub tank.
6) Remove a sems bolt (F9) M12×30, and remove
a capscrew (9) M12×30.
7) Remove 6 capscrews (F12) M8×20. F12
8) Sling duct (F1) to hoist and remove the duct.
Weight : 40kg (88 lbs) F1
: 13 mm, 19 mm
F9
F11
F12
Fig. 5-50 Removing duct assy (F1)
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
Unit : N.m (lbf.ft)

Size Capscrew Sems bolt
M8 35.3 (26) 23 (17)
M10 46.5 (34) 46.5 (34)
M12 121 (90) 80 (59)
5-32
5.5.5 FUEL TANK (SK125SR, SK135SR-2)

(1) Draining fuel. (See Fig. 5-52)
1) Unlock cap (B1) with a starter key and open it.
2) Loosen valve (A8) under the tank.
3) Draining fuel
Capacity of tank : 200L (53gal)
(2) Remove cover assy (36) and guard assy (34).
(See Fig. 5-43)
(3) Remove panel assy (C3). (See Fig. 5-45)
(4) Remove under cover (1),(2).
(5) Remove the connector for fuel level sensor (A3).
(See Fig. 5-52)
B
(6) Remove fuel hose A
1) Loosen clip (20),(32) and draw out hoses (11)

and (12). 24
11
20 12
2) Put in plugs that match the hose bore. 24
(7) Fuel filter assy removal 33 17
16 32
DETAIL A
DETAIL B
Fig. 5-51 Removing fuel hose (11), (12) and
fuel filter assy
5.5.5.2 REMOVAL
(1) Remove 4 capscrews (A2) M16×35. B1
(2) Remove 2 capscrews (A7) M16×55.
A2
: 24 mm
B6
(3) Hook the wire to the lifting eye on the fuel tank assy
(B6) and remove the fuel tank.
(4) Remove shim (A14).
Record the shim locations. A3

A5
A8 A14
A7
Fig. 5-52 Removing fuel tank
5-33
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A2) M16×35
Tank attaching bolt (A7) M16×55
: 24 mm, Apply Loctite #262

Tightening torque : 191 N•m (140 lbf•ft)
If the gap (looseness) between tank mount and frame

exceeds 1mm (0.04inch), adjust the gap with shim
(A14) and tighten capscrew (A2) to install the tank.
(2) Tightening torque

No. Name Q'ty N.m (lbf.ft) No. Name Q'ty N.m (lbf.ft)
A2 Capscrew 4 191 (140) A7 Capscrew 2 191 (140)
A5 Machine screw 5 1.96 (1.45) A8 Stop valve 1 34 (25)
When the stop valves (A8) was loosened, replace the seal tape with new one. On the occasion of this work, prevent
entry of dust.
5-34
5.6 WEIGHT OF COMPONENTS

5.6.1 SK125SR, SK135SR-2
Unit ; kg (lb)
Model
SK125SR SK135SR-2 SK135SRLC-2
Item
13,000 13,800 13,900
Fully equipped weight
(28,600) (30,420) (30,640)
1. Upper frame assy (Assembly of following :) 6,710 (14,789) 7,298 (16,085) ←
1.1 Upper frame 1,385 (3,053) 1,400 (3,086) ←
1.2 Counter weight 2,840 (6,259) 3,400 (7,494) ←
1.3 Cab 266 (587) ← ←
1.4 Engine * 395 (871) ← ←
1.5 Hydraulic oil tank * 112 (247) ← ←
1.6 Fuel tank * 89 (196) ← ←
1.7 Slewing motor (including reduction unit) * 106 (234) ← ←
1.8 Control valve * 158 (348) ← ←
1.9 Boom cylinder * 96 (212) × 2 ← ←
1.10 Pin (for mounting boom) 61 (134) ← ←
1.11 Pump * 85 (187) ← ←
1.12 Radiator (including intercooler) * 77 (170) ← ←
2. Lower frame assy (Assembly of following :) 4,031 (8,884) ← 4,224 (9,310)
2.1 Lower frame 1,411 (31,10) ← 1,471 (3,242)
2.2 Slewing bearing 150 (330) ← ←
2.3 Travel motor (including reduction unit) * 145 (320) × 2 ← ←
2.4 Upper roller 9 (20) ← 9 (20) × 2
2.5 Lower roller 25 (55) × 12 ← 25 (55) × 14
2.6 Front idler 74 (163) × 2 ← ←
2.7 Idler adjuster 58 (128) × 2 ← ←
2.8 Sprocket 40 (88) × 2 ← ←
2.9 Swivel joint * 24 (53) ← ←
2.10 Track link with 500mm (19.7in) shoes assy (STD) 732 (1,613) × 2 ← 760 (1,675) × 2
Track link with 600mm (23.6in) shoes assy 872 (1,922) × 2 ← 912 (2,010) × 2
3. Attachment (Assembly of following :)
{4.68m (15ft-4in) Boom + 2.38m (7ft-10in) Arm + 0.45m3 (0.59cu•yd) Bucket} 1,962 (4,324) — —
{4.68m (15ft-4in) Boom + 2.38m (7ft-10in) Arm + 0.50m3 (0.65cu•yd) Bucket} — 2,126 (4,686) ←
3.1 Bucket assy (STD) 353 (778) 384 (846) ←
3.2 STD Arm assy (Assembly of following :) 600 (1,322) 628 (1,384) ←
3.2.1 STD Arm 369 (813) 397 (875) ←
3.2.2 Bucket cylinder 82 (180) ← ←
3.2.3 Idler link 30 (66) ← ←
3.2.4 Bucket link 42 (93) 64 (141) ←
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket) 46 (101) ← ←
3.3 Boom assy (Assembly of following :) 1,009 (2,224) 1,344 (2,962) ←
3.3.1 Boom 790 (1,741) ← ←
3.3.2 Arm cylinder 138 (304) ← ←
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 29 (64) ← ←
5-35
[MEMO]
5-36
6-1
6-2
6.1 CHECK-UP & MAINTENANCE

6.1.1 EVERYDAY CHECK-UP
A. DAILY INSPECTION
Before starting the engine, walk around the machine to check for any loose nuts and bolts, any oil, fuel or coolant
leakage, and the condition of attachment and hydraulic system.
Check for any looseness in the electrical wiring and for any accumulated material (leaves, dirt , etc.). Repair and
clean as necessary.
The deposit of combustible, fuel leakage and oil leakage in heated area around the engine, muffler and
battery may cause fire of machine. Check the area sufficiently, and if the abnormality is found, repair it or
contact our dealer/distributor.
1. Check the engine for any oil, fuel or coolant leakage.

Repair as required.
2. Check the area around the engine and radiator for any accumulated material and remove as required.
3. Check the hydraulic equipment, hydraulic oil tank, hoses, and joints for oil leakage, and repair as required.
4. Check the travel system, such as the crawler, idlers, and sprockets, for any damage or wear, and the bolts for
looseness.
5. Check the attachments, cylinders, linkages and hoses for any cracks, wear or looseness and repair as required.
6. Check the door, cover, steps and handrails for damage, and the bolts for looseness. Repair and tighten bolts as
required.
7. Verify that the gauges and the monitor panel (gauge cluster) function properly.
8. Check rear view mirror for abnormality, and if abnormality is found, repair it.
Clean the surface of mirror and adjust the angle so that the rear sight is visible from the operator seat.
9. Check seat belt and attaching metal for possible damage and if damaged, replace it with new one.
6-3
6.1.2 CHECKING BEFORE STARTING ENGINE

The following checkup should be performed once before the first engine startup in a day.
A. Checking Coolant Level for Shortage and Making Up
• Do not open radiator cap if not required.

Check coolant level of the reserve tank (1) when LOW ENG WATER
LEVEL
engine is cooled down.
• Never remove radiator cap when engine is hot. S
Allow engine to cool down before removing
radiator cap.
The coolant level check switch is provided on the upper

part of radiator upper tank.
When the engine is running and the engine switch is on,
if warning is displayed on the multi-display, loosen the
radiator cap and supply coolant to the neck of radiator.
(1) Open left rear cab door and check coolant level of
reserve tank (1). 2
(2) Open side door of radiator with starter key and

1
check that the coolant level is in the range of FULL
– LOW of reserve tank. If shorted, remove filler cap
(2) of reserve tank and supply to FULL level. FULL
(3) After supply, tighten the cap securely.
(4) When the reserve tank is empty, after checking it for LOW
oil leak check radiator coolant level for shortage,
and if shorted, first supply coolant to the engine and
then to the reserve tank.
(5) Close the side door on the left side face of machine
and lock it with starter key.
6-4
B. Checking Oil Level of Engine Oil Pan and Making Up
G F
Immediately after engine is stopped, there is a
possibility of getting burn with heated parts and
oil. Start working after the temperature is not
hot.
• Make sure the machine is on firm level when

checking engine oil level.
• Always make sure to check engine oil level
before starting the engine.
• Keep the engine to standstill for at least 30 H
minutes, when checking engine oil level after
working. L
(1) Release catch of bonnet, open engine hood on

the rear side of machine and lock it with stay.
(2) Pull out oil level gauge (G) and wipe oil with a
clean cloth.
(3) Insert oil level gauge (G) in oil pan fully.
(4) When the level is in the range of H – L of oil level
gauge (G) it is proper. If the level is insufficient
for L level, make up engine oil for the shortage
through oil filler cap (F).
If the oil is contaminated and deteriorated,
change it ahead of schedule without depending
on the periodic change interval.
For oil in use, refer to "LUBRICANT, FUEL &
COOLANT SPECIFICATIONS" in page 1-10.
(5) When the oil level is H level or higher, drains
excess engine oil through drain valve (P) and
check the oil level again.
(6) If the oil level is proper, insert level gauge (G) P
securely, close engine hood and lock it with
bonnet catch.
6-5
C. Checking Fuel Level and Making Up
• Use diesel fuel only and stop engine before

refilling.
1
• Do not overflow fuel while refilling. It may cause
damage to the fuel system and cause oil
spouting. Clean up all spilled fuel to prevent fire.
• Dispose of all hazardous waste in accordance
with government environmental laws and
regulations.
• It is possible to operate machine for 2 days (8 hours

a day) in general use when the tank is full. Be sure to
fill it up to the brim after the work in 2nd day was
finished. But do not supply with fuel to the level more
than necessary (to the top end of tank). There is a
possibility of overflowing because the fuel expands
as the outside air temperature rises.
• Use specified diesel oil for fuel.
This engine is equipped with electronic control high
pressure fuel injection system to obtain the features
like excellent fuel consumption and emission in clean
condition. This system requires the parts in high
precision and high lubricating ability. Therefore if low
viscosity fuel in low lubricating ability is used, the
durability may be notably lowered.
(1) Check fuel level with fuel gauge by turning starter

switch on. The fuel level is low when the fuel gauge
reads close to E point.
(2) Stop engine with starter key, remove filler cap (1) of
fuel tank and make it up with fuel making sure of the
level.
When strainer is fitted to filler port, do not remove
the strainer for making up.
(3) When dirt is adhered on strainer (2), take out the
strainer and clean it with light oil or air gun, and then
fit it to filler port again.
(4) Refer to "LUBRICANT, FUEL & COOLANT
SPECIFICATIONS" in page 1-10.
• Fuel tank capacity: 200 L {53 gal}
2
(5) After refueling, tighten filler cap (1) securely.
6-6
D. Fuel Filter Drain

Draining water collected in fuel filter the fuel filter is used to separate water contaminated in fuel.
When warning "DRAIN WATER SEPA" is displayed, or water is collected in fuel tank, drain water.
(1) The fuel filter (1) is installed in front of fuel tank on
the right side of machine. DRAIN WATER SEPA
(2) Open side door on the right side. 4

(3) Put container for drain oil under drain hose (2). 1
(4) Loosen drain plug (3) and air bleed plug (4) and
3
drain water collected in fuel filter (1) in the
container.
2
(5) After draining, tighten drain plug (3) and air bleed
plug (4) securely.
(6) Lock side door on the right side.
E. Checking Radiator, Oil Cooler and Filter

(1) Using starter key, unlock side door on left side of
counterweight, and open it.
(2) By visual check, check mud, dust and leaves which
contaminate filter (1).
(3) When filter is contaminated heavily, refer to "" page
of Section 4 "" and clean these filters.
6-7
F. Check Hydraulic Oil Level
Hydraulic Oil Level Check Position
It is very danger because the inside of hydraulic

tank is heated and pressurized.
When removing filler port plug, stop engine and
remove breather top end cap (1) and then release
pressure from hydraulic oil tank by pressing the
valve head.
For safe operation on inclines, the hydraulic oil
level must be maintained between "Proper Level"
and "Upper Limit" mark.
Checking
(1) The hydraulic tank is installed on the right side. H
(2) Move the machine to firm level ground and set it in
G
the hydraulic oil level check position.
L
(3) Check the oil level through sight level gauge (G)
provided on the side of the hydraulic tank.
Hydraulic oil level should be between H and L.
Oil level varies depending on oil temperature.
Check the oil level referring to the followings.
• Before starting :
"L" level oil temp. 10~30°C (50~86°F)
• Normal operation :
"H" level oil temp. 50~80°C (122~176°F) 1
Avoid overfilling. It causes damages on hydraulic

equipment or oil spouting.
For make up procedure of hydraulic oil, refer to section

"" in page .
6-8
G. Checking Belt Tension
Rotating parts can cause injury.

Keep away from fan and belt when engine is
running.
Stop engine before servicing.
Check the fan and alternator belt for insufficient

tension, wear, and damage. Insufficient belt tension
may cause battery charge failure, engine overheating,
or abnormal belt wear. If too much tension is applied to
the belt, the bearings or belt may be damaged
prematurely.
Apply a force of 98 N {22 lbf} to the center of belt
between pulleys, and measure the belt deflection. The
table below shows normal condition.
SK125SR, SK135SR-2
When
When
new belt Force
Belt inspected
replaced N {lbf}
mm (in)
mm (in)
Alternator, 4~6 7~9 98
Fan (0.16~0.24") (0.28~0.35") {22}
3~4 5~6 23
Air-conditioner
(0.12~0.16") (0.20~0.24") {5.2}
• When replace with new belt, there is a lack of initial

adaptability of the belt. Run the engine at idling
speed for about three or five minutes. After that,
adjust the belt tension again.
• New belts get complete initial elongation after being
run about two hours.
See the section "250 HOUR (3-MONTH) INSPECTION

& MAINTENANCE PROCEDURE" OPERATION
MANUAL for details on the inspection and adjustment
procedure for the belt.
6-9
6.2 LUBRICANT, FUEL & COOLANT SPECIFICATIONS

6.2.1 SK125SR, SK135SR-2
The following chart provides information on the specification of oils, grease, fuels and coolant to be used in various
climates and working conditions.
Climete Zone
Type of Capacities
Components -22 -4 14 32 50 68 86 104 F Specified Lubricant
Lubricant (When changed) -30 -20 -10 0 10 20 30 40 C
(KOBELCO BRAND)
98.5 Liters Long life hydraulic oil
ISO VG46
(26 Gal) KW5046 (20 L)
Hydraulic 140 Liters P/No. KAP2421R157D9
Hydraulic oil tank
oil (37 Gal) (KOBELCO BRAND)
Hydraulic Long life hydraulic oil
ISO VG32
system KW5032S (20 L)
P/No. KAP2421R157D7
[Total volume] (KOBELCO BRAND)
18.5 Liters
(4.9 Gal) JASODH-1
Engine oil SAE 10W-30
[H level] P/No. KAPYN01T01053D1
Engine oil pan JASO 17.5 Liters (20 L)
DH-1 (4.6 Gal)
[L level]
14.5 Liters SAE 15W-40 SAE 15W-40
(3.8 Gal)
Swing motor 1.65 Liter (KOBELCO BRAND)
reduction unit (0.4 Gal) A.P.I clssification for
Gear oil EXTREME GEAR OIL SAE #90
"service GL-4"
Travel motor 2.1 Liter X 2
P/No. KAPSPG90020
reduction unit (0.6 Gal X 2)
Swing motor reduction 500 g
(1.1 lbs) EP GREASE
unit (Housing)
Attachment pins 16 places EP GREASE
(KOBELCO BRAND)
Slewing ring gear 1 place EP GREASE
EP grease Extreme pressure
Track tension 2 places multipurpose
EP GREASE
Adjustment grease No.2*2
Operating lever As required EP GREASE
(Pilot valve)
8.2 kg
Swing gear EP GREASE
(18 lbs)
ASTM D-975 No.2

ASTM D-975
200 Liters Grade 2-D
Fuel tank Diesel fuel ASTM D-975 No.2
(53 Gal)
ASTM D-975
ASTM D-975 No.1
Grade 1-D
(KOBELCO BRAND)
8.0 L If commercial coolant
Engine is used, the mixing
Radiator Total
coolant 50% Mixture rate should conform
(Reserve tank) volume with the specified.*1
(Antifreeze) 16 L P/No. KAPLLC95-20
(20 L)
6-10
Handling method of long life hydraulic oil

When changing and replenishing hydraulic oil, make sure to use oil specified by KOBELCO.
The use of unspecified hydraulic oil or the use of mixed oil causes deterioration of oil resulting in shortening life of oil.
The above hydraulic oil change time is 5,000 hours.
Specified oil :
Maker : Shell
Brands : Shell Tellus Oil S46
Shell Tellus Oil ST32
Be sure to select hydraulic oil adaptable to the ambient temperature.
• When the oil leak and damage are found in the lower roller, upper roller and frond idler, contact our dealer/
distributor for repair.
• Use ASTM D-975 No.2 oil for fuel without fail.
This engine is equipped with electric control high pressure fuel injection system to obtain the features like
excellent fuel saving and emission in good condition. This system requires the parts in high precision and high
lubricating ability. Therefore if low viscosity fuel in low lubricating ability is used, the durability may be notably
lowered.
*2 : Cartridge part number KAPG0420D1 (400 g × 20). Pail can part number KAPG1601D1.
AVOID ANTIFREEZE/COOLANT FIRE HAZARD

Antifreeze/Coolant is flammable. Direct contact with hot surfaces of flames may cause the Antifreeze/
Coolant to burn. Repair leaks immediately and dispose of used Antifreeze/Coolant promptly and in
accordance with government environmental regulation.
*1 : L.L.C means "Long Life Coolant"

KOBELCO GENUINE ANTIFREEZE/COOLANT
The cooling system is filled long life coolant LLC which is KOBELCO Genuine Antifreeze/Coolant specified by
KOBELCO for this machine. KOBELCO Genuine Antifreeze/Coolant protects the cooling system from harmful
corrosives while providing superior cooling performance necessary for emissions compliant engines for up to 2 years
or 2000 hours of operation. KOBELCO Genuine Antifreeze/Coolant also protects the engine from freezing in cold
climate regions. Use of coolant other than KOBELCO Genuine Antifreeze/Coolant is not recommended and may
result in poor machine performance and possible damage to the engine and cooling system. KOBELCO Genuine
Antifreeze/Coolant is specified for all machines operating in all regions including areas where cold temperatures or
freezing is not normally expected.
6-11
6.3 MAINTENANCE PARTS

A. Filters & Elements, and Bucket (SK125SR, SK135SR-2)
Replace parts, such as filters and elements, during the periodical maintenance or before the service life.
The machine can be used economically if the parts are changed properly and timely.
When you place an order of parts, confirm the parts number on parts manual.
Table6-1 Maintenance Parts Table
System Part Number Parts Name Q’ty Replacement Interval
Return filter element kit After 50 hours (first change)
YV52V01001R300 1
(STD. Breaker) Every 1000 hours (from 2nd
change)
Hydraulic oil tank (ZD11G19000) (O-ring) 1 (Breaker specification : Every
250 hours)
YN50V00025F2 Suction strainer 1
Every 2000 hours
(ZD11G20000) (O-ring) 1
After 6 times of cleaning or one
YY11P00008S003 Element (Outer) 1
year whichever comes first
For machines equipped with W
(double) element the inner
Air cleaner
element must be replaced
YY11P00008S002 Element (Inner) 1
together with the outer element.
Replace the inner element with
new one.
After 50 hours (first change)
Engine oil filter VA34240–11101 Cartridge 1
Every 500 hours
Fuel filter VA32G62–00100 Cartridge 1 Every 500 hours
YN50V01015P3 Air-con filter (Outer) 1 Every 10 times cleanings

Air conditioner When heavy clogging of filter
YN50V01014P1 Air-con filter (Inner) 1 occurs, clean or replace
Pilot line filter YN50V00020F1 Line filter 1 Every 2000 hours (Cleaning)
2412N278D11 Side cutter (R.H) 1
2412N278D21 Side cutter (L.H) 1
ZS13C20050 Bolt 8
Bucket (STD) When required
ZN13C20016 Nut 8
2412U16F1 Tooth Asse (Inner) 3
2412U112F1 Tooth Asse (Outer) 2
Items enclosed in parenthesis ( ) are the parts to be

changed at the same time.
6-12
6.4 USE OF BIO-DEGRADABLE OILS

When using Bio-degradable Oil (BIO OIL), refer to the following infomation.
A. Recommended Oil
Maker Mobil
Brand MOBIL EAL Envirosyn 46H
B. Precaution for the Use of Oil

1. When filling the former machine in which mineral oil is charged with BIO oil, try to flush the machine three times.
The mineral oil will be left in the circuit of the machine without flushing, resulting in the reduction of effect of
biodegradation ability.
2. When you use BIO OIL, slewing and travel parking brake performance will be reduced because of lower friction
factor of BIO OIL compared to that of mineral oil.
C. Flushing Procedure
(1) Drain mineral oil from the hydraulic tank completely.
(2) Drain mineral oil from the cylinder completely.
(3) Fill hydraulic oil tank with new BIO oil.
(4) After starting engine, move every cylinder 10 strokes respectively.
The abrupt operation may cause burning of seal because of trapped air in the cylinder.
Try to operate first 4 strokes slowly at engine low idling to charge hydraulic oil in the entire cylinder.
(5) Idle travel motor right and left for about 3 minutes.
(6) Repeat swing operation 10 rotations.
(7) Drain BIO oil from hydraulic tank completely.
(8) Drain BIO oil from each cylinder completely.
(9) Fill hydraulic tank with new BIO oil.
Similarly, repeat the procedure 4. to 9. two times.
(10)For hydraulic oil in final condition, analyze the hydraulic oil and be sure of amount of remaining mineral oil.
D. Bio Oil Change Interval

The BIO oil change interval is 2,000 hours.
6-13
6.5 REQUIRED TOOLS

6.5.1 TOOLS (SK125SR, SK135SR-2)
1 2-2
4
2 3
2-1
8
5 9
10
11
7 12
16
13 14 15
20
19
17 18
6-14
No. P/No. Parts Q'ty Remarks

YY01T00015F2 Tool & accessory Include following parts
1 2421Z294 Driver 1
2 YY01T01007F1 Grease gun assy 1 For lubrication
2-1 2421R145 Grease gun 1 •For grease 24.5MPa •Cartridge 400cc
2-2 PW01T01008P1 Seal 1
3 2421R140 Nozzle 1
4 PW01T01003P1 Spanner (1 set) 1
5 2414T4185 Tool case 1
7 2406R527 Ratchet handle 1
8 2408R587D1 Socket 1
9 2408R587D2 Socket 1
10 2408R587D3 Socket 1
11 2408R587D4 Socket 1
12 2408R587D5 Socket 1
13 2421R397 Hammer 1
14 2421R392 Plier 1
15 2406Z623D4 Extension bar 1
16 2421R394 Adjust wrench 1
17 YW01T01014P1 Adjust wrench 1
18 2421R398 Pipe wrench 1 Loosening tool for grease nipple of idler adjuster
19 2421Z183 Grease 1
20 YN20T01261P1 Label 1 Do not operate tag
6-15
6.6 INSPECTION & MAINTENANCE CHART

6.6.1 SK125SR, SK135SR-2
Follow the chart below for recommended intervals of regular inspection and maintenance procedures. Perform
inspection and maintenance according to the calendar time or operation time shown by the hour meter, whichever
comes first.
See the inspection and maintenance procedure mentioned below for details.
Symbols and their meanings :
: Necessary regular inspection item to hour meter

: Only first replacing is performed
: inspection and/or maintenance is needed
See page 1-10 for detail specification for lubricant, coolant, fuel and etc.
LLC : Our genuine antifreeze/coolant.
System
When Interval (Hours on Hourmeter) Lubricant, etc.

Maintenance to Perform
required 8H 50H 100H 250H 500H 1,000H 2,000H 5,000H (Replacing part)
Check oil
O
level
Engine oil Engine oil
*1
Change O
(First)
*1
Change oil filter O Cartridge
(First)
Drain O
Fuel filter Cartridge
Change O
Outer element
Check/ (When outer element is

O changed, inner element
clean
must be replaced without
Air cleaner elements When warning is indicated on multi-display
fail)
Engine
or every 250 HOURS.
Change After 6 times of cleaning or one O Outer, inner element

year whichever comes first
Check
O
Coolant level and level
cleaning of cooling O
Change/
system (or every LLC
cleaning
2 years)
Hoses in cooling system O

Checking and cleaning of
radiator/oil cooler core/ O O
intercooler and filter
Check O
Check belt tensioner
Adjust O
When the machine works at dusty site, clean the filter and the core of radiator often. Clean the filter and core
depending on their dirt.
6-16
System When Interval (Hours on Hourmeter) Lubricant, etc.

Radiator cap Clean O

Checking for rubber hose of intake
O
system
Checking of engine mount bracket for *1
O
tightening (First)
*2 Checking and adjustment of valve

O
clearance
*2 Checking and adjustment of
O
compression pressure
*2 Checking of intake and exhaust *1
O
manifold for tightening (First)
*2 Checking of oil pan and other *1

O
accessories for tightening (First)
*2 Checking of installing turbo charger *1

O
for tightening (First)
*2 Checking of turbo charger rotor and

O
impeller for rotating
*2 Checking of turbo charger rotor for
O
looseness
*2 Checking of turbo charger for
O O
Engine
lubrication
*2 Checking and cleaning of stator
O
brush and commutator
*2 Checking of oil pan and for intrusion
O
of water and fuel
*2 Checking of fan mounting bolt for
O
tightening
*2 Checking of thermostat for function O
*2 Checking of starter for function O
*2 Checking of stability, exhaust color
O
and noise
*2 Checking of heater plug/intake air
O
heater (Starting aid)
*2 Checking of alternator for function O
*2 Checking of each pipe joint for *1
O
tightening (First)
*2 Checking of exhaust pipe and

*1
muffler for installation looseness O
(First)
and damage
*2 Checking and cleaning of alternator
O
brush (If equipped)
• Contact our dealer/distributor for checking and adjustment shown by asterisk *2.
• *1–Break–in (After first 50, 100, 500 Hours) Inspection & Maintenance Required.
6-17
System

Checking leakage of fuel

O
system
Engine
Checking engine oil leakage O

Check engine electrical O
Check/fuel level O
Fuel system
Drain water and

O
Fuel tank deposits
Clean cap and
O
strainer
Air bleeding fuel system O
Check oil
O
level
Hydraul
O Hydraulic oil
ic oil
Change 1,000H O
Hydraulic (Breaker)
Hydraulic system
tank Suction
Clean O Strainer
strainer
O
*1
Return filter (Breaker O Element
(First) attachment
)
Check for oil leaks O

Check hoses/lines O
Pilot line filter Clean O
Check oil O
Extreme gear oil
Swing reduction oil level (120hr)
SAE #90
level & fill *1
Change O GL-4
(First)
Grease slewing ring O EP grease

Check slewing ring & pinion
O
gear
Upper frame
Change grease in slewing ring

O EP grease
grease bath
Check slewing brake O
Greasing of control lever push
O EP grease
rod and universal joint
Check bolts/torque (Slewing
O
ring)
Check bolts/torque *1
O
(Counterweight) (First)
Grease swing reduction unit O

Check oil O
Extreme gear oil
Travel reduction unit level (120hr)
SAE #90
oil level & fill *1 GL-4
Lower frame
Change O
(First)
Adjust track tension O

Check for oil leaks O
Check lines for damage O
Check steps & handrails O
6-18
System
Check frame structure O

Check tracks & links O
Lower frame
Check sprocket wear O

Check idler wear O
Check roller wear O
Check track tension O
*3
Grease for pins O O O
(50H)
EP grease
*3
Grease bucket pins O O
Attachment
(50H)
Replacement of backhoe
O
bucket
Bucket clearance O
Check bucket teeth and side
O
cutters
Check bolts/torque O
Battery electrolyte O
Battery
Battery O
Electrical
maintenance
Voltage check O
Inspect all wiring O
Check switches/light O
Check A/C
O
Refrigerant
Check A/C
Air condenser and O
conditioner clean
Clean O
Accessories
Filter
Change After 10 times cleaning is done
Check wiper washer fluid level O

Check frame structure O
Check bolts/torque O
Check O
Seat belt O
Change
(3 years)
*3: All attachment has to be lubricated every 8 hours for the first 50 hours of operation.
Then the attachment should lubricated every 250 hours of operation.
Next it should lubricated every 500 hours of operation, but the lubrication around bucket has to be applied every
250 hours.
6-19
6.7 PERFORMANCE INSPECTION STANDARD TABLE

6.7.1 SK125SR, SK135SR-2
Unless otherwise specified, measure it on "H" mode.
Table6-2
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
50°C~-10°C
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — (122°F~14°F)
H mode Lo idle 1000 + 30 - 30 LOW throttle
Measure the engine
Engine speed
H mode Hi idle 2000 + 30 - 30 Full throttle (HI idle)
not required
Adjustment
speed at multi display on
B mode Hi idle 2000 + 30 - 30 Perform all
the gauge cluster, or min-1
A mode Hi idle 2000 + 30 - 30 measurement with
measure with diesel
Decel 1050 + 30 - 30 the air-conditioner
speed meter.
S mode Hi idle 1900 + 30 - 30 "OFF".
Pilot primary pressure circuit G pump a3 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure
P1 a1
Main relief
ATT 34.3 (4970) + 0.7 (+100) - 0.5 (-73) MR1 Boom up

P2 a2
P1 a1
Boost — — — — —
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
High pressure circuit
H 37.8 (5480) 0 - 4.0 (-580) OR3 Boom up

Over load relief valve pressure
R 37.8 (5480) 0 - 4.0 (-580) OR8 Arm out

Main pump
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-580) (psi) OR2 Bucket dump
Bucket a1
H 37.8 (5480) 0 - 4.0 (-580) OR1 Bucket digging
RH 28.0 (4060) + 3.4 (+493) + 0.5 (+73) OR6 Swing RH
Swing a2
LH 28.0 (4060) + 3.4 (+493) + 0.5 (+73) OR5 Swing LH
FW —
RH a1 34.3 (4970) + 1.7 (+240) - 0.5 (-73) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 34.3 (4970) + 1.7 (+240) - 0.5 (-73) RH and LH
RV —
6-20
Standard
Inspection item Unit
value
Sprocket revolution 1st speed 30.4 ~ 33.6
min-1
(RH,LH) 2nd speed 50.6 ~ 56.0
Up 3.0 ~ 3.6
Boom
Down 2.7 ~ 3.3
Operating speed
Operating time of In 2.8 ~ 3.4

Arm sec (At no load)
cylinder Out 2.4 ~ 3.0
Digging 2.2 ~ 2.8
Bucket
Dumping 2.1 ~ 2.7
RH
Swing speed 4.7 ~ 5.9 sec / 1 rev
LH
1st speed Iron shoe 20.6 ~ 22.8
Travel speed sec / 20 m
2nd speed Iron shoe 12.8 ~ 14.0
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance
55 ~ 75 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 90
ATT amount of drift Boom cylinder 3 mm / 5min (At no load)
Arm cylinder 4
Amount of horizontal play at the bucket tooth 30 ~ 50 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

6-21
[MEMO]
6-22
7. DATA 1
7-1
7. DATA 1
7-2
7. DATA 1
7.1 WORKING RANGES

7.1.1 SK125SR, SK135SR-2
A. Backhoe Attachment
A
A’
G
C
H
D
E
K L
F
J
B
YY11Z00263P1
YY11Z00267P1
Unit : mm (ft-in)
Attachment 2.38 m (7’-10") Arm 2.84 m (9’-4") Arm
Item + 0.50 m3 (0.65 cu•yd) Bucket + 0.50 m3 (0.65 cu•yd) Bucket
A Maximum digging reach 8,340 (27-4) 8,780 (28-10)

A’ Maximum digging reach at ground level 8,190 (26-10) 8,640 (28-4)
* B Maximum digging depth 5,520 (18-1) 5,980 (19-7)
* C Maximum digging height 9,190 (30-2) 9,550 (31-4)
* D Maximum damping clearance 6,740 (22-1) 7,110 (23-4)
* E Minimum damping clearance 2,580 (8-6) 2,220 (7-3)
* F Max. vertical wall digging depth 4,890 (16-1) 5,350 (17-7)
G Minimum swing radius 2,000 (6-7) 2,400 (7-10)
* H Height at min. swing radius 6,830 (22-5) 6,850 (22-6)
* J 8 feet level digging depth 5,290 (17-4) 5,790 (19-0)
K Horizontal digging stroke at Stroke 4,210 (13-10) 4,700 (15-5)
L ground level Minimum 2,140 (7-0) 2,090 (6-10)
Marked * dimensions do not include height of shoe lug
7-3
7. DATA 1
B. Face Shovel Attachment
A
A'
G
C
D
H
D'
K L
J
B
YY11Z00268P1
YY11Z00269P1
Unit : mm (ft-in)
Attachment 2.38 m (7’-10") Arm 2.84 m (9’-4") Arm
Item + 0.50 m3 (0.65 cu•yd) Bucket + 0.50 m3 (0.65 cu•yd) Bucket
A Maximum digging reach 8,480 (27-10) 8,920 (29-3)

Maximum digging reach at ground
A’ 8,330 (27-4) 8,780 (28-10)
level
* B Maximum digging depth 5,660 (18-7) 6,120 (20-1)
* C Maximum digging height 9,320 (30-7) 9,690 (31-9)
* D Maximum damping clearance 6,930 (22-9) 7,300 (23-11)
* D' Maximum damping clearance (45°) 5,510 (18-1) 5,660 (18-7)
* E Minimum damping clearance 2,450 (8-0) 2,080 (6-10)
G Minimum swing radius 2,000 (6-7) 2,400 (7-10)
* H Max. height at min. swing radius 6,830 (22-5) 6,850 (22-6)
* J 8 feet level digging depth 5,290 (17-4) 5,930 (19-5)
K Horizontal digging Stroke 3,440 (11-3) 4,240 (13-11)
L stroke at ground level Minimum 4,730 (15-6) 4,380 (14-4)
Marked * dimensions do not include height of shoe lug
7-4
8-1
8-2
8.1 SUMMARY OF MECHATRO CONTROL SYSTEM

8.1.1 MECHATRO CONTROL SYSTEM IN GENERAL (SK125SR, SK135SR-2)
ELECTRIC
CONTROLLER INPUT SIGNAL
HYDRAULIC MAIN CONTROL VALVE
PILOT SECONDARY PRESSURE VOLTAGE OUTPUT
SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE
SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT SE-29
LH RH LH RH
OPTION PILOT VALVE ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT
(8) (2) (4) (3) (6) (8) SV-13
PILOT VALVE
P1 UNLOAD
PILOT VALVE
SELECTOR VALVE
CONFLUX
BOOM UP
FOR TRAVEL
BOOM LOW SPEED

FOR ATT
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
SE-9
SE-10
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
SOL
SE-11
MULTI CONTROL VALVE OR SENSOR BLOCK
P1 P2
LOW PRESSURE SENSOR
SE-4 (1) (3) (5) (7)
(4) DIGGING UP REVERSE REVERSE RIGHT ARM IN
SE-3
(3) SOLENOID VALVE
GAUGE CLUSTER
SE-2
(2)
LCD DISPLAY
FOR SELECTION SE-1
(1)
FUEL GAUGE
COOLANT TEMP. GAUGE SE-8
(8)
LOWER SW.
SCREEN CHANGE SE-7
(7)
BUZZER STOP
MODE (6)
WASHER SWING MOTOR PARKING RELEASE
WIPER SE-5
(5)
OUTPUT VOLTAGE
TRAVEL
DECEL
TRAVEL MOTOR 1,2 SPEED SELECT

BOOM CYLINDER
ACCEL DIAL BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE

SE-16
SAFETY LOCK LEVER

SE-23
PROPORTIONAL VOLTAGE
TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
HIGH PRESSURE SENSOR
ARM IN 2 SPEED
C-1 SE-22
P1 UNLOAD
P2 UNLOAD
MECHATRO CONTROLLER A1 A2
ENGINE A3
INJECTOR SPEED SENSOR
SE-13
ARM CYLINDER
ARM OUT CONFLUX
KPSS ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV
RELEASE SWITCH PSV -P1 -A -D -C -B -3 -1 -4
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR
(FOR P1,P2 : 2pcs) PSV -P2
(7)
: INJECTOR P2 PUMP PROPORTIONAL VALVE
ARM IN
: E/G SPEED SENSOR CAN COMMUNICATION BUCKET CYLINDER
C-8 DIGGING / DUMP CONFLUX
: LOW PRESSURE SENSOR ENGINE CONTROLLER
(ATT : 7pcs, TRAVEL : 2pcs) ENGINE SPEED
COMMAND CURRENT
VOLTAGE 24V PROPORTIONAL VALVE
PROPORTIONAL COMMAND CURRENT SOLENOID VALVE ) BLOCK
8-3
8.2 HYDRAULIC CIRCUIT DIAGRAM

8.2.1 STANDARD (SK125SR, SK135SR-2)
D P
PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4
B FOR. FOR. A
SWING
A
REV. REV.
B
4 DB
PG
8 3
1
B DEE I HAC C
28.0MPa
Dr1
69kw 5.0MPa
/2000min-1 M
a3
B1
B3 Dr3 A3 11
PTO
(OCE SPEC.) A B
2 RIGHT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
PCb PAL SWING RIGHT
ARM OUT BOOM UP
AL ARM IN BOOM DOWN
14 CT2 CP2 BL
SE-8
SE-7
SE-4
SE-3
SE-2
SE-1
T3
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
Pss SE-5 8 7 6 5 4 3 2 1
SOL/V PAb PAs
P1 BLOCK LEVER
A1 LOCK As
SV-4
(ROD)Bb
37.8MPa Bs
PBa1
16
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa 17 ATT.
PILOT
1/2 SPEED
SV-3
A3 CHANGEOVER
BUCKET
CYLINDER
9 9
PBb
37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
37.8MPa BOOM ARM
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2 37.8MPa
Ao
Bo 3 6 4 1 5 2
A8 ARM 2 37.8MPa
17 PBo
LEFT TRAVEL FORWARD
SE-9 SE-10
13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
T2 P2
(P3) (P4)
17
YY01Z00069P1 02
8-4
8.3 HYDRAULIC CIRCUIT N&B SPECIFICATION (OPTION)

8.3.1 SK125SR, SK135SR-2
NIBBLER & BREAKER

SPECIFICATION YY01Z00070P1 (01)
NO. PARTS PARTS No. MODEL No.
50 SELECTOR VALVE YB30V00018F1 VBY-181
51 STOP VALVE 24100P1006F1
52 PILOT VALVE YN30V00080F1 16030-00000
NOTE 1:This hydraulic circuit is used to add to standard circuit.

2:For using of nibbler confluence/single flow or breaker,
choosed condition and an order.
CHOOSED CONDITION
AN ORDER OF OUTPUT FOR
AN ORDER OF OUTPUT FOR PROPORTIONAL SOLENOID VALVE (W: , W/O:-)
CONFLUENCE/SINGLE FLOW PROPORTIONAL SOLENOID VALVE
CHANGEOVER SWITCH IN VALVE SELECTOR(ITEM 50) TRAVEL P1 P2
(W: , W/O:-) P1 PUMP P2 PUMP STRAIGHT UNLOAD UNLOAD
CONFLUENCE FLOW OF NIBBLER CONFLUENCE ON
SINGLE FLOW OF NIBBLER CONFLUENCE OFF
BREAKER CONFLUENCE OFF
3:When using nibbler, according to specification of nibbler

installed, choose confluence or single flow by
"confluence/single flow changeover switch"
51
52
50
YY01Z00070P1 01
8-5
8.4 ELECTRIC CIRCUIT DIAGRAM

8.4.1 SK125SR, SK135SR-2
HORN,HORN RELAY
ENG.CONTROLLER
KEY SW.STARTER RELAY
GAUGE CLUSTER
APPLICABLE YV05-04501-
DC-DC CONVERTER,
ROOM LIGHT TUNER
ENG.CONTROLLER
LUBRICATION OIL
AUTO GREASE
CONTROLLER
CONTROLLER
CONTROLLER
PRESS.SENSOR
MACHINE No. YY05-12001-
RELAY,HOUR
LEVER LOCK
BATTERY RELAY
MECHATRO
MECHATRO
CIGARETTE
YH05-07001-
GLOW RELAY
BACK UP
LIGHTER
BACK UP
METER
TUNER
C-8:ENG.CONTROLLER ENG.HARNESS
E-1:FUSE & RELAY BOX

RDS/RAIL PRESS.
R-26: (NONUSE) BOOST PRESS.

LEVER LOCK RELAY SENSOR
WATER TEMP
SENSOR
CRANK SENSOR
LIGHT,TRAVEL ALARM,
OPT.HAND
CONTROL
OPT.4
AIR CON.(AMP.)
GAUGE CLUSTER
WIPER,WASHER
SOLENOID,LMN/BH
WORK LIGHT
CAB WORK LIGHT
CAB WORK LIGHT

AIR CON.
AIR CON.
ROOF WIPER
FLASHER,REARWORK
OPT.BACKET
CONTROL
OPT.1
OPT.3
RELEASE SW.(KPSS)
LEVEL CONTROLLER,
DC-DC CONVERTER
RADIATOR COOLANT
SH2 SHEILD
ONE WAY CALL

CAM SENSOR
SH3 SHEILD
E-12: E-12: INJECTOR 1

BATTERY BATTERY
STARTER CABLE
INJECTOR 2
INJECTOR 3
R-1: ACCEL REDUNDANT

BATTERY REAY POTENTIO
E-15: INJECTOR 4
FUSIBLE LINK
75A
R-23: MPROP
AUTO IDLE STOP RELAY 1 R-24: R-25:
AUTO IDLE STOP ENG.EMERGENCY STOP
RELAY 2 RELAY LUBRICATION OIL
KEY ON PRESS. SENSOR
G
N TIN
IO EA
SIT EH
PO PR
TERMINAL
O A O S
T
F C A
F C N R TERMINAL FOR SERVICE
T
R-3:
GLOW RELAY GLOW
R-53:
GLOW RELAY
SW-1: KEY SW. (ECU)
M-1:
STARTER MOTOR
C-1:
MECHATRO CONTROLLER(TCO-60-2)
R-2:
STARTER RELAY
R-4: SAFETY RELAY C-6:

AUTO GREASE
CONTROLLER
SH8 SHIELD
E-3:
HOUR METER
CHARGE
KEY ON
CONTROL:
(SENSOR,5V,CPU)
(PULL UP)
OUT SOURCE:
(PSV.SOL.MOTOR)
R-28:ALTERNATOR RELAY
TO(2/5)
(1/5)
YY03Z00022P1 (03)
8-6
C-1: MECHATRO CONTROLLER(TCO-60-2)
FROM (1/5)
SE-16:ACCEL POTENTIO
N
IO AL ASE
PRESS.SENSOR SIT O RM ELE
PO N R
TERMINAL
SW-4:
SE-1:BUCKET DIGGING SWING PARKING RELEASE SW.
SE-2:BUCKET DUMP SV-1:SWING PARKING BRAKE SOL.
SV-3:TWO-SPEED SELECT SOL.

SE-3:BOOM RAISING
PSV-B:P2 UNLOAD PROPORTIONAL SOL.

SE-4:BOOM LOWERING
PSV-C:TRAVEL PRIORITY PROPORTIONAL SOL.

SE-7:ARM IN
PSV-D:P1 UNLOAD PROPORTIONAL SOL.

SE-8:ARM OUT
PSV-A:ARM TWO-SPEED INVERSE PROPORTIONAL SOL.
SE-5:SWING
SE-9:TRAVEL RIGHT PSV-E:OPT RELIEF ADJUSTMENT

PROPORTIONAL SOL. 1
SE-10:TRAVEL LEFT PSV-I:OPT RELIEF ADJUSTMENT

PROPORTIONAL SOL. 2
SE-22:PUMP P1
N
IO AL ASE
SIT O RM ELE
PO N R SW-22:
TERMINAL
SE-23:PUMP P2 RELEASE SW. (KPSS)
E-38: RESISTOR
SE-20:P1 OPT.
C-2:GAUGE CLUSTER
PSV-P1:PUMP P1 PROPORTIONAL SOL.
SE-11:P2 OPT.
ENG.WATER TEMP METER
PSV-P2:PUMP P2 PROPORTIONAL SOL.
FUEL METER SE-15:FUEL SENSOR
SE-13:ENG.REVOLUTION SENSOR
SHIELD
SHIELD
DISPLAY BUZZER STOP MODE WASHER

SELECT SW.
ENTER DECEL TRAVEL WIPER TO(3/5)

2-SPEED
(2/5)
YY03Z00022P1 (03)
8-7
C-1:MECHATRO CONTROLLER(TCO-60-2)
FROM 2/5
SW-8:AIR FILTER RESTRICTION SW. R-5:HORN RELAY
E-5:HORN HIGH
E-6:HORN LOW
SW-36:WATER SEPARATOR
RESTRICTION SW. SW-10:HORN SW. LEFT
SW-5:HORN SW. RIGHT
(WIPER RELAY)
SW-15:
CONFLUX/SINGLE SELECT SW. R-31: R-29:
PREVENT SPARK WIPER MOTOR RELAY
RELAY L-5:ROOM LIGHT
M-3:
WIPER MOTOR
R-30:
WIPER MOTOR
REVERSING RELAY
R-32: E-14:CIGARETTE LIGHTER

M-4:
WINDOW WASHER WASHER MOTOR
MOTOR RELAY
E-1:
FUSE & RELAY BOX
R-26: E-11:
SW-11: LEVER LOCK SV-4:OPERATING E-10:
LEVER LOCK SOL. AIR COMPRESSOR
LEVER LOCK SW. RELAY RECEIVER DRIER CLUTCH
STOP R-6:
REVERSE WORK LIGHT RELAY
AIR CON.AMP.
(GROUND OUTPUT)
SW-19:WIPER INTERLOCK SW.
R-8:TRAVEL ALARM RELAY
E-13: COOLING
TRAVEL ALARM UNIT
SE-29:OPT.SELECT
DETECT SENSOR
SW-13:
TRAVEL ALARM SW
DOMESTIC,AUSTRALIA
SV-13:OPT.SELECTOR SOL. DOMESTIC OPT.
KCMA KCMA STD.
AUSTRALIA STD.
SW-17:ROOF WIPER SW.

POSITION
TERMINAL
M-9:ROOF WIPER MOTOR
ROOF WIPER
TO 4/5
(3/5)
YY03Z00022P1 (03)
8-8
C-1:MECHATRO CONTROLLER
FROM 3/5
E-7:TUNER AM & FM
C-6:AUTO GREASE E-8:SPEAKER LEFT

CONTROLLER
FM / AM
E-9:SPEAKER RIGHT
M-8:GREASE MOTOR (BACK UP)
E-2: WITH OUT EU

ALTERNATOR
OPT.
AUTO GREASE
C-1:MECHATRO CONTROLLER (TCO-60-2)
R-6:WORK LIGHT RELAY L-6:BOOM WORKING LIGHT RIGHT OCEANIA
L-1:BOOM WORKING LIGHT LEFT
L-2:FRAME WORKING LIGHT RIGHT 9P CONNECTOR

C-4:AIR-CON AMP
SW-55:
BOOM,DECK WORKING LIGHT SW.
R-19:
FLASHER RELAY
L-3:
SWING FLASHER LEFT
DOWNLOAD
L-4:
SWING FLASHER RIGHT
SWING FLASHER & WORKING LIGHT

E-16:ONE WAY CALL AMP
E-17:
ONE WAY CALL SPEAKER
OPT.
MIC ONE WAY CALL
TO 5/5
(4/5)
YY03Z00022P1 (03)
8-9
C-1:MECHATRO CONTROLLER (TCO-60-2)
R-26:
LEVER LOCK RELAY SV-6:
SW-33: REVOLUTION
R-12: REVOLUTION RIGHT SOL.
REVOLUTION RIGHT SW.
RIGHT RELAY
SV-7:
SW-34: REVOLUTION
R-13: REVOLUTION LEFT SOL.
REVOLUTION LEFT SW.
LEFT RELAY
REVOLUTION N&B
SW-29: SV-9:
NIBBLER NIBBLER OPEN SOL.
R-15:
NIBBLER OPEN SW.
OPEN RELAY
(CASE OF HAND CONTROL
NIBBLER CONNECT WITH 571)
(CASE OF HAND CONTROL

BRAKER CONNECT WITH 572)
SV-10:
SW-30: NIBBLER
NIBBLER CLOSE SOL.
EASY OPERATING R-16: CLOSE SW.
NIBBLER NIBBLER
CLOSE RELAY
(5/5)
YY03Z00022P1 (03)
8-10
8.5 ELECTRICAL EQUIPMENT LIST
GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
MECHATRO CONTROLLER YN22E00214F1 L-1 BOOM WORK LIGHT (LH) YW80S00001F1 R-1 BATTERY RELAY YN24S00008F1 SWING PARKING
(C) CONTROLLER
C-1 SV-1 YN35V00051F1

(TCO-60-2) (HARD) L-2 FRAME WORK LIGHT (RH) YT80S00002F2 R-2 STARTER RELAY ENGINE ACCESSORY BRAKE SOL.
(YY35V00013F1)
C-2 GAUGE CLUSTER YN59S00021F3 L-3 SWING FLASHER (LH) YY80S00001F1 R-3 GLOW RELAY 34390-00601 TWO SPEED
SV-3 SOLENOID YN35V00050F1
AIR-CON CONTROLLER L-4 SWING FLASHER (RH) R-4 SAFETY RELAY ACCESSOR OF RELAY BOX SELECT SOL
C-4 YN20M01468P2 VALVE ASSY
(INCLUDING PANEL) L-5 ROOM LIGHT YT80S00001P1 R-5 HORN RELAY YN24S00010P1 SAFETY LOCK
SV-4
(SV) SOLENOID
C-8 ENGINE CONTROLLER 32G87-01020 R-6 WORKING LIGHT RELAY LEVER SOL
R-8 TRAVEL ALARM RELAY SV-5 BUCKET DUMP CUT SOLENOID
(L) LIGHT
D-4 DIODE ACCESSORY OF FUSE RELAY BOX R-12 REVOLUTION RIGHT RELAY SV-6 REVOLUTION RIGHT SOLENOID -
D-5 DIODE R-13 REVOLUTION LEFT RELAY SV-7 REVOLUTION LEFT SOLENOID -
D-6 DIODE R-15 NIBBLER OPEN RELAY SV-9 NIBBLER OPEN SOLENOID -
D-9 DIODE R-16 NIBBLER CLOSE RELAY SV-10 NIBBLER CLOSE SOLENOID -
D-10 DIODE R-19 FLASHER RELAY YY24S00001F1 SV-13 OPT. SELECTOR SOLENOID
(R) RELAY
D-12 DIODE R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1
D-13 DIODE R-24 AUTO IDLE STOP RELAY 2
(D) DIODE
D-14 DIODE R-25 ENGINE EMERGENCY STOP RELAY

D-15 DIODE R-26 LEVER LOCK RELAY
D-16 DIODE M-1 STARTER MOTOR 32G66-0010 R-28 ALTERNATOR RELAY SW-1 KEY SWITCH YN50S00029F1
D-17 DIODE M-3 WIPER MOTOR YN53C00012F2 WIPER MOTOR RELAY SWING PARKING BRAKE RELEASE
R-29 YN24S00012P2 SW-4 YN50S00047P1
(M) MOTOR
M-4 WASHER MOTOR (TANK ASSY) YT54C00003F1 (NORMAL ROTATION) SWITCH
M-8 GREASE MOTOR LC71V00001P1 WIPER MOTOR RELAY SW-5 HORN SWITCH (RH) YN50E00017P1
R-30
M-9 ROOF WIPER MOTOR YN76S00005P1 (REVERSE ROTATION) SW-8 AIR FILTER CLOGGING SWITCH YR11P00008S005
R-31 PREVENT SPARK RELAY SW-10 HORN SWITCH (LH) YN50E00017P1
R-32 WASHER MOTOR RELAY SW-11 SAFETY LOCK LEVER SWITCH YN50S00041F1
R-53 GLOW RELAY(ECU) SW-13 TRAVEL ALARM SWITCH YN50S00040DF
ARM 2 SPEED CONFLUX/SINGLE SELECT
SW-15 YN50S00040DD
PSV-A INVERSE YN35V00049F1 SWITCH
PROPO.VALVE SW-17 SKYLIGHT WIPER SWITCH YN50S00040D9
E-1 FUSE AND RELAY BOX YY24E00008F1 P2 UNLOAD (YY35V00013F1) SW-19 WIPER INTERLOCK SWITCH YT50S00004P1
PSV-B YN35V00048F1
E-2 ALTERNATOR 32G68-00100 PROPO.VALVE SOLENOID SW-22 KPSS RELEASE SWITCH YX50S00001F1
E-3 HOUR METER YT58S00006P1 TRAVEL STRAIGHT VALVE ASSY PRESSURE SENSOR : SW-26 CAB WORK LIGHT SWITCH YN50S00040D4
PSV-C SE-1 YX52S00013P1
E-5 HORN (HIGH) LC53S00001D1 PROPO.VALVE BUCKET DIGGING SW-29 NIBBLER OPEN SWITCH 2406P5872
E-6 HORN (LOW) LC53S00001D2 P1 UNLOAD PRESSURE SENSOR : SW-30 NIBBLER CLOSE SWITCH
(P) PROPORTIONAL
SOLENOID VALVE
PSV-D SE-2
E-7 TUNER AM/FM (OCEANIA) YN54S00046P1 PROPO.VALVE BUCKET DUMP SW-33 REVOLUTION RIGHT SWITCH YN03M01231P3
E-8 SPEAKER (LEFT) YN54S00050P1 OPT. RELIEF ADJU- SE-3 PRESSURE SENSOR : BOOM UP SW-34 REVOLUTION LEFT SWITCH
PSV-E -
(SW) SWITCH
(E) ELECTRIC FITTINGS
E-9 SPEAKER (RIGHT) STMENT PROPO. VALVE 1 PRESSURE SENSOR : WATER SEPARATOR
SE-4 SW-36 32G90-00300
E-10 RECEIVER DRYER YN54S00041P1 OPT. RELIEF ADJU- BOOM DOWN RESTRICTION SWITCH
PSV-I -
E-11 AIR-CON COMPRESSOR YX91V00001F1 STMENT PROPO. VALVE 2 SE-5 PRESSURE SENSOR : SWING SW-37 TRAVEL INDEPENDENT SWITCH YN50S00040DB
E-12 BATTERY 2484U171 P1 PUMP SE-7 PRESSURE SENSOR : ARM IN SW-55 BOOM WORK LIGHT SWITCH YN50S00040D1
PSV-P1 YN35V00052F1
E-13 TRAVEL ALARM YN53S00004F1 PROPO VALVE (YY10V00013F1) SE-8 PRESSURE SENSOR : ARM OUT
E-14 CIGARETTE LIGHTER YN81S00003P1 P2 PUMP PUMP ACCESORY SE-9 PRESSURE SENSOR : TRAVEL RH
PSV-P2
E-15 FUSIBLE LINK YY73S00003P1 PROPO VALVE SE-10 PRESSURE SENSOR : TRAVEL LH
(SE) SENSOR
E-16 ONE WAY CALL AMP 2447R145 SE-11 (PRESSURE SENSOR : P2 OPT.)
E-17 ONE WAY CALL SPEAKER 2479R2098 SE-13 E/G SPEED SENSOR ENGINE ACCESSORY
E-22 DC-DC CONVERTER YN77S00005F1 SE-15 FUEL SENSOR YN52S00045F1
SE-16 ACCEL POTENTIOMETER YN52S00032P1
SE-20 (PRESSURE SENSOR : P1 OPT.) YX52S00013P1
SE-22 PRESSURE SENSOR : PUMP P1 YN52S00048P1
SE-23 PRESSURE SENSOR : PUMP P2
SE-29 OPT. SELECTOR DETECT SENSOR YX52S00013P1
NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. YY03Z00022P1 03
8-11
[MEMO]
8-12

Training Text SK125srl

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Training Text SK125srl

Uploaded by

Copyright:

Available Formats

HYD.

Book Code No. S6YY00201ZE01

2. CONSTRUCTION & FUNCTION

3. MECHATRO CONTROL SYSTEM

4.12 TROUBLESHOOTING BY DIAGNOSIS CODES..................................................... 4-24

6. CHECK-UP & SERVICE

8. DATA 2 (CIRCUIT DIAGRAM)

1.1 SK125SR, SK135SR-2, SK135SRLC-2

(Side of control valve)

Material of lower roller shaft is reinforced Improvement of durability

New control valve is equipped. Low fuel consumption by

decreasing back pressure

Design improved Design of machine is improved

and noise is reduced remarkably

New design of engine bonnet, guard and so on

Comparison between new and former models

comfortable interior for operator

model of hydraulic pulsations pressure

2.1 NAME OF COMPONENTS

BUCKET LINK RADIATOR

BOOM CYLINDER MUFFLER

IDLER ADJUST COUNTERWEIGHT

2.2 SPECIFICATIONS AND PERFORMANCE

2.2.1.1 SPEED AND CLIMBING CAPABILITY

Engine model MITSUBISHI D04FR-74kW

2.2.1.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

2.3 OPERATOR CAB NOMENCLATURE

No. NAME No. NAME

2.3.2 LOCATION OF SWITCHES AND METERS (SK125SR, SK135SR-2)

No. NAME No. NAME

2.3.3 GAUGE CLUSTER (SK125SR, SK135SR-2)

BOOM LOW SPEED

DIGGING UP REVERSE REVERSE RIGHT ARM IN

SWING PARKING BRAKE

SAFETY LOCK LEVER

TRAVEL 1,2 SPEED

2.4.2 UNLOAD VALVE CONTROL

PILOT SECONDARY PRESSURE

2.4.3 POSITIVE CONTROL & P-Q CONTROL

(LEFT) (RIGHT) PILOT PILOT

PILOT SECONDARY PRESSURE

(1) Positive control

POSITIVE CONTROL P-Q CONTROL

PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

PILOT PRESSURE PUMP DELIVERY PRESSURE

2.4.4 BOOM UP CONFLUX CONTROL

BOOM UP PILOT SECONDARY PRESSURE

BOOM UP PILOT SECONDARY PRESSURE

BOOM UP PILOT SECONDARY PRESSURE

2.4.5 ARM IN RECIRCULATION & CONFLUX CONTROL

ARM IN PILOT SECONDARY PRESSURE

PILOT SECONDARY PRESSURE

ARM IN PILOT SECONDARY PRESSURE

PILOT SECONDARY PRESSURE

P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

(1) Recirculation and conflux (Low loading)

2.4.6 ARM-IN ANTI-CAVITATION CONTROL

ARM IN PILOT SECONDARY PRESSURE

ARM IN PILOT SECONDARY PRESSURE

ENGINE SPEED (COMMAND VALUE) MECHATRO

2.4.7 ARM-OUT CONFLUX CONTROL

ARM OUT PILOT SECONDARY PRESSURE