HYDRAULIC EXCAVATOR SHOP SK40SR MANUAL modell SK45SR ‘This is the shop manual for KOBELCO hydraulic excavator. Contained is the necessary technical data concerning the maintenance and repair of this model. The manual is divided into the following four major sections; GENERAL, SYSTEMS, COMPONENTS and PROCEDURE. *GENERAL PHO1. SPECIFICATION PHO4, MAINTENANCE STANDARD AND — OPERATION AND CONTROLS (Refer to Operators Manual) PHO3. LOCATION AND ‘TEST PROCEDURE — PREVENTIVE MAINTENANCE (Refer to Operators Manual) WEIGHT OF COMPONENTS. PHO7, WORKING STANDARD *SYSTEMS PH12, HYDRAULIC SYSTEM PH22. CONTROL SYSTEM PH15. UPPER STRUCTURE PH25. ELECTRICAL SYSTEM PH18. TRAVEL SYSTEM PH29. TROUBLE SHOOTING PH21. ATTACHMENTS *COMPONENTS 12, HYDRAULIC PUMP 16, SWIVEL JOINT 13. CONTROL VALVE 17, HYDRAULIC CYLINDER 14, OTHER VALVES 21, REDUCTION UNIT - 15, HYDRAULIC MOTOR 50, ENGINE *PROCEDURE When checking or repairing the machine we suggest that you refer to this manual carefully. We hope that reference to this manual will help to maintain a high level of working efficiency and reliability. For further details on maintenance and checks refer to the “OPERATORS MANUAL” which has been supplied with the machine. Although all data was correct at the time of printing, due to continual design changes and improvements, some contents may not conform to the actual machine. Take special care to order parts only after confirming the validity of the part number in the “PARTS MANUAL”. If you notice any explanatory discrepancies, after consulting one of our representatives, please update your manual according to the latest data. However, in the event of any specification ee INDEX KOBELCO Book code No. SSPHOOO1E)7 Ie SAFETY The proper and safe lubrication and maintenance for this machine, recommended by KOBELCO are outlined in the OPERATION & MAINTENANCE GUIDE for this machine. Improper performance of lubrication or mainte- nance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE GUIDE before performing any lubrication or maintenance. ‘The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component, Because of the size of some of the machine components, the serviceman or mechanic should check the’ weights noted in this Manual. Use proper lifting procedures when removing any components, Following is a list of basic precautions that should always be observed. 1. Read and understand all Warning plates and decals on the machine before operating, lubricating or repairing this product. 2, Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses. when pounding ‘on any part of the machine or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding Job being performed. Do not wear loose-fitting ‘or torn clothing. Remove all rings from fingers ‘when working on machinery. 3. Disconnect battery and discharge any capacitors before starting to work on machine Hang “Do Not Operate” tag in the Operator's Cab. 4, If possible, make all repairs with the machine parked on alevel, hard surface. Block machine 80 it does not roll while working on or under machine 5. Do not workon any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any disassembly. Do not operate this machine unless you have read and understand the instructions in the OPERATORS MANUAL. Improper machine operation is dangerous and could result in injury or death, 6. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected cr removed, Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure, 7. Lower the bucket, blade, ripper or other attachment to the’ ground before performing any work on the machine, If this cannot be done, make sure the bucket, blade, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly. 8. Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face machine when using stops, ladders and walkways, When it is not possible to use the designed access aystem, provide ladders, scaffolds, or work platforms to perform safe repair operations 9, To avoid back injury, use a hoist when lifting components which ‘weigh 23 kg (60 Ibs) or more. Make sure all chains, hooks, slings, ete., are in good condition and’ are in the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. 10, To avoid bums, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and components, 11. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely. 12, Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just beon stopped because fluids can be hot.18. Always use tools that are in good condition and be sure you understand how to use them before performing any service work. 14, Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replace- ments are necessary. 15. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledge- able in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. Always disconnect battery during welding operations to protect sensitive electric equipment. 16.Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 17. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution, 18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect ines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks. 19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly. 20. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. 21. On track-type machines, be careful when servicing or separating tracks. Chips can fly when removing or installing a track pin. Wear safety glasses and long sleeve shirts. ‘Track can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks are disengaged from the sprockets. Block the machine to prevent it from moving. 22, Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this, dust is inhaled, it can be hazardous to your health. Components in KOBELCO products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates and some gaskets. The asbestos used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust which contains asbestos is not generated. If dust which may contain asbestos is present, there are several common sense guidelines that should be followed. a. Never use compressed air for cleaning. b. Avoid brushing or grinding of asbestos containing materials, ¢. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. 4. Use exhaust ventilation on permanent machining jobs. e. Wear an approved respirator if there is no other way to control the dust. Comply with applicable rogulations for the work place, Follow environmental rules and regulations for disposal of asbestos. h. Avoid areas where asbestos particles may be in the air. rules andSHOP SK40SR MANUAL model SK45SR TABLE OF CONTENTS 1, SPECIFICATION a PHO1 2. OPERATION AND CONTROLS (Refer to Operators Manual) fs 3. LOCATION AND WEIGHT OF COMPONENTS PHOS 4. MAINTENANCE STANDARDS AND TEST PROCEDURES al id 6. PREVENTIVE MAINTENANCE (Refer to Operators Manual) | 7. WORKING STANDARDS PHO . a Olfow to Index each Shop Manual Section ‘The GENERAL of this shop manual consists of 8 headings as shown above. Each section can be easily referred to by indexes appended to the margin of the page as indicated on the right. Please use the indexes for speedy reference. KOBELCO GENERALSK40SR $k45sR__ List of Shop Manual GENERAL Section Index Book Code No. Title a No. Distribution Year ~ Month 5 t ‘S5PHOIOIE PHOL SPECIFICATION 1997-05; _— _ ‘SPHOOOTE S2PHOOOZE Cee [Refer to Operators manual[Reter to Operator manual ‘pHos | LOCATION AND WEIGHT ‘S5PHO30O1E OF COMPONENTS: 1997-05 prog [MAINTENANCE STANDARDS ‘S5PHO4OIE AND TEST PROCEDURES 1997-05 _ PREVENTIVE ‘S2PHOOOIE S2PHOOOZE MAINTENANCE, Refer to Operators manusllRefer to Operators manual S5PHO70IE PHoT | WORKING STANDARDS fee — = PHO0101~01100 PHO1101~ eee PY06001~07100 Pyo7101~KOBELCO SHOP MANUAL me DHO Tote SK40SR SK45SR —— SPECIFICATION — TABLE OF CONTENTS TYPE OF SHOES TYPE OF BUCKETS , LIFTING DIAGRAM eeneaaeer NAME OF COMPONENTS GENERAL DIMENSIONS - SPECIFICATIONS AND PERFORMANCE WORKING RANGES OF ATTACHMENTS . ENGINE SPECIFICATIONS ENGINE CHARACTERISTIC CURVE <© KOBE STEEL,LTD.Applicable Machines PH00101~ PY06001~ Revision Firat edition Date of Issue May, 1997 Remarks SoPHOLOIE1. NAME OF COMPONENTS ‘ARM CYLINDER ARM . BOOM SLEWING MOTOR. BUCKET CYLINDER ‘CONTROL VALVE FUEL TANK HYDRAULIC TANK nocer RADIATOR DOZER CYLINDER DOZER BLADE: MULTI CONTROL, VALVE (OPT) IDLER TRACK ADJUSTER SOLENOID VALVE UPPER ROLLER SLEWING BEARING SWIVEL JOINT’ LOWER ROLLER TRAVEL MOTOR ENGINE HYDRAULIC PUMP RUBBER SHOE % This machine is canopy spec. for SK40SR.2. GENERAL DIMENSIONS Unit:mm, 2.1 [SKAOSRIGENERAL DIMENSIONS @ GENERAL DIMENSIONS (CANOPY SPEC.) 2,300 (2.310) 1520 1760 = 2 fl &| | A ami Es 200 2,900 [2310] 1.900 ast 1.500 6.080 ans Note: Numerical values marked Include the height of the shoe lug. Numerical values endosed in parentheses [_] indicate the steel crawler specifications. 22.2 [SK@SSRIGENERAL DIMENSIONS @ GENERAL DIMENSIONS (CANOPY SPEC.) 1980_ e204) @ GENERAL DIMENSIONS (CAB SPEC.) Unit: mm 5.360 ass Note: Numerical values marked » include the height of the shoe lug. Numerical values enclosed in parentheses [_] indicate the steel crawler specifications. 383. SPECIFICATIONS AND PERFORMANCE @ SPEED AND GRADABILITY ‘Model! SK40SR_ SK45SR Tem “Type| Rubber shoe spec. | Steel shoe spec. _| Rubber shoe spec. | Steel shoe spec. Swing speed 7pm 7 r Tow] High | iow High | Tow [High] Tow | _figh ‘Travel Speed km/h | Clpeed | Geneat) | armen | cmecd | copead | aenten | aapeen | creed a7 | 47 [| 25 | 44 | 29 | 48 | 26 | 44 Gradability 30° (58%) @ ENGINE Model SK40SR SK45SR_ Engine model YANMAR DIESEL 8TNE88 YANMAR DIESEL 4TNE88 ‘Type ‘eycle, water-cooled in-line 3-cylinder, | 4-cycle, water-cooled in-line 4-cylinder, Pe direct injection type direct injection type Number of Cylinders xé8mmXo0mm 4x88mmXx90mm Total Displacement 1,64¢ (0.43gal) 2.19¢ (0.58gal) Bee eer 30.5PS/2,400rpm 37PS/2,200rpm Maximum Torque? Rotation Speed 10.5kgfm / about 1,600rpm 13.5kg¢'m/ about 1,600rpm_ Starter 2V LAW 12V/2.0kW Alternator 12V/40A 12V/404 @ HYDRAULIC COMPONENTS ‘Model SK40SR SK45SR Hydraulic pump Hydraulic motor Glowing) Hydraulic motor (Travel) Control valve Cylinder (boom, arm, bucket and dozer blade) Variable displacement axial piston +2 gear pump Axial piston motor 2—axial piston, 2-speed motor functions multiple control valve Double action cylinder Return filter Safety valve containing filter type (10w) @ SIDE DIGGING ‘Model SK40SR SK45SR Type ‘Boom swing by hydraulic cylinder Boom swing [Canopy 55° (Right) 85° (Left) angle Cab 55°(Right) 80° (Left) @ WEIGHT, Unit jke ‘Model SK40SR SK45SR Rubber shoe Steel shoe Rubber shoe Steel shoe Fully equipped weight | Canopy | Cab | Canopy [Cab | Canopy | Cab | Canopy [Cab 3970 | 4100 | 1,030 | 4,160 | 4660 | 4,790 | 4,700 | 4,890 Upper machinery 1,950 | 2,080 | 1,950 | 2,080 | 2320 | 2450 | 2,320 | 2,450 Lower machinery 3925 | <— | 1,585 | <— | 1750 | <— | 1,790 | <— a5 | <— | <— | | 590 | < [ — | — ‘Attachment 263m Boom+1.35m Arm 284m Boom+143m Arm +0.13m* Bucket +0.14m9 Bucket Dover blade (width x height) 7,960mm 350mm 7.980mmX 350mm Strokes of blade (up/down) 360mm/380mm 370mm/380mm 44. TYPE OF SHOES Mote Track shoe | Total width of | Ground Pressure (kgtem®) ode! crawler width (mm) (nm) Canopy Cab SK40SR 400 1,960 0.25 0.26 SKASSR 400 1,980 o2t 0.28 SK40SR 400 41,960 0.25 0.26 SKA5SR 400 1,980 028 029 5. TYPE OF BUCKETS SK40SR Heaped Siruck ‘Width of bucket iam) : Backhoe bucket a a dt i Number | Weight Capacity | capacity With, ‘Without en) in’) "| side cutters | side cutters | of teeth | xe) 0.086 0.066 450 390 3 80 STD 0.13 0.10 600 540 4 100 HD 0.13 0.10 600 540 4 105 mas 0.6 032 700 640 5 110 NOTE: HD means Heavy Duty Type. [SK45SR| Heaped Biruck Width ofbucket_ Gam) 5 Backhoo bucket a Number ] Weight Capacity | capacity ‘With ‘Without im’) mn)" _| side cutters | side cutters | of teeth | (ke) 0.088 0.068 450 390 3 90 012 0.086 550 490 4 100 STD 0.4 oat 650 590 4 110 HD 0.14 oat 650 590 4 ua 0.16 012 700 640 5 120 mon] 0.18 oa 750 690 5 125 NOTE:HD means Heavy Duty Type.6. WORKING RANGES OF ATTACHMENTS. [SK40sR| @ BACKHOE ATTACHMENT (CANOPY SPEC.) s f 7a} “| 4 : ta x L Ei Attachment Type| 1.35m arm 1.65m arm Item 0.13m? bucket, 0.13m" bucket A |Maximum digging reach 5,550 5,840 ‘A [Maximum digging reach at ground level 5,420 5,720 x B |Maximum digging depth 3,330 3,630 % C [Maximum digging height 5,390 5,640 x D [Maximum dumping height 3,800 4,050 ¥_E [Minimum dumping height 1,510 1,230 x F | Vertical digging depth 2,570 2,910 [Minimum slewing radius 2,040 2,40 %_H [Height at minimum slewing 4,070 4,070 x J [B-fect level digging depth 2,880 3,240 —K |Horizontal digging —_| Stroke 2,360 2,800 L [stroke at ground level Minimum 1,840 1,700 imensions marked % do not include the height of the shoe lug.[SK40SR| @ FACE SHOVEL ATTACHMENT (CANOPY SPEC.) A A i t 4 « “] _ K L Uni ‘Attachment ‘Type| 1.35m arm 1.65m arm Item 0.13m® bucket 0.13m® bucket ‘A [Maximum digging reach 5,630 5,980 A’ [Maximum digging reach at ground level 5,510 6,820 % B [Maximum digging depth 3420 8,720 % C [Maximum digging height 5,490 5,740 % D [Maximum dumping height 3,870 4,180 XD’ [Maximum dumping height (45°) 3,250 3,360 % E [Minimum dumping height 1,420 1,140 F [Minimum slewing radius 2,040 2,140 % G | Height at minimum slewing 4,070 4,070 x J |B-feet level digging depth 2,990 3,340 ~_K [Horizontal digging | Stroke 1,820 2,380 1 [stroke at ground level Minimum 3,610 3,400 NOTE : Dimensions marked do not include the height of the shoe lug.[SK40SR| @ BACKHOE ATTACHMENT (CAB SPEC.) A z s i & Sg wal \ Unit:mm ‘Attachment Type 135m arm 1.65m arm Item 013m? bucket 013m? bucket ‘A [Maximum digging reach 5,550 5,840 ‘A’ [Maximum digging reach at ground level 5,420 5,720 % B [Maximum digging depth 3,380 3,680 % © [Maximum digging height 5,180 5,860 % D [Maximum dumping height 3,570 3,800 % E [Minimum dumping height 1,870 1,080 % F | Vertical digging depth 2,570 2,910 G [Minimum slewing radius 2,190 2,250 3H [Height at minimum slewing 3,950 3,950 % J [Befeet level digging depth 2,880 3,240 “K |forizontal digging | Stroke 2,360 2,800 T, [stroke at ground level inimum 1,840 1,700 NOTE : Dimensions marked + do not include the height of the shoe lug.SK40SR| @ FACE SHOVEL ATTACHMENT (CAB SPEC.) 7 : 1 | / Pal Ey : : ¥ Unit: mm Tieden] ia oe fs Item 0.18m® bucket. 0.13m° bucket. fe ao aa sce aes ard i » B |Maximum digging depth 3,420 3,720 2x C |Maximum digging height 5,260 5,490 Daye Sed faa 3% D’| Maximum dumping height (45°) 3,150 3,260 2 E |Minimum dumping height 1,290 1,000 % J |B-fect level digging depth 2,990 3,340 __X |Horizontal digging _| Stroke 1,820 2,830 L |stroke at ground level! Minimum 3,610 3,400 NOTE : Dimensions marked x do not include the height of the shoe lug.SK45SR| © BACKHOE ATTACHMENT (CANOPY SPEC.) é i 5 Unit: mm Attachment Type! 143m arm 1.73m arm Item 0.14m! bucket, 0.12m* bucket. ’A [Maximum digging reach 6,880 6,160 A’| Maximum digging reach at ground level 5,750 6,040 3 B |Maximum digging depth 3,570 3,860 % C |Maximum digging height 5,600 5,800 HD [Maximum dumping height 3,980 4,180 2 E |Minimum dumping height 1,580 1,300 ¥F [Vertical digging depth 2,850 3,090 G [Minimum slowing radius 2,100 2,190 H [Height at minimum slowing 4250 4.270 J |8-feet level digging depth 3,090 3,440 —_K |itorizontal digging [Stroke 2,580, 3.010 L |stroke at ground level) Minimum. 1,910 1,770 NOTE : Dimensions marked % do not include the height of the shoe lug.ISK45SR| @ FACE SHOVEL ATTACHMENT (CANOPY SPEC.) Unit: mm Attachment Type| 1.48m arm 178m arm Item 0.14m? bucket 0.12m? bucket ‘A [Maximum digging reach 5,960 6,250 ‘A’|Maximum digging reach at ground level 5,840 6,130 » B [Maximum digging depth 3,650 3,950 % C [Maximum digging height 5,710 5,910 %_D [Maximum dumping height 4,040 4,240 D’ [Maximum dumping height (45° 3,430 3,540 XE [Minimum dumping height 1,500 1,210 ¥ [Minimum slewing radius 2,100 2,190 x G [Height at minimum slewing 4,250 4270 x J |8-feet level digging depth 3,200 3,540 —K |Horizontal digging | Stroke 1,890 2,390 L |stroke at ground level | Minimum 3,860 3,660 NOTE : Dimensions marked 3 do not include the height of the shoe lug. uw[Sk45SR| @ BACKHOE ATTACHMENT (CAB SPEC.) 2 A x s { “| & A K L y =| Unit: mm ‘Attachment Type 143m arm 173m arm Item, O.14m? bucket 0.12m* bucket ‘A [Maximum digging reach 5,880 6,160 ‘A’ [Maximum digging reach at ground level 5,750 6,040 % B [Maximum digging depth 3,570 3,860 x C [Maximum digging height 5,250 5,400 % D [Maximum dumping height 3,660 3,890 x E [Minimum dumping height 1,420 1,180 % F |Vertical digging depth 2,850 3,080 G [Minimum slewing radius 2,480 2,480 x H [Height at minimum slewing 4,070 4,090 x J |8-fect level digging depth 3,090 3,440 “K [Horizontaldigging [Stroke 2,580 3,010 L [stroke at ground level| Minimum 1,910 1,770 NOTE : Dimensions marked do not include the height of the shoe lug.[SK45SR| @ FACE SHOVEL ATTACHMENT (CAB SPEC.) ey V4] a " 4 ; wal Unit: mm ‘Attachment Type 143m arm 778m arm Item 0.14m® bucket 0.12m! bucket ‘A [Maximum digging reach 5,960 6.250 A’|Maximum digging reach at ground level 5,840 6,130 % B |Maximum digging depth 3,650 3,950 x C |Maximum digging height 5,390 5,550 x D |Maximum dumping height 3,650 3,820 [Maximum dumping height (5 3.280 3,380 % E |Minimum dumping height 1,340 1,040 F [Minimum slewing redius 2.100 2480 % G [Height at minimum slewing 4070 4.000 % J | 8-feet level digging depth 3,200 3,540 _K |Horizontal digging _[ Stroke 1,890 2,890 L |stroke at ground level| Minimum 3,860 3,660 NOTE : Dimensions marked 3 do not include the height of the shoe lug. 137. LIFTING DIAGRAM Pr Do not use this excavator as a crane. Unless you have complied with the legal requirements as laid down. To do otherwise puts yourself and your company into risk. (@) Calculation condition The numerical values in the diagrams indicate either 87% of the hydraulic lift capacity or 75% of the tipping load, whichever value is smaller. 1) The load point is the fulcrum of the bucket and the bucket position is an embraced posture. 2) The figures on the upper stage indicate the lifting-up ability of a machine facing sideways, while the figures at the bottom stage represent a machine facing longitudinally. 3) Dozer blade up 4) Main reliof pressure : 210kgf/em* 5) Crawler : Rubber 6) Unit : ton (2) Lifting diagram arrange No. table EU Spec. ‘The numerical values in the diagrams indicate either 87% of the hydraulic lift capacity or 71% of the tipping load, whichever value is smaller. ("Marks indicate values limited by the hydraulic lift eapacity.) (@ PREVENT UNAUTHORIZED LIFTING OPERATION Prepare the following equipment under the pro- vision of EN474-5 sub clause 4.1.7.3, 4.1.7.4, 4A. 1. Load safety valve. 2. Safety valve. 3. Bucket hook. 4, Rated object handling capacity table. 5. These lifting charts are calculated with KOBELCO standard buckets. 6. The lifting capacities are calculated without any devices to increase stability. The dozer equipment dose not have an interlocking de- vice and it is therefore not permitted to use it to increase stability. PN A standard equipped hydraulic excavator can not be used for lifting operations, Serious damage, injury or death may occur. ‘A hydraulic excavator must be equipped per EN 474-5, section 4.1.7.3, 4.1.7.4 and 4.1.7.5, prior [SKa0SR, Blade AT| _1.36m standard arm + 0.13m? bucket 1.65m long arm + 0.18m* bucket Rear @ @ Front @) @ [Ska5sR| Bide | 143m standard arm + 0.14m? bucket 1.73m Jong arm + 0.12m* bucket Rear © © Front @ ®ges¢ge sz ce op se AM a ee aa SSMS 45 4 35 3 25 2 15 1 55M S45 4-35 3°25 245 1 08 15 sM45 4 35 3 25 2 15 1 05 a5 325215 1 05 ™ + SM 4S8 8 3 z 5 5 43 iS ‘ le 3 a i f° 3 2 a 5 oo g al i ag 3 3 le 2 12 3 ie 2 ae = i" pe ie ates ae BB ig 2 eee er oe ° ae ae _ 7 5 168. ENGINE SPECIFICATIONS ‘Model SK40SR SK45SR_ Parts No. PHO2P00001F1 PY02P00007F1 Engine model STNES8—-YB 4TNE88—YBB No. of cylinders~Bore Stroke| 3-88mmX90mm 4-88mmX90mm, Total displacement 1,642ce 2,189¢e Compression ratio 18.0 Output rating 30.5 PS / 2,400rpm (22kW/2,400 rpm) 87.0 PS/ 2,200rpm (27kW/2,200 rpm) Max. torque 10.5kgf-mv/1,600rpm 13.5kgf-m/1,600rpm High idling 2,600-+25rpm 2,400-+25rpm_ Low idling 1,175+25¢pm 1,07525¢rpm Injection start pressure 200"%' kgffem? — ‘Thermostat temperature Valve opening 71°C Full open 85°C — Ignition order 1-3-2 1-3-4-2 Compression pressure 39 Ikgtlem™ at 250rpm (at battery rating) ‘35 1kgflem? at 250rpm (at battery rating) Operating lube oil pressure reading Fuel injection timing (bTDC) waet1 121 Valve Valve learance Open Close clearance, o?— before the |A0°=B0" bore tho valve action [Intake valve _[02:%0.05mm)on dead point [botiom dead point min o.camnl6t"~61 belor tel 13°~25° before the] im Exhaust valve [0.2%0.05m™ yom dond point topdend pant Starter capacity 1aVx1.4kW 122.0KW Generator capacity 12x40 — Cooling fan drive method ©8365 Discharge type, 6 blades, crank pulley/fun pulley=2110/96 2350 Discharge type, 6 blades, erank pulley/fun pulley =2120/290 Engine oil volume Full volume 4.7¢ (1.2gal), Effective 1.8¢ (0.48gal) Full volume 5.8¢ (L.5zal), Effective 2.3¢ (0.6igal) Dry weight 15573kg 180*tkg Fuel consumption rate Less than 180g/PS-h Less than 175g/PS-h Allowable tilting angles Back and forth, left. and right 25° (Gnomentary 30") <—— Engine dimension mm — (total longth> : 6mm OW turn ‘The set pressure increases. CCW turn The set pressure decreases 8) After adjusting the port relief pressure, turn back set screw (6) of the main relief 1/2 turn again. Check the main relief pressure and tighten lock nut (7. eet: 22mm o— : 6mm 4) Pressure adjustment is complete if a set pressure is stable. 3.5 MEASURING THE SLEWING & DOZER CIRCUIT PRESSURE (1) Mounting position of pressure gauge Port a3 of Fig. 5 on page 7. (2) Pressure measuring procedure ‘As mentioned above (the same as Par. 3.4 2) (8) Pressure adjusting procedure 1) Loosen lock nut (7) of main relief valve MR2 and tighten set screw (6) half turn. (See Fig. 7.) 2) Loosen lock nut (1) of port relief PR5 or PRG and adjust pressure by means of set screw (2). ‘Tighten lock nut (1) again. é Fig. 7. Main relief valves MR1, MR2 Fig. 8 Port relief valves PR1,2,3, 4,7, 8,9 SKAOSR, GA (Lue) PRE °. PRS ic Oo ° cs B © Mu oO cB (piu) Fig. 9 Slewing port reliof valves PRS, PRG36 a @ » 2) 3) MEASURING THE TRAVEL CIRCUIT PRESSURE Mounting position of pressure gauge ‘The main relief valve for the travel action is common to the main relief valve MRI of the attachment for boom and others, Therefore the mounting position is the same as above- mentioned. Pressure measuring procedure Tighten the main relief valve MR1 by half turn the same way as above. [SKa0SR] ‘Travel left forward : port relief of TRI side (A port) Travel right forward : port relief of TR2 (B port) Loosen the lock nuts of the above-mentioned port relief valves, adjust the pressure with the set screw, and tighten the lock nuts again. [SKa5SR] ‘The pressure can not be adjusted as to travel port relief valve is not equipped. [SK40SR ‘Travel port relief TRI \ iE: ‘Travel port relief ‘TR Fig. 10. Travel port relief valves TR1, TR24, MEASURING TRAVEL PERFORMANCES 4.1 TRAVEL SPEED (@) Purpose Measure the travel sprocket revolution and confirm the flow rate between the hydraulic pump and the travel motor. @ D 2) Preparation Conditions ; Operating oil temperature 50:5°C Crawler on the right and left sides are tensioned evenly Install the reflection panel with a magnet to the travel motor cover. Lift up the body, using the bucket bottom and the dozer blade. 3) (3) Measurement I (sprocket revolution) Engine speed ; Hi idle Measure revolution with a stroboscope or count the revolution for one minute. (4) Measurement 1 (20m travel) Travel for preliminary run by 5m on a solid level ground and measure a time required as the machine travels straight in 20m, 10 Fig. 11 Measurement of sprocket revolution [SKA0SR. Table 3-1 Unit : rpm Measurement | Standard | Reference] Service item value | value for | “limit RAT ist-epood | 38~84 |" 90~26 | 25~ Liz | 2nd-speed| 70~63 | 54~49 | 47~ [SK45SR_ ‘Table 3-2 Unit : rpm ‘Measurement | Standard | Reference] Service item value | Value for} “limit os ist-speed | 36~32 | 28~25 24~ Ti| 2nd-specd| 62~56 | 48~44 | 41~ Minimum ground f clearance 30~40cm Fig. 12. Measurement of travel speed {SK 4082 Table 4-1 Unit : see Reforence Moasurement item | Waiter" value for| Stimic® Travel stspeed | 27~30 | a4~37 | 40~ ut [2nd-speed| 15~17 | 20~22 | 23~ Lit] sien [Stspeed | 24-29 [31-36 [97 land-speed| 15~18 | 19-22 | 23~ [SK46SR| Table 4-2 Unit : sec Standard [Reference] Service Measurement item | Sniie" | value for| Serv navpalistspeed | 29-25 | 20~51 | 34~ REI end-speed| 1416 | 18~20 | 21~ fist-speed | _— = = LH| stoot “ot! [2nd-specd| = T=© » 2) © v 2) 3) 4) oO D Amount of travel deviation Take a travel posture. Measure the max. deviation X as the machine travels straight in 20m at travel 2nd-speed, provided the level and solid ground, Fig. 13 Measuring the travel deviation Travel deviation ‘Table 5 Unit:m Measuring | Reference | Reference | Service position | value | value for | “limit x 12 24 3.0 Amount of natural drift when parking (no parking brake) Engine Stop Tilting angle. A slope with 1/6 gradiont Minimum round Measuring posture Stopped condition in a dearance no-load travel posture 30~40cm 4/5 Gradient (12' slope) Measure the distance between the frame and the shoe at the Y position for five minutes. Y Fig. 14 Measuring the amount of natural drift during parking Amount of natural rift when parking Table 6___unit:mm/5min Measuring | Reference Reference Service position | value for | Timi ¥ ‘0=120_| 240~350 | _360~ eater eal ee DIRECTION OF FORWARD Preparation a) Place a stopper under the RH and LH travel sprocket b) Stop the engine and vent air from the hydraulic oil tank. ©) Connect a hose with the drain port of the travel motor and drain the oil in a container. ROTARY 7 DIRECTION STOPPER “B” Unless you observe the rotary direction Fig. 15 Location of stopper applied to travel sprocket at travel lock (shown in Fig. 16), rib Sob “A” may be broken by stopper in 22 PIPE e109 some cases. 50 1. Sl Fig. 16 Stopper “B” size u2) Measurement ISK40SR | a) Start the engine and relieve pressure at DRAnTPORT the full stroke of the travel lever. PFU4 b) Measure the drain rate for 30 seconds of = relieving. arom: MET AO ruorrom{ 0), a B PORT: _. PFU2 DRAIN PORT # PFU4 Fig. 17 Measuring port of the drain rate of travel motor Drain rate of Reval inotor Table 7 Unit £30500 . Reference Measuring | Reference Service value for i Position | value | Yalue for | “Yim Depot | 25 60 30 SKE] A Sprocket mounting surf rocket mounting surface c1 ° P q q C2 B Motor mounting surface Fig. 18. Measuring port of the drain rate of ‘travel motor Table 8 Unit 80sec Measuring | Reference | Reference | Service position | value | Yalue f Timit Gi, C2 port] 25 6.0 80 12@ D 2) @) 5.2 a » 2) 3) @ D 2) 5. MEASURING SLEWING PERFORMANCE SLEWING SPEED Purpose Measure the slewing time and confirm the flow rate between the hydraulic pump and the swing motor. Preparation Conditions; Hydraulie oil temperature 50:5°C Machine posture Retract the arm cylinder to the minimum stroke while extending the bucket cylinder to full stroke so the boom foot pin is at the same level as the bucket pin, Then bring the dozer blade down to the ground. Measurement Swing the machine by bringing the swing ever to its full stroke, Measure the time required to make two turns after one turn of preliminary run, SLEWING INERTIA BRAKING PERFORMANCE Preparation ‘The posture is the same as that when the slewing speed is measured as mentioned above. Put a matching mark on the outer circumference of the slewing bearing of the upper frame side and of the track frame side. Erect two poles at the front and back of the extended line of the matching mark, Measurement, Slew the machine 180 degrees at full speed and operate the lever to its neutral position in the position of the poles. After the upper structure stops, measure the amount of shift of the matching mark on the slewing race by the length of the outer circumference (are) of the slewing bearing. Formula ; Measured length Circumferential length 860" 13 BUCKET PIN BOOM FOOT PIN Fig. 19 Slewing speed measuring posture Slowing speed [SK40SR_| ‘Table 9-1 Unit: secirev ; Reference Measuring | Reference Service condition | value | YAN 20F | limit One tum | 73-83 | 93-106 | ti~ SKASSR Table 9-2 Unit: seclrev Measuring | Reference | Reference condition | “value.” | Yalu for One tun | 72-78 | 9.2~10.0 180° Fig. 20. Slewing inertia braking performance Slewing drift [SKAOSR,SKA5SR] Table 10 Unit: dogreo Reference ; Reference Service Model | “value | Yalte for | “limit SK40SR | 10-20 | 25~35 35~ SK4ssR | 10~20 | 25~35 35~5.3 DRIFT OF THE MACHINE WHEN THE SLEWING 1S STOPPED ON A SLOPE Preparation On a slope with 1/6 (12° slope) gradient @ D 2) The machine takes the same posture as that: when the slewing speed is measured i. e. when the upper structure is placed with its side facing a slope, 3) Put a matching mark over the outer circumference of the slewing bearing on the upper frame side and on the track frame side, (2) Measurement When five minutes has passed after the engine stops, measure the length of the distance of the matching marks. 5a a » DRAIN RATE OF SLEWING MOTOR Preparation Stop the engine. 2) Bleed air from inside the hydraulie oil tank, 8) Disconnect the slewing motor drain hose from its end returning to the hydraulic oil tank and drain oil in a container. 4) Put a plug to the tank side. (2) Measurement 1) Start the engine and put the side faces against the blocking thing. 2) Relieve the slewing motor at full stroke of the slewing. 8) Receive in a container the amount of drain accumulated in 30 seconds of relieving. “ Length of Sie the distance 1/5 gradient Fig. 21. Drift of the machine when the slewing is stopped on a slope parking WINE Table 11 Unit:mm/Smin i Reference ; Measuring | Reference | Reference | Service caging | Reem | vatiefor | Sv Slewing race! 0 1 2 Fig. 22 Measurement drain rate of slewing motor Drain rate of slewing motor ‘Table 12 Unit: €/30sec , Reference , Measuring | Reference Service postion | value | Yalue for | “Timi SKASR_| 60 80 i SKas5R | 3.0 78 1064 @ @) » 2) @) D 3) 6. OPERATING TIME OF CYLINDERS Purpose Measure the operating speed of the attachment and confirm the flow rate between the hydraulic pump and the cylinder of the attachment, Preparation Condition ; Hydraulic oil temperature 50:45°C. Posture With the bucket empty, bring the dozer blade down on a flat ground, retract the arm cylinder to the minimum stroke and extend the bucket cylinder to full stroke. Measurement Boom eylinder speed (Fig. 23) Measure the required time from the grounded position (max. hoisting position) of the bucket: to the maximum hoisting position (ground contact position). (Not include the cushioning time) Arm cylinder speed (Fig. 24) Measure the required time from the most extended position (or most retracted) to the most retracted position (or most extended) of the arm cylinder. (Not include the cushioning time) Bucket cylinder speed (Fig. 25) Measure the required time from the most extended position (or most retracted) to the most retracted position (or most extended) of the bucket eylinder. 15 MEASURING ATTACHMENT OPERATING SPEED Fig. 25 Measuring the bucket cylinder speed SKAOSR | ‘Table 13-2 Unit: see : ‘Reference Measuring | Reference Service condition | value’ | Yaluefor | “fmt x 29-35 | 36~44 [45m 3B 22-28 | 29~3.5 | 3.6~ ¢ 36=42 | 46-53 | 54~ D 3.0=3.6 | 38~4.5 | 4.6~ E 32-38 | 41-48 | 4.9~ F 23-29 | 30-36 | a7~ SKA5SR | Table 13-2 Unit soe = Reference , ‘Measuring | Reference Service condition | value | Value for | “limit x 30-56 [374.5 | a6~ B 29-35 | 36-44 | 4.5~ Cc 31-37 | 3846 | 4.7~ D 32~36 | 41-46 [48> E 27~33 | 85~41 | 42~ F i9~25 | 26~a1 [| a2~4) Swing cylinder speed Take the same posture as that when the stewing speed is measured, Measure the required time as the boom is swung from the left (right) to the right (left) to full stroke, (Not include the cushioning time) 5) Dozer eylinder speed Lift up the dozer blade by the bucket bottom as shown in the Fig. 27. Measure the required time for the dozer blade to roachs top (bottom) position from bottom (top) position. Fig. 27. Measuring the dozer cylinder speed SK40SR | ‘Table 14-1 Unit: see Measuring | Reference | Reference | Service condition | value | Yalve for | “Tmt ¢ Gin70 [78-90 | 9a~ E 46-55 | 69-69 | _7.0~ r 2a~28 | 29-86 | 42> 3 122 | 23-28 | 29~ SK458R | Table 14-2 Unit see Reference Measuring | Reference | Refere condition | value | Value for @ 63-69 | 8.1~88 H 51-67 | 65-18 I 19-25 | 26~82 z 2-18 | 19-23 1662 a D 2) @ D 2) OIL TIGHTNESS OF CYLINDERS Preparation Bucket empty Posture Retract the dozer and the arm cylinders to full stroke and extend the bucket cylinder to full stroke so the boom foot pin is at the same level as the bucket pin. Measurement Attachment cylinder Measure a change in the length of the cylinder rod five minutes after the engine stops. ‘Swing cylinder On a 1/6-gradient (12° slope) direct the upper structure so it crosses the slope and take the same posture as that for the oil tightness measurement of the attachments. Stop the engine and five minutes later, measure the change in the length of the eylinder rod. Fig. 28 Measurement oil tightness of Att cylinder Oi tightness of cylinders Table 15__Unit: mm/5min_ in Reference i Measuring | Reference Service Position | value | Yate for | “limit A 6 12 18 B 5 10 15 c = = = D 90 180 270 E 3 6 10 1/5 gradient Fig. 28 Measurement oil tightness of swing cylinder a7 Table 16 _Unit:mm/Smin 5 Reference i Measuring | Reference Service position | value | Value for | “limit RHF 2 4 6 LH_G 3 6 97. MEASURING PERFORMANCES OF SLEWING BEARING 7.1 AXIAL GAP OF SLEWING BEARING (Purpose Measure the play of the slewing bearing and confirm the wear of the bearing. (2) Preparation 1) The slewing bearing mounting bolts are not loosened. 2) Lubricate the slewing bearing and confirm Fig. 90 Measuring position of the axial play of that no abnormal sound is heard. slewing bearing 8) Install a dial indicator to the magnetic base and fix it to the track frame. 4) The posture is ; the arm 90~100°, the dozer blade raised, and the attachments at the front and back and at the right and left. (8) Measurement 1 1) Direct the upper structure and the truck frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the slewing body side and set the reading at zero. Fig. 31 Measuring the axial play of slewing bearing 2) Raise the one side crawler for the measuring as shown in the Fig. 31. Axial play of slewing bearing ‘Table 17 Unit: mm 5 Reference 5 ‘Measuring | Reference Service position | value | Yalue for | “ime x oa~10 | 12-19 | 20 7.2 HORIZONTAL PLAY OF SLEWING BEARING (THE PLAY OF THE ATTACHMENT IS INCLUDED) () Preparation ‘The posture is ; the arm most extended, the bucket dumped, and the tip of the bucket, tooth lifted up by about 10mm as shown in the Fig. 82. (2) Measurement Push the tip of the bucket to the right and left by human hand and measure the amount. of distance. Fig. 32 Measuring the play at the tip of the bucket tooth Table 18 Unit: mm : TSI | Gere Measuring] Reference Service foaton® | faa’ | vaefor | Sti Yee [60m 180 | 160 18me PHOTote KOBELCO SK40SR SHOP MANUAL SK45SR _—_ WORKING STANDARD —_ TABLE OF CONTENTS 1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS eee 1 2. TIGHTENING TORQUES FOR NUTS AND SLEEVES SPECIAL SPANNER FOR TUBE SCREW SIZE AND TIGHTENING TOOL SIZE INTERNATIONAL UNIT SYSTEM UNIT CONVERSION LOGARITHMIC CHART ABBREVIATIONS IN THIS SHOP MANUAL 3. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND - 7 PHO <© KOBE STEEL,LTD.Applicable Machines PHOO101~ PY06001~ Revision Date of Issue First edition May, 1997 | SsPHOTOLE1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS Tables 1 and 2 indicate tightening torques and a fracture under load. applicable to cases where no special note is Insufficient tightening may lead to a loosening or given. loss of bolts. Always tighten bolts to proper Overtightening of bolts may result ina twist-off torques. Table 1 Standard tightening torques for metric coarse screw threads unit: kgm (ft-lbs) Classification 4 T 7 it: 70 T ‘Nominal size [No lubrication|Oil lubrication |No lubrication [OM Tubrieation|No lubrication [Oil lubrication T45z005 | Oa8t004 | 0.9801 | OBSt008 | 177x018 | 15x01 Benes @3£04) |_@7t03) | c.1+07) | @ot06 | G31) ais ae 109011 | 0.92#0.09-|— 24f02) 2.0402 | —ase04 | 30204 a9xos) | @7t07 | are 41) (528) 2643) aa 22402 | 1832018 | 47405 | 40404 | 85409 | 72207 dex1) asin) (B44) (293) (617) (5245) Maa Paizs | Sized | 32k03 |— 81x08 | 68t07 | i4ozi5 | i2atiz E 7x3) (23:42) (596) ors) | Giori) | Ga+s) aaTeEes 39206 | 5.0405 | 2813 | 108E1T BER 195ELD (434) (36:4) (9349) isx8) | _azoxia | G40 ae 9.0£09 | 1620.7 | 19.5420 | 164416 B54 2948 = (6547) (545) | _do14 | 20412) | @50%29) | (1022) ye poas | 12dzL2 | To5t10 ‘a7E3 | 9542 55 aed 2 (G09) 67) | 0022) | «70x14 | (@50%36) | (900:29) wa Pozs | fisziv | Wa7dia | sata 3243 BET BTE6 5 _|_aso%12) | atox10) | 7020) | 3022) | ca9051 | (i043) won peas | oe? 19.642.0 S1E6 aia 9259 T7E8 6 | atot1g | adoe14 | (370t36) | (1029) | (7065) | (560358) ay 32048 WES 336 Tist12 96410 ish (22022) | (17022) (38036) | (85087) | (690272) a 4444 3624 7828 TisEi7 —|— 4014 (32029) | (26029) (660458) _| (1800120) | (1000100) aan COLE S025 isitis | tori a35t24 —[ oat20 (43043) | (36036) _| (95094) | (80080) _| 1700170) | (14004140) fs Bites BET Ti6£18 | 148415 | 31798 | 266427 (59058) | _(490451)_| 1300130) | (4100110) | 2300230) | (19003200) af 10510 B49 227423 [ i90z19 | 409E41 “| $43E54 id (76072) | (640%65)_| (1600170) | 1400140) | (90002300) | (2500250) Table 2. Standard tightening torques for metric fine screw threads _unit: kgm (ft tbs) Classification 4 T Z T 10 T ‘Nominal size [No lubrication [Oil lubrication|No lubrication [Oil lubrication |No lubrication [Oil lubrication Ms peat | USE0dl | O97z01 2et02 | 21402 | 46204 | 38204 = @3to8) | (0-07 | ast) as1 3x3) @rt3) mio pois | 28402 | 191£019 | 49205 | 42z04 | g0z09 |— T5407 =125 | are @4zy) (54) (303) 6447) 648) aaa 40504 | 34403 | 87209 | 7320.7 | 157416 | 12413 12 P=125 | (2943) (2542) 6347) (5345) (1012) 59) 94209 | 79408 2042 TI2EL7 STEAL 3153 Mié P=15 | (68i7) (3746) a4ot14 | (20412) | @70+20) | (22022) 1st19 | 15.8416 aide 349. TAET “256 M20 P=15 | aaoé1d) | 10412) (s00+29) | (250+22) | (64051) _| (45043) S2E8, 218 LT 5826 126512 10510 M24 P=2 | (30%22) | @oot22) | ciots1) | 4204s) | (1ois7 | 76072) aaeeea 6526 B45 Wa2ti4 | 1ieti2— | 25696 | 21921 (47043) _| (99036) _| 000100 | (85087) _| (1800190) | 4500150) o9E11 238423 | 0820 | 4u8k43 |" a57E36 M36 P=3__ | (79080) (1700170) | 400140) | (9100810) | (26002260)2. TIGHTENING TORQUES FOR NUTS AND SLEEVES ‘Table 3 indicates standard tightening torques nuts and sleeves in bite type tube fittings may applicable to cases where no particular note is develop oil leaks through pipe connections. given. Always tighten nuts and sleeves to proper Overtightening or insufficient tightening of torques Table 9-1 ‘Tube size , Working pressure Opposing | Tightening torque Manufacturer's name | “gt/emt (pad | ODXthickness | MNTTEY| etm (els) TOXL5 a SEL (0,304%0,059) (967) 15x20 a 12E12 (0.591X0.079) @it9) 300 18X25 itis Nippon AMC; (4270) (0.709%0.098) i 081i) 22X3.0 a BE22 (0:866%0.118) (15918) 28x4.0 al 28428 (1.100157) (20020) 300 35X5.0 5545 ee 4270) 2.88x0.197) io (33033) Table 3-2 SLEEVE NUT B ‘Tube size Parts No. ‘Tube size nore) Parts No. ed __| Thara Koatu | Nippon AMC. | od 0) Thara Koatu | Nippon AMC. @_| 293806000 = © |__14 _ | ar9aNo6000 = 8 | ZF98808000 17 | ZF93N08000 = 10 | ZFessi0000 | ZA9aS10000 io |__19 | ZF9aNi0000 | ZAsaN10000 12 | 293812000 = a2 |__22 | ZF9aN12000 = 15__| ZFessis000 | _ZA99S15000 18 | __27 | @F9anis000 | ZA93N16000 18_| ZFessi8000 | _ZA93S18000 is | 32 | ZF9aNis000 | ZA93N18000 22 | 293822000 | ZA93822000 36 | ZFOSN22000 | _ZA93N22000 28 | zF93s28000 | 293528000 41__ | ZF93N28000 | ZA93N28000 32_| ZF99832000 60 __| ZFeaNa2000 = 8/88] 8) ‘35 | Zrossa5000 | ZA93S35000 85__| ZFOSN35000 | _ZAQ3N35000 38__| ZF93838000 38 | 60 | ZFosNas000 =3. SPECIAL SPANNER FOR TUBE Table 4 “Applicable tube diameter] Width across flat i 5 , ble tubs a Part No aon Drawing of a special spanner mm (in) a7 80315), A 24217160 27 coat j PART-No, 6 (0.591) as : Hesy oan © 12.7484(0.500 28884.) 70.276) 2210368) 2.88) i 24917138 32 19 29 (0.709) (ons PART-NoFET | Gs HEX32 0 12.7483(0.600 #38 481.89) Tere 1.500.485) 22 FAL T 22 23 (0.866) pemeae bad (0.906), PART-No si [cose HEX36 5 12.7283(0.500*33 ) oa35 T0929) 14.5057) a 24217115 a a ~PART-No. FBT [éieo 10 FY neat 0 12.7433(0.500°835 ) 8019.15) 109 4.29) 20.510.807 24217231 46 1 co 35 (2.10) 0.23) ~PART-No. EE |ci-38) E a HEX. 019.05 488(6. 00.15) 1094.29 20,500.80 a 2aniT232 50 a9 Fay 1.35, 2.26) a3] SPARTNo. “FAT |di8m ima oy 019,05224(6.7502922 S119 S050 20.5:0.807) 35 24217314 55 t (1.38) at] -PARTNo. EAT [dfn cy HEXSS 520 (0.787)4, SCREW SIZE AND TIGHTENING TOOL SIZE (1) Capscrew (Hexagon bolt) () Hexagon bolt (Socket bolt) a a E © u g B Table 5-1 Table 5-2 Table 6 NOMINAL | 5 am NOMINAL] bam NOMINAL] 5 am SCREW SIZE SCREW Siz SCREW SIZE | STANDARD UNIFIED | STANDARD @ | STANDARD DIMENSION _—_(SoREW THRBADs)| DIMENSION DIMENSION NG 10 W4-20UNG, WL Me 5 MB 13 fi6-18UNC 13 MB 6 M0 17 3e-16UNG cry M0 3 ia 19 7hg-14UNC 16 Miz 10 ania) (a2) Va-18UNG 19 Mid 2 M6 24 Se1TUNG, 2 M6 “4 ‘ais) i 31 0UNC 29 ans) 4 M20 30 7-90NC 33 720 i (@t22) 32 1-8UNC 38 a4 19 ‘M24 36 1ie-8UN, 3 M30 22 ana) ay 1 i4-8UN, 48 36 27 30 46 Lia SUN, 31 Maa 32 M36 55 Mae 36 nm = @ Plug Mas 70 M48 75 B M56 85 ‘@teo) 90 M4 95 tes) 100 M72 106 ‘M76 110 M80 115 Table 7-1 Table 7-2 Plug parts No. [PF SCREW| B mm [O ring parts No[Nominal Oring © _PT'SOREW| B mm zp72xoso00 | PFia | 19 | zbiaPoti00 | PFI4 Prue 5 za72x06000_| PFs | _22 | zp1aPo1400 | _PFare Prue 6 ma2xos000 | PFua | 27 | zb1ap01800 | PF12 Pros 3 ze72xi2000_| PFs | 86 | zp1aPoz400 | PFal4 Prue 10 ‘e72xi6000 | PFi | 41 | zD12P02900, PFI Pra ry PTt 17 Priva 22 PTL 22,Introduetion Although this manual uses the JIS unit system. If you need SI unit, refer to following international system of units, Given hereinunder are an excerpt of the units that are related to this manual : 1, Etymology of SI Units French : Le Systeme International 4’ Unites International System of Units 2. Construction of SI Unit System English INTERNATIONAL UNIT SYSTEM. (4) Derived Units bearing Peculiar Designations Table 11 ‘DESIGNATION|SIGN| Motive power, Electric power| [Derived units of] Si unit] Bolt leystem (1) Basie Units yearing peculiar} (n-th power of 10, where n is an integral) Newton Pascal Pa Watt (Ohm (Celcius degree) jor degree thu QANTITIES DESIGNATION (6) Prefixes of ST Length Mass Time Current ‘Thermodynamic temperature Gram molecule Luminous intensity (2) Supplementary QANTINIES DESIGNATION [SIGN Piane angle Solid_angle (8) Derived Units of Basic Units QANTTTIES DESIGNATION Brea Volume Velocity Acceleration Density [Meter per second [Meter per second / second ‘Table 12 PREFIX DESIGNATION] SIGN _|POWER © 10" M | 10° kK 10° h 10° da 10 a | 107 e | 107 m | 107 n | to n | 107? Bao 3. Unit Conversion Table ‘Table 13, QUANTITIES] JIS Si__[ REMARKS ke Ike IPs. j0.7355kw [Kilogram per cubic meter] ket fon | 9.807 gem |10N-m | 9.807N-m lkgfiem* |o.1MPa | 0.098MPa lpm __|min rhmin_¥d %1 Units that are allowed to use6. UNIT CONVERSION LOGARITHMIC CHART TORQUE IN-m=0.102kg¢m 10 50300 500 1,000 5,900 10,000 20,000 Nm 1 as 30 100 500° 3,000 2400. kgm Lkgém=9.807N'm ERESSURE 1MPa=10.197kgtiem? oa 1 10 100 MPa i Had Hal 1 i 10 10 1,000 klen* Ikgtiem®=0.098MPa 7. ABBREVIATIONS IN THIS SHOP MANUAL Table 14 Abbreviations Original words ‘Abbreviations Original words AIC | Airconditioner MAX | Maximum AC | Alternating current MIN | Minimum ACC | Accessory OD _| Outer diameter Assy | Assembly On| Overhaul ATT | Attachment OPT | Option Brg__| Bearing Press | Pressure GV [Control valve PIV | Pilot valve Cw | Counter weight RD___| Radiator COW | Counter clock wise RH [Right hand cw [Clock wise RV___| Relief valve Cyl___| Cylinder sid Swivel joint DO__| Direct current SM___| Stepping motor EG [Engine SOL [Solenoid Fig__| Figure STD | standard GND | Ground SWV___|Solenoid valve Hyd___ | Hydraulic SW [Switch 1D Inner diameter Tomp _ | Temperature vO IN/OUT v Valve LH [Left hand8. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND ‘Table 15 MANUFACTURER, SERVICE FEATURES LOCKTITE | THREE-BOND - #242 1360K Low strength ee #262 1374 Middle strength #271 1305) High strength Sealing compound #516 1215 SealingSHOP oO KOBELCO SK40SR MANUAL model SK45SR TABLE OF CONTENTS HYDRAULIC SYSTEM UPPER STRUCTURE TRAVEL SYSTEM ATTACHMENTS: — CONTROL SYSTEM ELECTRICAL SYSTEM TROUBLE SHOOTING How to Index each Shop Manual Section ‘The SYSTEMS of this shop manual consists of 9 headings as shown above. Each soction can be easily referred to by indexes appended to the margin of the page as indicated on the right. Please use the indexes for speedy reference. PH22 alo) PH29 SYSTEMS Book code No. S5PH1001E()SKAOSR List of Shop Manual SYSTEMS Section Book Code No. ines ‘Title ‘Distribution Year ~ Month pHi2 | HYDRAULIC SYSTEM nas aera puis | UPPER STRUCTURE Toros — PHS TRAVEL SYSTEM 39705 ~—_ PHL ATTACHMENTS Stoo0s S900 PH22 CONTROL SYSTEM Sos —_ pH25 | ELECTRICAL SYSTEM Soros aa pug | TROUBLE SHOOTING Soros ~— Avplicable Machines | Pyosoot—o7t00 | _pvor10r~SHOP MANUAL ==" DH 1 Doren KOBELCO SK40SR ee HYDRAULIC SYSTEM TABLE OF CONTENTS 1. SUMMARY 2. HYDRAULIC CIRCUITS AND COMPONENT MODELS 3, EXPLANATION OF HYDRAULIC CIRCUITS 4, NEUTRAL CIRCUIT 5, TRAVEL CIRCUIT 6. SLEWING CIRCUIT 7. BUCKET CIRCUIT 8. BOOM CIRCUIT 9. ARM CIRCUIT 10. SWING CIRCUIT 11. DOZER CIRCUIT AT DOZER LOWERING 12, COMBINED CIRCUIT 13. PILOT PIPING 14, MAIN PIPING <@ KOBE STEEL,LTD. SK45SR TiApplicable Machines PHO0101~01100 PY06001~07100 PHO1101~ PY07101~ Editing the hydraulic system For the convenience of editing, we have edited SK40SR and SK45SR in the same volume. ‘The functional explanation of the circuits is represented by SK40SR. The reason is that both models have the same control valve circuit and are basically identical in terms of the concept of the system circuit. The difference is the way the device circuits are expressed as the manufactures of the pump and the motors differ between the two models. Revision Date of Issue ‘Remarks First edition May, 1997 | SSPH12018 K First revision | September,1999_ | SsPH1201B0 K1. SUMMARY 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. Table 1 Perfor novice Function Features @ Travel straight Travel straightness in combined operation avavell of boom and dozer © Prevention of over run on a slope Prevention of over running of motor by brake valve action # Independent slewing Stabled slewing speed, case in the slanted 2 arm traction and pressed slewing digging, 3 and stabled loading operation @ |e Automatic slewing parking brake ‘To prevent slewing motion from drifting 2 on a slope 5 ‘© Hydraulic pilot control type Delicate controllability B |. |e Swing cylinder Side digging to 110mm/165mm(40SR/45SR) Bl & outside of shoe width (left 85°/right 55°) 2 & ‘@ Multi control valve (option) Four operating patterns by single lever S| & Je AB super shift (option) Changing the operation into two operating £ ed patterns by shifting the lever to the right 8 and the left ep ¢ Closed hydraulic oil tank ‘To prevent hydraulic oil from being as contaminated © Suction strainer Removing dirt from the suction side @ Line filter ; pilot circuit ‘To prevent pilot operating circuit from lOthers| aa malfunctioning Return filter To prevent hydraulic oil from contamination © Cooling hydraulic oil by oil cooler To prevent hydraulic oil from being deteriorated. ~ ‘© Total power control Effective utilization of engine power by 2 the total power control of the variable & |Pump displacement pumps (with two discharge g ports) and the gear pumps, and prevention » of engine failure during operation & lavavel|® 18% 2nd-speed travel Changing over the travel speed between a 2.11 4.Then/h {rubber crawler (40SR) } Z ‘2 @ |» Recirculation in light load arm digging Positive and speedy arm digging action in Ze combined operation BS |g |e One touch deceleration (option) To change engine revolution and to save e| 3 fuel consumption and sound level when B8| a waiting for a dump truck 2 102.1 STANDARD SPECIFICATION [SK405R] HYDRAULIC CIRCUITS AND COMPONENT MODELS Boom of auc dg | | eam aie) ‘na VT Goma Inet nl? om owe om oa ‘Arm yl, Swing ey, Dozer oy stetg 9 Be dtm” [Pan HE om sig 0 6 Fig. 11 Standard specification Hydraulic diagram Applicable machines: PH00101~01100 PHOL101~ No.| __NAME PART No. MODEL No 1 [pump PHt0vo0001F1 |psvo2-19 2 |controt v PH30VO0001F1 |BCv-65. 3 [SLEWING UNIT |PH1Svoo001FI |sco15E-071 alfrnaewcrron iis voonosel vEseD==="anreacsad 5 [poom cvnoer |rorvo00%2F |80-30-695 (FOR CANOPY) 6 [ARM CYLINDER _|PHO1vo0011F1 |g0-So-715 7 [BUCKET CYLINDER |PHOTvoooOaFI |75-40-535 8 [SWING CYLINDER |PHotvo0010FI |100-55-541 al zen evewoen antvosoeis0Ta==r7s 10 [swivel JOINT _|[24100112703F1 =aeeeee| 11a [Pot v _[pHa0voo002F1 [rHaoMioTA 113 PLOT V (OPT) lpuzovoooosr1 |rHaowar0r3 12 [SOLENOID V__[PH3svoO001F1 |axwesa-207 Gr2W5=206% 13 [SHUTTLE V PH26v00001F1 = 14 |mutti crv (PT) [2aa6u2621F1 _|k16AR6—11 | 15 [Heck Vv 2436R1062062 |515A-K2 16 [RETURN FILTER |2446R336F1 17 [RELIEF V 2a36R876F1 ; 18 [SUCTION STRAINER|2aaeRaaar1_[y-1405 i 19 [Por FILTER _|PYSovooo01F1 |Y-410200 20 [oi COOLER —_|PHS3v00001P1 |E/G PARTS 129211-44910 3% In the case of serial number PHO1101 and up. No. NAME PART No. MODEL No. 21 [CONTROL V PH30V00001F3| BCV65-AA9 4A-1 | TRAVEL MOTOR PH15v00005F3| PHV-350 48-1 | TRAVEL MOTOR (OPT)| PH15VO00006F3| PHW-350 with P/B Abbreviation table cyl. [CYLINDER PIB_| PARKING BRAKE NW | CONTROL VALVE PAV _| PILOT VALVE 6/6 _| ENGINE R_| CYLINDER ROD SIDE H_| CYLINDER HEAD SIDE || Spec. | SPECIFICATION opt | oPrion v_[vatve2.2 BREAKER SPECIFICATION (0PT) [SKa0SR’ ae Fait No. NAME PART No. MODEL No. d BREAKER - = 22 [CONTROL V PH30V00003F1_|BcV-35 Breaker Tighten up this port at using the breaker. cen 6 karswms | |ia-atvo2 en, hal foz_os 20 corry ria asl fos Pun tt on cua 6 wo Hh” " wlt@ cman? rare crus Me Cie Fig. 2-1 Breaker specification Hydraulic diagram23 COOLER MODE SPECIFICATION (SPEC. BY COUNTRY) [SKA0SR) fons Rai No. NAME PART No. MODEL No 1 [puMP PH10voo002F1_[PSvD2-19 7 21 |sotenow v 'ys35vo0004F1 [07096-00000 oman krrstaas an xen, 2) 281 los [oan lov on AS* vo] Gt G2 fz lees! adi fan ol [ao es| o> lar i 1 1 ' 1 ' 1 ' 1 h 1 ' 1 1 1 1 Funtt on cary 6 * alt an (7-000) Fig. 3-1 Cooler mode specification Hydraulic diagram2.4 STANDARD SPECIFICATION [SK45SR] Applicable machines: PY06001~07100 PYO7L01~ - Backes Soom of ‘Arm ef. Swing of. Dozer of. | a eens | t NAME | PART No. MODEL No. {Es : contro. v _|PY30vo0003F1 |scves-aBa ‘| am SLEWING UNIT _[PYisvo0004F1 |pci-150 _| aul , [4 [Ravel motor [pyisvoooer1 [emoeve “ 1 [7s fooom cramer [pranyoooair a Seon cary : 6 [ARM CYLINDER |[pYotvo00z3F1 |90-50-730 1/7 Jaucxer cvLnoéR |Pv01vo0019F1 |s0-45~s40 _] 1 |_8 |SWING CYLINDER PY01V00022F1 |105~60-541 _ ome at adhe | [fo [swiver sont —_[2at00312703"1 |— | Gtalpnor v pHsovo0oc2r: |THaoMToitA | | fine [ROT Y (OPT pusovoooosrr |raaonani013 | [72 [souewow v_|pnasva0o01Ft [axwesn-20rraws— 0a ! 13 |sHUTTE V PHzevooo0iFt |— i 74 [MULT civ (OPT) |2a36u2621F1 |KI6AR6-11 I 15 |CHECK V 2436R 1062062 |$15A-K2 ' | 16 [RETURN FILTER |2aa6Ra36F1 fe i 17 [RELIEF V 2436R876F1 |— a PL we i | [te |sucriow sraamen|aessnaeers _| ~ cow HE toma [aweae Hf ome | ego Hf uae Fab oom ' 20 [OIL COOLER PY53V00001P1 |E/G PARTS i 3 _In the case of serial number PYO7101 and up. : No. | NAME PART No. | _ MODELNo. 1 24 | CONTROL V PY30V00003F3| BCV65-AB9 ' A1 [TRAVEL MOTOR __|PY15vo0O06F2| GMOBVL + [apaa [reaver motor (OPT prisvo0o05F2| GMOBVL with 7a _| : Fig. 1-2 Standard specification Hydraulic diagram2.5 BREAKER SPECIFICATION (OPT) [SK455R pet eee eee eee ie | H d ' No. NAME PART No. MODEL No. | BREAKER = = i 22 |CONTROL V PH30V00003F1 |BCV-35 a he x al 3 Taner wp Wiper a ne Teena tae apm kersvenrs | |ea-aunra Breaker * al fez queen cpllor Jered KEM? nul ct sz lee, sil ad foe Fun tt an cama) 6 “ontt an wo Han” cyan cam’ conan? 19 Fig. 2-2 Breaker specification Hydraulic diegram2.6 COOLER MODE SPECIFICATION (SPEC. BY COUNTRY) [SK455R Arann have No. NAME PART No. MODEL No. 1 [PUMP, PY10v00007F1_|AP2D25LV 21 [SOLENOID V 'ys35vo0004F1 {07096-00000 4 5 lve ave Ik AeA aan Fitton cana) 5 mam? earn'e qT eA 141A MF) ue Toe 1 ts Fig. 3-2 Cooler mode specification Hydraulic diagram3. EXPLANATION OF HYDRAULIC CIRCUITS Displaying the flow circuit and standby circuit when operating. Regarding the electrical symbols in this manual, refer to the electric circuit diagram.4, NEUTRAL CIRCUIT ‘The following functions are described in this section: 1) Remote control safety lever and pilot circuit 2) Pump total power control circuit, Bevis rane 4.1. REMOTE CONTROL SAFETY LEVER AND PILOT CIRCUIT Purpose ; For safety and to prevent careless operation Principle; The system cuts off the pressure supply of the pilot (remote control) valve and fixes the travel lever. ‘Function ; If both of the safety levers located in front of the control boxes on both sides are turned forward after the engine staris, the limit switehes (SW-5, 13) on the right and left are actuated. This switches over the lever lock in the solenoid valve (SV~1) of the 2-stack solenoid valve (12) and makes the pressure supply of the pilot operating circuit in a standby condition. However, the Cab spec. machine is equipped with a safety lever on the one side only. Meanwhile, the action of the travel lever is released by the travel lock motor. 4.2 PUMP TOTAL POWER CONTROL CIRCUIT Purpose ; To make the best use of the engine power. Principle ; If the self pressure of the pump rises as the load to the pump increases, the delivery rate of the pump decreases to perform total power control, Function ; The pump consists of two variable displacement double- piston pumps (P1 and P2 as discharge ports) of equal capecity that are controlled by a single cylinder block, a trochoid pump (PP as discharge port) as the pilot pressure source, and a gear pump (PG as the discharge porti, all of which are arranged in series. The variable displacement pump has a single swash plate (P38) one side of which is held by springs (P38, P39) in its maximum tilting position. The discharge flow of the pumps is so controlled that the pressure created by the load to the P1 pump, the P2 pump and the: gear Pump pushes respective control pistons (P15) and decreases the angle of the swash plate. Power control is effected by controlling the delivery rate of the piston pumps in such a way that the sum of loads to the Pi pump, the P2 pump, the trochoid pump, and the gear pump does not exceed the engine output power (torque). In the hydraulic circuit, the oil discharged from the P1 port of the main pump enters the P1 port of the control valv2 (C/V). In the neutral position, the oil comes out of the T1 and T2 ports and returns to the hydraulic oil tank. ‘The oil discharged from the P2 port of the main pump enters the P2 port of the control valve, goes out of the ‘Ti end T2 ports and returns to the hydraulic tank. The oil discharged from the PG port of the gear pump enters the 8 port of the control valve, goes out of the TI port and returns to the hydraulic oil tank, The oil discharged from the PP port of the trochoid pump is used as a pressure source for the pilot circuit. ropa aera y A A tars? carne Fig. 4 Neutral circuit at safety lever release5. TRAVEL CIRCUIT The following functions are described in this section: 1) Main circuit for travel motor 2) Primary pilot pressure for travel 2-speed select command “in spe a i a) Jan et de pt arp eons 5.1 MAIN CIRCUIT FOR TRAVEL MOTOR Purpose ; To drive the crawler to create powerful drive power, to insure safe drive on a slope, and to perform fast drive on a flat ground. Principle; 1) The hydraulic energy supplied by the pumps is converted to rotating motion and transmitted to the reduction gear. 2) The reduction gear changes the high-speed rotating motion of the hydraulic motor to low-speed high torque 0 as to turn the outer casing. 3) The brake valve spool is controlled by the discharge pressure of the pump to prevent over run by inertia force. 4) High speed travel by switching over the variable 2- speed motor. Function ; The travel spool of the control valve (2) is actuated via the cable. If the travel lever is turned forward, the cable move the spool. The oil discharged from the Pl port of the main pump enters the control valve through the Pl port of it and acts on the main relief valve. At the same time, the oil flows into the B port of right travel motor via the travel straight valve. The main circuit opens the check valve (T216) in the brake valve spool (T215) and enters the suction port of the hydraulic motor. As the spool (T215) is changed over by the feed pressure, the returned oil flow to the A port instead of passing through the check valve and causes the hydraulic motor to rotate, If the travel lever is bought to neutral, the brake valve spool (T2165) returns to neutral by spring action and attempts to shut off the path, but the return speed is regulated by the throttling effect of the choke (1226) in the return passage of the spring chamber. The travel motor attempts to turn by inertia even if the hydraulic pressure to port B is shut off. On that occasion, the return oil is restricted gradually by the changeover speed of the spool (T215)and the notch in it, thereby causing the hydraulic motor to stop smoothly. 5.2 PRIMARY PILOT PRESSURE FOR TRAVEL 2-SPEED SELECT COMMAND Purpose ;To select between the low-speed high-torque and the high-speed low-torque modes. Principle; Change the swash plate tilting angle of the variable displacement motor by the primary pilot pressure. Function ; If the rabbit and the turtle marked switch on the travel lever grip is pressed, the travel 1.2-speed solenoid (SV— 2) of the 2-stack solenoid (12) is selected. This causes the primary pilot pressure to enter the PP port of the travel motor (4), changes over the 2-speed spool (7211), pushes the 2-speed select piston (1218), and changes the tilting angle of the swash plate to the 2nd step. The oil is connected with the drain port via the 2-speed spool (211) when the engine stops. This brings the swash plate back to the 1-speed by spring action. Therefore, the motor is always started at 1-speed. | pr a 5 br i ™ rst (7226) 10 nasa en, 8) tay Hau Bs ey U [fanlt on cam 5 ‘otto [" witw A a carne ovat are 1 apo 7 Fig. 5 Travel circuit at forward 2-speed changeoverSei spot Slewing parking take (815) Poppet oie S56) (358), ‘taco bate 6. SLEWING CIRCUIT The following functions is described in this section: LD) Slewing pilot circuit 2) Automatic parking brake for slewing 3) Anti-cavitation circuit for slewing deceleration 6.1 SLEWING PILOT CIRCUIT Function ; If the slewing motion is performed, the secondary pilot pressure from port, (5) or (6) of P/V (11A) enters port bl or al of C/V (2) and actuates the slewing spool. 6.2 AUTOMATIC PARKING BRAKE FOR SLEWING Purpose ;To prevent tho slewing motion from Grifting when the levers is brought to neutral on a slope. Principle; The mechanical brake is released only in slewing and arm digging operations and is actuated in other operations. Function; The primary pilot pressure is always acting upon port PG of the hydraulic timer. If slewing motion is carried out, o a o. © [Al ee eae sical | Sting 3 eM) (eH) a9) [_ = the secondary pilot pressure is admitted lrrsemmrr | Jer-ansn a to the SH port of the hydraulic timer T by way of the shuttle valve (13) and lex (77% do 2s when the pressure rises above 6kgiem’, it changes over the selector valve, causes the primary pilot pressure of B5kgflem* to enter the mechanical brake (S15) and releases the slewing brake, 6.3. DELAY BRAKE BY HYDRAULIC TIMER WHEN SWING INERTIA OCCURS Purpose ;To release the parking brake when slewing inertia is acting. Principle; The oil returned from the mechanical brake is throttled to delay the brake action. Function ; If the operating lever (11A) is brought to neutral, the return circuit of the selector spool (S59) closes. This closes the return oil path from the mechanical brake (S15). The oil thus enclosed drains out, being throttled by the poppet (S56). This delays the action of the slewing parking brake by 5 to 7 seconds. 6.4 ANTI-CAVITATION CIRCUIT AT SLEWING DECELERATION Purpose ; To prevent cavitation when the slewing operating lever is brought to neutral or when slewing action is decelerated. Principle ; Oil is supplied from the supply circuit by. the action of the make-up valve when the supply pressure becomes negative. Function ; The oil returned from port T of C/V is sucked into port Mu of the motor when pressure becomes negative. This opens the make-up valve (S80) to make up for oil shortage. iat {te b a thy fs Fig. 6 Slewing circuit at left slewing12 Reavy tae a 8s nama 7 arse | feoaena 7 oe oo] on] [ar _ 2 Ul Peso 4 irs al hart (ey Let TTI: : Lal au) Wh 4 f& | x [| ey Pay | i 4 | a cP py a i : | ie A carennes? arn Rank can 5 Fig. 7 Bucket circuit at digging 7. BUCKET CIRCUIT The following functions are described in this section: D) Pilot circuit for bucket digging 2) Main circuit for bucket digging 8) Pilot cireuit for bucket dump ® Main circuit for bucket dump 7.1 PILOT CIRCUIT FOR BUCKET DIGGING Function; If the bucket digging operation is carried out, the secondary pilot pressure comes out of port 1 of the pilot valve (1A), enters port a8 of C/V and actuates the bucket spool. 7.2 MAIN CIRCUIT FOR BUCKET DIGGING Function ; The oil discharged form port P1 of the main pump enters port Pl of C/V (2). When the bucket spool is charged over, the oil is supplied to the H side of the bucket cylinder (7) from port A8 and causes the bucket digging action to occur. The oil returned from the R side of the cylinder enters port BS of C/V and returns to the hydraulic oil tank from ports T1, T2 and by way of the oil cooler. 7.3 PILOT CIRCUIT FOR BUCKET DUMP (NOT SHOWN) Function ; If bucket dump operation is performed, the secondary pilot pressure comes out of port 2 of the pilot valve (11A), enters port b8 of C/V (2), and actuates the bucket spool. 7.4 MAIN CIRCUIT FOR BUCKET DUMP (NOT SHOWN) Function ; The oil discharged from port Pl of the main pump enters port Pl of C/V (2). When the bucket spool is charged over, the oil is supplied to port R of the bucket cylinder (7) from port B8 to cause the bucket dump action to occur.ray eae Kone o o © cama & Fig. 8 Boom circuit at raising 8. BOOM CIRCUIT ‘The following functions are described in this section: 1) Pilot circuit for boom raising 2) Main circuit for boom raising 8) Pilot circuit for boom lowering 4) Main cireuit for boom lowering 8.1 PILOT CIRCUIT FOR BOOM RAISING Funetion ; If boom raising operation is performed, the secondary pilot pressure comes out ofport 3 of the right pilot valve (114), enters port a7 of C/V (2) and actuates the boom spool. 8.2 MAIN CIRCUIT FOR BOOM RAISING Function ; The oil discharged from port P1 of the main pump enters port Pl of C/V (2) and flows into the boom spool. The oil is then supplied to the H side of the boom cylinder (6) from port AT of the boom spool. The ofl returned from the R side of the boom cylinder flows into the return circuit from port B7 and runs out to the tank ports TI, T2. If a combined operation of bucket digging and boom raising is carried out, the system under lighter load operates earlier as the bucket circuit and the boom cireuit are connected in parallel, 83 PILOT CIRCUIT FOR BOOM LOWERING (NOT SHOWN) Fanetion ; If boom lowering action is performed, the secondary pilot pressure coming out of port 4 of the pilot valve (11A) enters port b7 of C/V (2) and actuates the boom spool. 8.4 MAIN CIRCUIT FOR BOOM LOWERING (NOT SHOWN) Function ; The oil discharged from port P1 of the main pump enters port Pl C/V (2). When the boom spool is changed over, the oil enters the R side of the boom cylinder from port B7. The oil returned from the H side of the boom cylinder goes out to ports Tl, T2 from port A7 of C/V (2) and returns to the tank. Tn that case, the boom cylinder tends to operate earlier than oil feed because of the self weight of the attachments. Therefore, if the boom is lowered jerkily, the oil on the tank side is replenished by the action of the check valve built in the port relief valve.ras mT a Krsrams | |esmassra | 7 | al laa _o9 |_| [ar xX ZN Xr r | | | t | | i outta ett HET | 1 Wonmn? aan’ cnet Fig. 9. Arm circuit at digging 9. ARM CIRCUIT The following functions are described in this section: D) Pilot circuit for arm digging 2) Main circuit for arm digging 3) Pilot circuit for arm extending 4) Main cireuit for arm extending 9.1 PILOT CIRCUIT FOR ARM DIGGING Function; If arm diggings is carried out, the secondary pilot pressure from port 7 of the pilot valve (11A) enters port a4 of CIV (2) and actuates the arm spool. 9.2 MAIN CIRCUIT FOR ARM DIGGING Function ; The Hydraulic oil from port P2 of the main pump enters port P2 of C/V (2), passes through the travel straight valve and the load check valve and flows to the arm spool. The oil then runs out to port Ad through the notch on the outer circumference of the arm spool and is supplied to the H side of the arm cylinder. The pressurized oil returned from the R side of the arm cylinder returns to tank ports T1, T2 through the notch on the circumference of the arm spool from port B4 of C/V (2). However, when the arm is subject to light load and if the pressure on the R side of the arm cylinder gets higher than the feed side because of the self weight of the arm and the bucket, the oil enters the spool through the hole in the circumference of the arm spool, pushes open the check valve (C) built in the spool and combines with the oil in the Ad port. This is called “Arm Recirculation Function”. 9.3 PILOT CIRCUIT FOR ARM EXTENDING (NOT SHOWN) Function ; If arm extend action is performed, the secondary pilot pressure from port 8 of the pilot valve (11A) enters port b4 of C/V (2) and actuates the arm spool. 9.4 MAIN CIRCUIT FOR ARM EXTENDING (NOT SHOWN) Function ; The pressurized oil from port P2 of the main pump enters P2 of C/V (2), passes through the travel straight valve and the load check valve and flows to the arm spool. The oil then runs out to port B4 through the notch in the circumference of the arm spool and is supplied to the R side of the arm cylinder. The pressurized oil returned from the H side of the arm cylinder passes through port A4 of C/V (2) and returns to tank ports Ti, T2 from the notch in the cireumference of the arm spool.Kevyn avn cream) 7 hp —] | won Tiel 5 | he : he | (BS | i | La. — —_ |. te cotton Flin tt on oe on oe ee Fig. 10 Swing circuit at right swing 10, SWING CIRCUIT The following functions are described in this section : 1) Right swing by heel step 2) Left swing by toe step 10.1. RIGHT SWING BY HEEL STEP Function ; If the right pedal is stepped by your heel, the cable pulls out the swing spool of CIV (2). ‘The pressurized oil from port P2 of the main pump enters port P2 of CIV (2), passes through the travel straight valve and the load check valve and flow to the swing spool. When the swing spool is changed over, the oil is supplied to the H side of the swing cylinder (8) from port A8 and performs the right swing action. The oil returned from the R side of the cylinder enters port BS of CIV, passes through ports T1,-T2 and the oil cooler, and returns to the hydraulic oil tank. 10.2. LEFT SWING BY TOE STEP (NOT SHOWN) Function ; If the pedal is stepped by your toe the same way as above, the swing spool of CIV (2) is pushed in, The pressurized oil from port P2 of the main pump enters port P2 of C/V (2), passes through the travel straight valve and the load check valve and flow to ‘the swing spool. If the swing spool is changed over, the oil is supplied to the R side of the swing cylinder (8) and causes the swing left action to be carried out. The oil returned from the Hi side of the cylinder enters port A3 of CIV and returns to the hydraulic oil tank via ports Tl, T2 and the oil cooler. 1511. DOZER CIRCUIT AT BLADE LOWERING 7 | | | ‘The following functions are described in this section: 1) Blade lowering when the dozer lever is pushed forward 2) Blade hoisting when the dozer lever is pulled back moby tase 11.1. BLADE LOWERING WHEN THE DOZER LEVER IS PUSHED FORWARD Function ; If the dozer lever is pushed forward, the cable pushes in the dozer spool of cw @). The pressurized oil from port PG of the No.3 pump enters port P3 of C/V (2) and flows to the dozer spool. When the dozer spool is changed over, the oil is supplied to the H side of the dozer cylinder (9) to cause the dozer lower action to occur. The oil returned from the R side of the cylinder enters port P2 of C/V and returns to the hydraulic oil tank from - port TI. lersramrs | |es-anrra Y 11.2 BLADE HOISTING WHEN THE DOZER LEVER 1S PULLED BACK (NOT SHOWN) Function ; If the dozer lever is pulled back, the cable pulls out the dozer spool. The pressurized oil from port PG of the No.3 pump enters port P3 of C/V (2) and flows to the dozer spool, the same way as above. When the dozer spool is changed over, the oil is supplied to the R side of the dozer cylinder (9) to cause the dozer hoisting to occur. The oil returned from the H side of the cylinder enters port B2 of C/V and returns to the hydraulic oil tank from port TI. eS i ie co cam [" cotton 1 A A (smn? (gare coven 8 LS q-f-— Fig. 11 Dozer cireuit at, blade lowering