Sk480 Sk500dlc 8 Shop Manual

DEMOLITION MACHINE WITH
COMMON USE TYPE MAIN BOOM
SHOP MANUAL
SK480DLC-8 / SK500DLC-8
APPLICABLE YS10-01501~
Book Code No. S5LS6111E01

Printed in Japan 2009.09 (KE)
［61. DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］
61. DEMOLITION MACHINE WITH

COMMON USE TYPE MAIN BOOM
TABLE OF CONTENTS
61.1 FOREWORD ……………………………………………………………………………………………………61-3

61.2 GENERAL VIEW ………………………………………………………………………………………………61-7
61.3 ATTACHMENT …………………………………………………………………………………………………61-39
61.4 MAINTENANCE STANDARD AND TEST PROCEDURE …………………………………………………61-45
61.5 MECHATRO CONTROL SYSTEM ……………………………………………………………………………61-73
61.6 HYDRAULIC SYSTEM …………………………………………………………………………………………61-138
61.7 ELECTRICAL SYSTEM ……………………………………………………………………………………… 61-169
61.8 COMPONENTS …………………………………………………………………………………………………61-219
61.9 DISASSEMBLING & ASSEMBLING …………………………………………………………………………61-246
61.10 DISASSEMBLING & ASSEMBLING OF ATTACHMENT ………………………………………………61-248
61.11 DISASSEMBLY AND ASSEMBLY OF UPPER SLEWING STRUCTURE ……………………………61-289 61
61.12 DISASSEMBLING & ASSEMBLING OF TRAVEL SYSTEM……………………………………………61-293
61.13 TROUBLESHOOTING …………………………………………………………………………………………61-298
61.14 SAFETY EQUIPMENTS ………………………………………………………………………………………61-302
61.15 AUTOMATIC LUBRICATION EQUIPMENT ………………………………………………………………61-307
Book Code No. S5LS6111E01
61-1
Issue Data of Issue Applicable Machines Remarks

SK480DLC-8/SK500DLC-8 :
First Edition August, 2009 S5LS6111E01
YS10-01501~
61-2
61.1 FOREWORD
This separate volume describes the specifications, functions, construction, and operation of following
attachments which are equipped with the demolition machine with common use type main boom.
・ 3-Piece demolition ultra long attachment (LMN)

・ Separate boom
The explanations, values, and illustrations in this manual were prepared based on the latest information
available at that time. Continuing improvements in the design of this machine can lead to changes in
detail which may not be reflected in this manual. Some illustrated pictures may be different from your
machine, as technical improvement is continuous; manuals are periodically updated to reflect these
changes.
For further information about this machine, please contact our dealer/distributor.
For ordering parts and service, inform an authorized Manufacturer distributor of your machine's Serial
Number.Owing to the policy of continual improvement, changes may be made by Manufacturer to any
of its products without any obligation on the part of Manufacturer.
61
61-3
61.1.1 CHANGED MAJOR PARTS FROM STANDARD MACHINE

(1) Hydraulic main pump
1. Main pump is PTO type and equips 4th gear pump. This gear pump is used for crusher rotation.
(2) Main control valve

1. One optional valve was added to P1 side.
2. Two relief valves for optional valve were added to P2 side.
3. The relief valves of P2 side were used for crusher. The setting pressure of over load relief valve
was set at the factory in advance.
4. Switch the mode to "B" to use breaker, and selector valve is switched to the circuit for breaker.
And hydraulic oil returns to tank.
(3) Mechatro-controller
1. Internal software was changed.
(4) Undercarriage adopts Long Crawler, but it is different according to the machine model.
・ SK480DLC-8:
Mechanical VLC (Retractable crawler)
Rigid LC (Fixed crawler)
・ SK500DLC-8:
Hydraulic VLC (Hydraulic retractable crawler)
(5) Classification of appearance according to attachments

・ Demolition machine with ultra long attachment:
Basic arm spec.
Long arm spec.
・ Separate boom:
Basic jib cylinder spec.
Large diameter jib cylinder spec.
(6) Classification of connector for attachment

・ Stop valve spec.
(7) Counterweight
1. Replace the counterweight to the one piece weighted counterweight.
2. SK500DLC-8: New stack type counterweight is designed. (Transportability improvement)
(8) Replace two control lever grips to the grips with switch for rotation of crusher.
61-4
61.1.2 CHANGED PIPING PARTS FROM STANDARD MACHINE

(1) Foot pedal type 2 pilot valves were added to front of floor plate. And these pedals are used for
operation of jib cylinder and crusher.
(2) Regarding the hydraulic components, compare the components according to hydraulic circuit and
model numbers
(3) Switching of LMN/BH is conducted by replacement of connector.
When L.M.N attachment is equipped, make sure to select the switch of L.M.N side. If you select the
BH side when you use L.M.N, the arm moves reversely. In addition, the working range limitation
alarm does not sound, it is very dangerous. To match the operation of arm, replace the LMN/BH
connector.
(4) Add 3-face guard and skylight window wiper to the cab.
(5) To prevent tip-over, add 3 potentio meters to main boom, front boom, and inter boom.
(6) Add auto grease lubricator.
(7) Add one-way call device unit.
Regarding the electric circuit, refer to electric system section.

61
(8) In case of SK500DLC-8, add the devices and apparatus of retractable crawler unit.
61-5
61.1.3 OUTLINE FOR MACHINE

61.1.3.1 SPECIFIED WORK
The works in the following specification are allowed to use this machine.
A. In specification for long attachment (L.M.N) C. In specification for backhoe used for
Demolition work demolition work
B. In specification for separate boom Demolition work
Demolition work Light digging work
Light digging work Loading work
Loading work
For the working details, refer to Section 3 Machine Operation.
61.1.3.2 FRONT/REAR AND RIGHT/LEFT OF MACHINE

The terms Right-hand, Left-hand, Front, and
Rear are used in this Manual to indicate this
sides as they are seen from the operator's
seat when the cab is over the track idler
wheels.
61.1.3.3 RUNNING-IN PERIOD

This machine is shipped after sufficient
adjustment and inspection. The lowering of
function is made earlier by unreasonable
operation at the beginning and consequently the
lifetime is made shorter. Operate the machine in
the following 3 steps of running-in until every
part of machine moves smoothly.
Perform running-in using care especially the following points.
・ Do not work with heavy load and high speed.

・ Avoid abrupt start, abrupt speed up, unnecessary sudden stop and turn.
Full loading operation without running-in could cause seizure and flaws, and might exert bad influence
on the lifetime of machine. Do not neglect the running-in operation.
61-6
61.2 GENERAL VIEW
61.2.1 COMPONENTS
61.2.1.1 ATTACHMENTS
A. 3-PIECE DEMOLITION TYPE
B. 3-PIECE DEMOLITION TYPE (LONG ARM SPEC.)
61
C. SEPARATE BOOM TYPE
61-7
D. BACKHOE TYPE
61-8
61.2.1.2 DIMENSIONS
A. MECHANICAL VLC
B. RIGID LC
61
C. HYDRAULIC VLC
61-9
61.2.1.3 CRUSHER (NIBBLER)

A. DEMOLITION CRUSHER FOR FERROCONCRETE BUILDING (KR1100TPR) AUTO ROTARY TYPE:
3-PIECE ULTRA LONG ATTACHMENT
B. DEMOLITION CRUSHER FOR FERROCONCRETE BUILDING (KR1200PR) AUTO ROTARY TYPE:

SEPARATE BOOM
61-10
61.2.2 MACHINE DIMENSIONS

A. FULL ATTACHMENTS MACHINE
4.5M Main boom + 3.98M Insert boom + 2.68M Insert boom + 4.485M Front boom + 2.3M Inter
boom + 5.85M Arm + KR1100TPR Nibbler/Crusher
Track crawler Track crawler hydraulically

Dimensions Items Track crawler retracted type
fixed type retracted type
Overall height
M 3,310 3,310 3,310
of attachment
N Overall length 19,250 19,250 19,430
2,990(Most retracted) 2,980(Most retracted)
- Overall width 3,350
3,490(Most extended) 3,480(Most extended)
B. 4.5M Main boom + 3.98M Insert boom + 4.485M Front boom + 2.3M Inter boom + 5.85M Arm
+ KR1100TPR Nibbler/Crusher
61

Overall height
M 3,310 3,310 3,310
of attachment
N Overall length 16,570 16,570 16,750
61-11
C. 4.5M Main boom + 2.68M Insert boom + 4.485M Front boom + 2.3M Inter boom + 5.85M Arm
+ KR1100TPR Nibbler/Crusher

Overall height
M 3,310 3,310 3,310
of attachment
N Overall length 15,270 15,270 15,450
D. 4.5M Main boom + 4.485M Front boom + 2.3M Inter boom + 5.85M Arm

Overall height
M 3,310 3,300 3,300
of attachment
N Overall length 12,590 12,600 12,770
61-12
E. 4.5M Main boom + 2.68M Insert boom + 7.165M Front boom + 2.3M Inter boom + 8.5M Arm +
KR1100TPR Nibbler/Crusher

Overall height
M 3,490 3,490 3,480
of attachment
N Overall length 17,940 17,950 18,120
F. 4.5M Main boom + 7.165M Front boom + 2.3M Inter boom + 8.5M Arm
61

Overall height
M 3,490 3,480 3,480
of attachment
N Overall length 15,270 15,270 15,450
61-13
G. 4.5M Main boom + 4.7M Front boom + 3.45M Arm + KR1200PR Nibbler/Crusher
Jib cylinder standard

Overall height
M (M') 3,890 (3,550) 3,920 (3,570) 3,920 (3,570)
of attachment
N Overall length 14,210 14,220 14,390
Large diameter jib cylinder

Overall height
M (M') 3,890 (3,550) 3,920 (3,570) 3,920 (3,570)
of attachment
N Overall length 14,210 14,220 14,390
H. 4.5M Main boom + 3.9M Front boom + 3.45M Arm + 1.9m3 Bucket

Overall height
M (M') 3,650 (3,480) 3,670 (3,500) 3,680 (3,500)
of attachment
N Overall length 13,330 13,340 13,520
61-14
I. 4.5M Main boom

Overall height
M 3,430 3,550 3,560
of attachment
N Overall length 8,540 8,540 8,720
61
61-15
61.2.3 SPECIFICATION SHEET
Model SK480DLC-8 (Fixed track gauge[Retractable track gauge])

Ultra Long Attachment Separate boom
Basic jib Large diameter Demolition
Machine type
Standard Long cylinder jib cylinder backhoe
specifications specifications
Dimensions
Overall length 6,400mm [6,400mm]
Overall width of
3,000mm [3,000mm]
Upper structure
Overall width of
3,350mm [Most retracted : 2,990mm / Most extended : 3,490mm]
Crawler
Cab height (With
3,430mm [3,550mm]
cab guard)
Weight
55,900kg 55,400kg 56,000kg 56,500kg 52,300kg
Working weight
[57,400kg] [56,800kg] [57,500kg] [57,900kg] [53,800kg]
96.0kPa 95.0kPa 96.0kPa 97.0kPa 90.0kPa
Ground pressure
[98.0kPa] [97.0kPa] [99.0kPa] [99.0kPa] [92.0kPa]
Machine weight
Machine weight
53,500kg 52,900kg 51,300kg 51,700kg 50,000kg
(Without crusher
[55,000kg] [54,400kg] [52,800kg] [53,200kg] [51,600kg]
weight)
Machine weight 40,300kg 40,300kg 40,300kg 40,300kg 40,300kg
(Without attachment) [41,800kg] [41,800kg] [41,800kg] [41,800kg] [41,800kg]
Machine weight
13,100kg 12,500kg 10,900kg 11,300kg 9,700kg
(With full attachment)
Performances
Maximum arm top 24,840mm 26,310mm 13,050mm
14,490mm [14,610mm]
pin height [24,960mm] [26,430mm] [13,160mm]
Maximum arm top
13,000mm 9,000mm 12,610mm
pin radius
Swing speed 3.9min-1 7.8min-1
Travel speed
5.4 / 3.4km/h
(High/Low)
Engine
Model HINO Motor
Type Direct injection type diesel engine with intercooler turbo-charger
Output rating 243kW / 1,850mim-1
Front attachment
Demolition
Work tool Crusher(Nibbler) KR1100TPR Crusher(Nibbler) KR1200PR
bucket
Heaped
Jaw opening 1,100mm 1,150mm
capacity 1.9m3
Weight 2,450kg 4,800kg 2,150kg
61-16
The units in this table are shown "International system of units".

The working weight includes the weight of crusher (Nibbler).
The weight of crusher is excluded from the machine weight and the full attachment weight.
The values in [ ] show the retractable track gauge machine.
61
61-17
Model SK500DLC-8 (Hydraulic retractable track gauge)

Ultra Long Attachment Separate boom
Basic jib Large diameter Demolition
Machine type
Standard Long cylinder jib cylinder backhoe
specifications specifications
Dimensions
Overall length 6,580mm
Overall width of
3,000mm
Upper structure
Overall width of
Most retracted : 2,980mm / Most extended : 3,480mm
Crawler
Cab height (With
3,560mm
cab guard)
Weight
Working weight 59,200kg 58,600kg 59,300kg 59,700kg 55,500kg
Ground pressure 101.0kPa 100.0kPa 102.0kPa 102.0kPa 95.0kPa
Machine weight
Machine weight
(Without crusher 56,700kg 56,200kg 54,500kg 55,000kg 53,400kg
weight)
Machine weight
43,600kg 43,600kg 43,600kg 43,600kg 43,600kg
(Without attachment)
Machine weight
13,100kg 12,500kg 10,900kg 11,300kg 9,700kg
(With full attachment)
Performances
Maximum arm top
24,970mm 26,440mm 14,620mm 13,170mm
pin height
Maximum arm top
13,000mm 9,000mm 12,610mm
pin radius
Swing speed 7.8min-1
Travel speed
5.4 / 3.4km/h
(High/Low)
Engine
Model HINO Motor
Type Direct injection type diesel engine with intercooler turbo-charger
Output rating 243kW / 1,850mim-1
Front attachment
Demolition
Work tool Crusher(Nibbler) KR1100TPR Crusher(Nibbler) KR1200PR
bucket
Heaped
Jaw opening 1,100mm 1,150mm
capacity 1.9m3
Weight 2,450kg 4,750kg 2,150kg
61-18
The units in this table are shown "International system of units".

The working weight includes the weight of crusher (Nibbler).
The weight of crusher is excluded from the machine weight and the full attachment weight.
A. Length and Weight of Front attachment (Ultra Long Attachment)

Attachment Length (m) Weight (kg) Applications
Common to Separate boom type and Demolition
Main boom 4.5 3,280
Backhoe type
Insert boom 3.98 1,660
Insert boom 2.68 1,310
Front boom 4.485 1,960 Include Jib cylinder and piping
Front boom (Long) 7.165 2,760 Include Jib cylinder and piping
Inter boom 2.3 1,290 Include Arm cylinder and piping
Arm 5.85 1,800 Include Bucket cylinder and piping
Arm (Long) 8.5 2,380 Include Bucket cylinder and piping
B. Length and Weight of Front attachment (Separate boom)

Main boom 4.5 3,280 Common to Ultra Long Attachment
Front boom 4.7 3,690 [4,110]

Include Arm cylinder, Jib cylinder, and piping
Exclusive use for separate boom
61
Include Bucket cylinder and piping
Arm 3.45 2,600 HD rotary crusher & breaker
Common to demolition backhoe
The values in [ ] show the separate boom (large diameter cylinder) specification.
C. Length and Weight of Front attachment (Demolition Backhoe)

Main boom 4.5 3,280 Common to Ultra Long Attachment
Include Arm cylinder and piping
Front boom 3.9 2,550
Exclusive use for Demolition Backhoe
Include Bucket cylinder and piping
Arm 3.45 2,600 HD rotary crusher & breaker
Common to separate boom
61-19
61.2.4 TRANSPORTATION
61.2.4.1 PREPARATION
1. When transporting the machine with a trailer on roads open to the public, you must know and
heed the applicable laws and regulations as well as the rules provided by the different Agencies
owning the roads (Municipalities, Provinces, Region, and State).
2. Know the total weight, length, width, and height of the machine being transported.
3. Know the route where the machine is transported. Investigate bridges, overpass, and height of
road signs on route in advance.
4. Use trailer with a rated sufficient capacity to transport the machine.
5. Make sure the trailer has ramps or a ramp is available for loading and unloading the machine.
61.2.4.2 MAJOR DIMENSIONS OF SK480DLC-8/SK500DLC-8 FOR TRANSPORTATION

With counterweight, without front attachment
Items
Combination A : Width of L : Overall H : Overall W : Overall
Weight : (kg)
shoe (mm) length (mm) height (mm) width (mm)
Track crawler width
600 6,400 3,430 3,350 40,300
fixed type
2,990
Track crawler width (Most retracted)
600 6,400 3,550 41,800
retractable type 3,490
(Most extended)
2,980
600 6,580 3,560 43,600
hydraulic retractable type 3,480
(Most extended)
61-20
With main boom and without counterweight

Items
Weight : (kg)
Track crawler width
600 8,260 3,430 3,350 32,300
fixed type
2,990
600 8,260 3,550 33,700
(Most extended)
2,980
600 8,260 3,560 35,700
(Most extended)
Without counterweight and attachments

Items
61
Weight : (kg)
Track crawler width
600 6,120 3,430 3,350 27,800
fixed type
2,990
600 6,120 3,550 29,300
(Most extended)
2,980
600 6,120 3,560 31,300
(Most extended)
61-21
Counterweight specifications
Items
Combination L : Overall length H : Overall height W : Overall width
Weight : (kg)
(mm) (mm) (mm)
Counterweight 3,000 1,140 820 9,730
Bolt size of counterweight mounting bolt: M45

Tightening torque of counterweight mounting bolt: 4.5±0.45kN-m (Apply Loctite #262 or equivalent)
Add-on counterweight specifications

Items
Combination L : Overall length H : Overall height W : Overall width
Weight : (kg)
(mm) (mm) (mm)
Counterweight 2,440 450 740 2,820
Main boom specifications Insert boom specifications

Dimensions and weight 4.5m Main boom Dimensions and weight 2.68m Insert boom
Length X Height x Width Length X Height x Width
4.74 X 1.65 X 0.93 3.66 X 1.03 X 0.64
(L X H X W) (m) (L x H X W) (m)
Weight (kg) 3,280 Weight (kg) 1,310
61-22
Insert boom specifications Front boom specifications

Dimensions and weight 3.98 m Insert boom Dimensions and weight 4.485 m Front boom
4.96 X 1.03 X 0.64 4.73 X 1.48 X 0.83
(L X H X W) (m) (L x H X W) (m)
Inter boom specifications Arm specifications

Dimensions and weight 2.3 m Inter boom Dimensions and weight 5.85 m Arm
3.53 X 1.17 X 0.65 6.04 X 1.08 X 0.54
(L X H X W) (m) (L x H X W) (m)
Front boom specifications 61

Dimensions and weight 7.165 m Front boom
Length X Height x Width
7.41 X 1.51 X 0.83
(L X H X W) (m)
Weight (kg) 2,760
Long arm specifications

Dimensions and weight 8.5 m long arm
8.69 X 1.18 X 0.55
(L X H X W) (m)
Weight (kg) 2,380
61-23
Arm + Inter boom + Front boom specifications

Dimensions and weight 5.85 m Arm + 2.3 m Inter boom + 4.485 m Front boom
6.55 X 3.34 X 0.83
(L X H X W) (m)
Weight (kg) 5,210
Long arm + Inter boom + Front boom specifications

Dimensions and weight 8.5 m Arm + 2.3 m Inter boom + 7.165 m Front boom
9.23 X 3.51 X 0.83
(L X H X W) (m)
Weight (kg) 6,580
Front boom specifications Front boom specifications

(For separate boom) (For separate boom of standard spec.)
Dimensions and weight 4.7 m Front boom Dimensions and weight 4.7 m Front boom
4.99 X 1.57 X 0.85 5.04 X 1.49 X 0.85
(L X H X W) (m) (L x H X W) (m)
61-24
Front boom specifications

(For large diameter jib cylinder of separate boom) Arm specifications
Dimensions and weight 4.7 m Front boom Dimensions and weight 3.45 m Arm
5.05 X 1.53 X 0.85 4.71 X 1.91 X 0.80
(L X H X W) (m) (L x H X W) (m)
Arm + Front boom specifications Arm + Front boom specifications

(For separate boom of standard spec.) (For large diameter jib cylinder of separate boom)
3.45 m Arm +
4.7 m Front boom
3.45 m Arm +
Dimensions and weight Dimensions and weight (For large diameter jib
4.7 m Front boom
cylinder of
separate boom)
8.36 X 1.89 X 0.85 8.36 X 1.90 X 0.85
(L X H X W) (m) (L x H X W) (m)
61
Front boom specifications

(For demolition back-hoe)
Dimensions and weight 3.9 m Front boom
4.21 X 1.27 X 0.83
(L X H X W) (m)
Weight (kg) 2,550
61-25
Front boom + Arm specifications (For demolition back-hoe)

Dimensions and weight 3.9 m Front boom + 3.45 m Arm
7.50 X 1.76 X 0.83
(L X H X W) (m)
Weight (kg) 5,250
Standard jib cylinder specifications Large diameter jib cylinder specifications

(For separate boom) (For separate boom)
2.85 X 0.33 X 0.37 2.99 X 0.39 X 0.48
(L X H X W) (m) (L x H X W) (m)
Weight (kg) 580 Weight (kg) 991
Crusher (Nibbler) specifications

Crusher (Nibbler)
Dimensions and weight
KR1100TPR KR1200PR-2
2.45 X 1.72 X 0.83 3.07 X 2.00 X 0.99
(L X H X W) (m)
Weight (kg) 2,450 4,750
61-26
61.2.4.3 TRANSPORTATION POSITION AND WORKING POSITION OF BACKHOE ATTACHMENT 61

When the attachment is changed to demolition backhoe attachment by using the main boom for "Ultra
Long Demolition Attachment", make sure to use the positioning pin for the transportation position.
・ At transporting the machine, install the pin

for transportation to the indicated position
as shown in the right figure.
・ Before working, change the positioning pin
to the working position as shown in the
right figure.
The digging work in the transporting position causes the damage of the attachment. Do not operate
the digging work in transportation position.
61-27
61.2.5 TYPE OF BUCKET
61.2.6 LIMIT WEIGHT OF CRUSHER
Ultra long attachment

Separate boom machine
machine (LMN/Crusher)
Track crawler fixed type 2,450 kg 4,800 kg
Track crawler retractable
2,450 kg 4,800 kg
type
Track crawler hydraulically
2,450 kg 4,800 kg
retractable type
61-28
61.2.7 WORKING RANGE

A. Ultra Long Attachment Machine (LMN/Crusher)
61
Track crawler fixed type
61-29
Track crawler retractable type
Track crawler hydraulically retractable type
The dimensions of marked *does not include the shoe lug height (36 mm).
This drawing shows the values when KR1100TPR (Crusher/Nibbler: Weight is 2,450 kg) is attached.
The values of marked ** shows the maximum working reach on the hard and level ground.
Do not exceed the line of maximum working range to avoid the tip-over.
61-30
B. Ultra Long Attachment Machine (LMN/Crusher) : Long arm spec.
61
Track crawler fixed type
61-31
Track crawler hydraulically retractable type
61-32
C. Separate boom machine
61
Track crawler fixed type Track crawler retractable type
61-33
61-34
D. Demolition Backhoe Machine
61
Track crawler fixed type Track crawler retractable type
61-35
This attachment is adjusted into the specification for the demolition backhoe machine by adding the
exclusive front boom to the main boom on the machine used for the demolition work specially.
The counterweight of this machine is added in weight. When you use this machine as a backhoe
machine, limit the work to the light work, because there is an adverse effect in the durability of the
upper frame.
The dimensions of marked * does not include the shoe lug height (36 mm).
This drawing of working range shows the values in condition that the machine equips the bucket of
1.9 m3.
61-36
61.2.8 ENGINE SPECIFICATION

61.2.8.1 SPECIFICATIONS
Applicable machine SK460-8, SK480LC-8
Engine model HINO P11C-UP
Water-cooled, 4 cycle 6 cylinder direct injection type diesel
Type
engine with inter cooler turbo-charger
Number of cylinder × Bore × Stroke 6 × 122mm (4.80 in) × 150mm (5.91 in)
Total displacement 10,520cc (642 cu in)
Compression ratio 17.0
Rated out put 243 kW (330 PS) at 1,850 min-1 (rpm)
Maximum torque 1,400 N m (1,033 lbf ft) at 1,400 min-1 (rpm)
High idling 2,050 ± 30 min-1 (rpm)
Low idling 800 min-1 (rpm)
Injection starting pressure 3.2 MPa (464 psi)
Thermostat action Start 350 K (170 F degree)/Full open 363 K (194 F degree)
Firing order 1 - 4 - 2 - 6 - 3 - 5
Compression pressure 2.8 MPa (406 psi) to 3.0 MPa (435 psi) at 200 min-1 (rpm)
Fuel injection timing 0°
Valve clearance Open Close
11° before top 22° after bottom
Intake valve 0.45 mm at cool
Valve clearance dead point dead point
59° before top 13° after top
Exhaust valve 0.60 mm at cool
dead point dead point 61
Starter capacity 24 V × 6.0 kW
Generator capacity (Alternator) 24 V × 60 kW
ø850 (33.5 in) × suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.95
Full level 35.0 L (9.25 gal)
Engine oil quantity Low level 27.0 L (7.13 gal)
Total 42.5 L (11.2 gal)
Dry weight 1,150 kg (2,536 lbs)
Fuel consumption ratio 213 g / kw-h (157 g / PS-h)
Allowable inclination Front / Rear and Right / Left : 35°
1,440 mm × 921 mm × 1,154 mm
Dimension (L × W × H)
(4 ft 8.7 in × 36.3 in × 3 ft 9.4 in )
Rotating direction Counterclockwise seeing from flywheel side
61-37
61.2.8.2 ENGINE CHARACTERISTIC CURVE (HINO P11C-UP)
61-38
61.3 ATTACHMENT
61.3.1 PIN AND BUSHING CLEARANCE
61
61-39
61-40
61
61-41
61.3.2 CLEARANCE IN THRUST

DIRECTION
61-42
61
61-43
61-44
61.4 MAINTENANCE STANDARD AND TEST PROCEDURE
61.4.1 PRESSURE ADJUSTMENT STANDARD TABLE

61.4.1.1 ULTRA LONG ATTACHMENT (LMN)
Only items which differ from the standard long crawler are described here.
61
61.4.1.2 SEPARATE BOOM (LARGE DIAMETER JIB CYLINDER SPEC.)
Only items which differ from the rotary LMN with common use type separate boom are described here.
61-45
61.4.2 PERFORMANCE INSPECTION STANDARD TABLE
The mode is already "H" mode when power is thrown.

Unless otherwise specified, measure it on "H" mode.
61-46
61
61-47
61-48
61.4.3 MEASUREMENT OF HYDRAULIC PRESSURE

61.4.3.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge: 1unit
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and
instrument for analysis: 1 set
(2) Measuring cleanliness of hydraulic oil
Gauge port on main pump
61
After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.
61.4.3.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
After releasing the pressure in hydraulic oil tank and system, replace plugs PF1/4 of main pump
gauge ports (a1) (a2) with plugs for pressure measurement, and attach pressure gauge 49 MPa
(7100 psi).
(2) Pilot circuit
Replace pilot gauge plug (a5) with plug PF1/4 for pressure measurement, and attach pressure
gauge 6.9 MPa (1000 psi).
61-49
61.4.3.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
Relief valve position on main control valve
61-50
(2) Pilot relief valve

The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.
Pilot relief valve position
(3) Swing over load relief

The swing motor is equipped with plugs GA,GB for pressure measurement, but the measurement is
carried out using gauge ports (a1) and (a2). (See "Gauge port on main pump" Fig.)
61
Swing over load relief position
61-51
61.4.3.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).
Tools: Spanner: 24 mm,
Tightening torque : 29.4 N-m (22 lbf-ft)
Tools: Allen wrench: 6 mm
Pilot relief valve
(2) Main relief valve

(Commom for travel and ATT sections)
Start from the boosting side, first. Loosen nut (1), adjust the pressure with adjusting screw (2)
and tighten nut (1) after completion of the adjustment on the boosting side.
Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten
nut (3) after completion of the adjustment.
Tightening torque : 98 N-m (72.3 lbf-ft)
Tightening torque : 59 N-m (43.5 lbf-ft)
Tools: Spanner: 22, 27 mm, Adjust screw
Main relief valve (Travel section, ATT

common section)
61-52
(3) Over load relief valve

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw (2).
Tightening torque : 3.0 N-m (2.2 lbf-ft)
Over load relief valve (Boom, bucket, arm

sections)
(4) Over load relief valve (Swing)

This valve was adjusted by valve maker. If
adjustment is required, adjust with shim
thickness.
When you cannot perform a check of
setting pressure, do not adjust pressure by
any means. Swing over load relief valve 61
Pressure change [by SIMM 0.1 mm] :
about 0.5 MPa (73 psi)

Tightening torque : 157 N-m (116 lbf-ft)
(5) Travel over load relief valve

This valve was adjusted by valve maker.
Do not replace any inner parts except for
O-ring.
Travel over load relief valve
61-53
61.4.4 MEASURING TRAVEL PERFORMANCES

61.4.4.1 TRAVEL SPEED
(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.
(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Crawler on the right and left sides are
tensioned evenly. One side lifted position
(3) Preparation
Attach the reflection panel with a magnet to
the travel motor cover.
Swing the swing frame through 90C
degrees as shown in upper right Fig. and
make the crawler on one side take off the
ground, using the attachment.
Adhering position of reflection panel
(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st speed and 2nd
speed
Measuring points; Right and left
Method, example
Measure the revolutions per minute visually.
61-54
61.4.4.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20m
(66ft) travel and confirm the horizontal
balance between the hydraulic pump and
the travel motor of the travel drive system.
(2) Condition
Travel position
RH and LH crawler are tensioned evenly.
Firm, level ground
(3) Preparation
1.
Straight course more than 30 m (108 ft)
2.
Travel position in which the bottom of the
bucket is lifted by about 30 cm (1 ft).
Measuring method
(4) Measurement
1.
Measure the max. deviation distance of
the circular arc in the 20 m (66 ft) length,
excluding the preliminary run of 3 to 5 m 61
(10 to 16 ft).
2.
Operate the travel lever at the same time.
61-55
61.4.4.3 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose
To measure the drain rate of the travel
motor and to confirm the performances of
the travel motor.
(2) Conditions
Location of stopper applied to travel sprocket
(3) Preparation
1.
Place a stopper under the RH and LH
travel sprockets.
2.
Stop the engine and release pressure from
the hydraulic circuit.
3.
Connect a hose with the drain port of the
travel motor and take drain in a container.
Method of measuring the drain rate of travel

motor
(4) Measurement ; at Travel Lock

1.
Start the engine and relieve pressure at the
full stroke of the travel lever.
2.
Measure the drain rate for 30 seconds of
relieving.
Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Upper right Fig.)
61-56
61.4.5 MEASURING SWING PERFORMANCES

61.4.5.1 MEASURING SWING PERFORMANCES
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Firm, level ground
Swing speed measuring position (at the min.

reach)
(3) Preparation
Put the bucket empty and extend the
boom, arm and bucket cylinder fully.
And the machine becomes a position of
minimum reach.
(4) Measurement
Swing the machine by bringing the swing
lever to its full stroke. Measure the time
required to make three turns after one turn 61
of preliminary run.
61.4.5.2 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor
and confirm the performances of the swing
motor.
(2) Conditions
Hydraulic oil temperature; 45 to 55C
degrees (113 to 131F degrees)
Firm, level ground
(3) Preparation
1.
Stop the engine.
2.
Release pressure from inside the hydraulic
circuit.
3.
Disconnect the swing motor drain hose
from its end returning to the hydraulic oil
tank and take oil in a container.
4.
Put a plug to the tank side.
61-57
(4) Measurement; at Swing Lock

1.
Start the engine and put the side faces of
bucket against the inside of the right or
left shoe plates.
2.
Relieve the swing motor at full stroke of
the swing motion.
3.
Collect the amount of drained oil in a
container for 30 seconds.
61-58
61.4.6 MEASURING ATTACHMENT OPERATING PERFORMANCES

61.4.6.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm and crusher and confirm the performances between the
hydraulic pump and the cylinder of the attachment drive system.
(2) Condition
Hydraulic oil temperature; 45 to 55C degrees (113 to 131F degrees)
Operating time excluding the cushion stroke
(3) Preparation
Firm level ground with the crusher empty
(4) Measurement 1; Boom up and down

With the boom operating lever at full stroke, measure the required operating time of the crusher
between the ground surface and its highest position.
When lowering the boom, allow the crusher onto a soft ground or cushioning such as rubber tires ;
never put the crusher against concrete or other solid material.
Measurement 2; Jib in and out, crusher in and out 61

Measure the required time when the jib pedal moves from start to goal.
Measurement 3; Arm in and out, crusher in and out

Operate the crusher as shown in the right figure, and move the control lever at full stroke. And
measure the required time when the arm and crusher move from start to goal.
61-59
Measuring position for crusher in and out

Measuring position for front boom up and
motion (Separate boom spec.)
down motion (Separate boom spec.)
Measuring position for front boom in and

Measuring position for arm in and out motion out (Separate boom spec.)
(Separate boom spec.)
Measuring position for boom up and down

Measuring position for crusher in and out motion (LMN spec.)
motion (LMN spec.)
61-60
Measuring position for jib in and out motion

(LMN spec.)
Measuring position for arm in and out motion

(LMN spec.)
61
61-61
61.4.6.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by checking the moving length of the cylinder rods.
(2) Condition
Hydraulic oil temperature; 45 to 55C degrees (113 to 131F degrees)
Firm, level ground
After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness.
Retract the arm cylinder rod 60 mm (2.4 in) from stroke end. (Outside of the cushioning
mechanism.)
(3) Preparation
Remove the crusher. Extend the arm cylinder rod from the most retracted position. And extend the
bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at same height
with boom foot pin.
(4) Measurement
Measure the items 10 minutes after the engine is turned off.
Separate Spec.
LMN Spec.
61-62
61.4.7 MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose
Measure the gap between the lower frame
and the bottom face of the swing bearing
and estimate the degree of wear of the
swing bearing.
(2) Condition
Firm, level ground
The swing bearing mounting bolts are not
loosened.
The swing bearing is lubricated well, not How to measure the axial play of swing
making abnormal sound during turning. bearing
(3) Preparation
1.
Install a dial indicator to the magnetic
base and fix it to the lower frame.
2.
Direct the upper swing body and the lower
frame toward the travel direction, bring the
Measuring position 1
probe of the dial indicator in contact with
the bottom surface of the outer race on the
swing body side and set the reading at
zero.
61
61-63
(4) Measurement 1 (Measuring position 1 and

2)
1.
Measure the displacement of the outer race
in the axial direction in position 1 [The
arm at 90 degrees to 110 degrees and
the crawler front is lifted by attachment
about 30cm (1ft)] and in position 2, using a
dial indicator.
(5) Measurement 2 (Measuring position 3)

1.
With the arm cylinder most retracted and
the bucket dump, lift the tip of the tooth
of the bucket about 10mm (0.4in) and
swing the tip of the bucket to the right
and the left by the man power.
But in this case, the gap of the
attachment is included.
61-64
61.4.8 MECHATRO CONTROLLER

61.4.8.1 ENGINE CONTROL INPUT / OUTPUT
INPUT / OUTPUT
61.4.8.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B ADJUSTMENT)

A. PURPOSE OF THE ADJUSTMENT 61
There are 3 kinds of adjustment of mechatro controller as shown below; every adjustment is an
essential function to ensure performance of machine.
(1) Adjustment of engine ("A" adjustment)

This adjustment is performed to set the relation between the acceleration command voltage output
from mechatro controller to engine controller and the engine speed.
(2) Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the output variation by coordinating the output hydraulic
pressure with engine rated output.
B. 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) Bypass cut proportional valve, spool of bypass cut valve
61-65
C. PREPARATION
(1) Raise the oil temperature to about 50C degrees (122F degrees) to warm up the engine.
(2) Turn the air-con OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the
adjustment data is not entered.
A215, A225, A015, A025
As the error codes other than those shown above may suggest failures of machine, repair the
machine into the ordinary operating condition according to Error Code List.
For machines equipped with lifting magnet, turn the generator OFF.
61-66
D. ADJUSTING PROCEDURE
Gauge cluster
(1) Adjustment of engine ("A" adjustment)
Procedure
1. Turn starter key switch ON keeping the
work mode selector switch on the gauge
cluster pressed, and hold it for 5 to 10
seconds, and then release it. (If the
engine is started, the following indication is 61
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 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. Press selector switch on gauge cluster to

display "START ENG".
"Engine SPEED", P1, P2 "PUMP
PRESSURE" and "STEP" (acceleration
command voltage) are indicated.
61-67
4. After starting engine, press selector switch

on gauge cluster, and "MEMORY ENG" is
displayed, the engine speed is automatically
increased, and the adjustment of engine is
performed.
(When trying to limit engine speed, press
selector switch on gauge cluster at the
speed as it is, and the adjustment of
engine is terminated. The torque adjustment
and unloading adjustment required later
are not performed, and default value is
written.)
5. When normal HIGH idling speed is

detected, the adjustment is completed. And
"FINISH ENG" is displayed.
(Press the buzzer stop switch on gauge
cluster while this display is appeared, and
the adjustment of engine is completed.
The torque adjustment and unloading
adjustment required later are not performed,
and default value is written.)
(2) Adjustment of pump ("B" adjustment)
Procedure
1. The adjustment automatically shifts from
engine to pump, the speed shifts from
LOW idling to HIGH idling. And "MEMORY
PUMP" is displayed. And the unloading
proportional valve and pump proportional
valve actuate, accordingly the loading of
pump is increased.
The "ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value)
are indicated.
2. After detection of the engine rated speed,

the adjustment of pump is automatically
completed. And "FINISH PUMP" is
displayed.
(Press the buzzer stop switch on gauge
cluster while this display is appeared and
the adjustment is completed. The
unloading adjustment required later is not
performed, and default value is written.)
61-68
(3) Corrective actions taken when the

adjustment can not be performed;
1. In cases where the adjustment of engine

can not be performed; And ERROR ENG"
is displayed.
Judging condition: The read engine speed
is 50rpm lower than the last value.
It is conceived that the error is caused by

the speed read error, pump load applied
to the engine and unusual acceleration
command voltage applied to the engine
controller in the course of adjustment.
a. Checking speed sensor: Check that it is free from wrong reading of speed due to engine vibration.
b. Checking load applied to pump: Check that it is free from abnormal increase of pump pressure
during adjustment of engine through adjustment screen.
c. Checking acceleration command voltage: Measure the acceleration command voltage output from
mechatro controller to engine controller. Check that signal is regularly input to the engine
controller by actual measurement of voltage or with failure diagnosis tool of engine controller.
2. In cases where the adjustment of pump

can not be performed; And "ERROR
PUMP" is displayed.
Judging condition 1: 61
P1 and P2 average pump pressure at the
time when the adjustment is 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 30~34MPa.
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.
61-69
(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.
For machines equipped with lifting magnet, turn the generator OFF.
E. OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER

(1) Engine emergency mode
When the trouble occurs and the control of engine is impossible, the engine speed can be
controlled by operating emergency acceleration (E-27) provided on the seat rear side.
Operating procedure:
1. Set the emergency acceleration to NORMAL position.
2. Start engine.
3. Turn the emergency acceleration to HI side and control the engine speed.
4. When stopping the engine, set the emergency acceleration to NORMAL position before stopping.
Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed does not increase.
When the machine does not operate, set the emergency acceleration to NORMAL position.
(2) Pump emergency mode
In the event where a failure of P1 or P2 pump proportional valve represented in items of self
diagnosis is indicated on multi display provided on the gauge cluster, the full power control of
pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps
are automatically switched to emergency mode, making the operation with the power shift control
of pump and the constant power control by means of self-pressure possible. But be careful that, at
emergency mode, the accuracy of inching becomes poor, the frequency of engine down is
increased, and the engine stalls in LOW speed condition.
The emergency mode should be used in only case of emergency. We recommend that the defective
section is repaired by troubleshooting as early as possible.
61-70
61.4.9 ADJUSTMENT OF MECHATRO-CONTROLLER

61.4.9.1 LMN BASIC ARM
61.4.9.2 LMN LONG ARM
61
61-71
This page is blank for editing convenience.
61-72
61.5 MECHATRO CONTROL SYSTEM
PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This
manual summarizes the mechatro system and the function of the mechatro controller related
apparatuses. Regarding the conditions before and after each conversion, refer to the hydraulic system
and the electric system.
Though this machine is equipped with the "Unload" valve as well as other series, the function of the
"Unload" valve of this machine is different from the "Unload" valve of other models. In the series (PDA
in general) of other models, the "Unload" function is used as hydraulic control. But in this machine, it
is used only for the pressure release. The meaning of "Unload" used in this machine differs from other
models. And do not confuse it, though the same word "Unload" is used.
61
61-73
61.5.1 SUMMARY OF MECHATRO CONTROL SYSTEM

61.5.1.1 MECHATRO CONTROL SYSTEM IN GENERAL
61-74
61
61-75
61.5.1.2 POSITIVE CONTROL & P-Q CONTROL
61-76
(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.
61
61-77
61.5.1.3 BOOM UP CONFLUX CONTROL
61-78
(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.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves and 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.
(4) With original hydraulic pressure command, boom 1 speed spool and boom 2 speed spool are
switched, and also with the command by mechatro controller, P1 and P2 pumps are switched
and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during
boom up operation.
61
61-79
61.5.1.4 ARM IN RECIRCULATION & CONFLUX CONTROL
61-80
(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
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, 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.
4. The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps,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. 61
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.
61-81
61.5.1.5 ARM-IN ANTI-CAVITATION CONTROL
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and
is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller
processes pilot signal processing and outputs command according to the input voltage to P2 pump
proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse
proportional valve for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by
mechatro controller, and consequently since the reverse proportional valve for arm 2 spool is
controlled to spool stroke according to engine speed and changes recirculation rate to prevent the
cavitation from occurring even if pump delivery rate is low due to low engine speed.
61-82

61
61-83
61.5.1.6 ARM-OUT CONFLUX CONTROL
61-84
(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.
proportional 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 proportional valves are
switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump
side during arm-out operation.
61
61-85
61.5.1.7 BUCKET DIGGING (DUMP) CONFLUX CONTROL
61-86
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure
switches bucket spool and is input to low pressure sensor.
pump proportional valves, and P2 bypass cut proportional valve.
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P2 bypass cut valve of the control valve.
(4) P2 pump delivery oil confluxes into parallel passage of center section because the center bypass
passage of P2 is blocked.
61
61-87
61.5.1.8 BUCKET DIGGING ANTI-CAVITATION CONTROL
61-88
(1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches
bucket spool and is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
pump proportional valves.
(5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1
pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs
secondary pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is
low and pump delivery rate is low.
(7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed
according to the pump pressure, and when the pump pressure is high, the boost solenoid valve
does not work to control the stroke limit of bucket spool.
61
61-89
61.5.1.9 SWING PRIORITY CONTROL
61-90
(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to
low pressure sensor on starting swing operation (or arm-in operation during swing operation), and
swing operation pilot secondary pressure switches swing spool and swing priority valve, and is
input to low pressure sensor.
proportional valves, and inverse proportional valve for arm 2 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 pump delivery circuit of arm head side is restricted and the return oil on the arm
rod side is recirculated, the working pressure is raised and pump delivery rate is used for swing
operation by priority, and operated by the recirculated oil, making the operation with minimum
speed drop possible.
61
61-91
61.5.1.10 TRAVEL STRAIGHT CONTROL
61-92
(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 bypass cut proportional valve
Outputs switching pressure according to the high priority select pressure in the travle control and
the attachment control system operating pilot pressure during operation.
3. P2 unload proportional valve
Outputs switching pressure according to the high priority select in the travel control and the
attachment control system operating pilot pressure during operation.
4. P1 pump proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system
operating 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. 61
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61.5.1.11 PRESSURE RELEASE CONTROL
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(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge
cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item
22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal
(operating pilot, accel potentiometer, etc.) the mechatro controller;
1.
Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump
to minimum tilt angle.
2.
Outputs command of pressure release and outputs command of pressure release control to ECU
and fixes engine speed to pressure release control speed.
3.
Switches unload solenoid directional valve and open the opening of unload by pushing travel
straight valve from back side.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the
pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge
cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped
pressure) to be released by operating each control lever and switching spool with the unload
opening of travel straight valve opened.
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61.5.1.12 N&B SWITCH CONTROL (OPTION)
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(1) Nibbler circuit

1. Select nibbler mode through select switch.
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 nibbler mode through select switch, the breaker pressure sensor has not function
to output.
It is in normal when there is no output from sensor in nibbler mode, and in cases of other than
above, error display is output to gauge cluster.
(2) Breaker circuit

1. Select breaker mode through select switch.
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 breaker mode through select switch, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in breaker mode, and in cases of other than
above, error display is output to gauge cluster.
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61.5.1.13 OPTION CONFLUX CONTROL (OPTION)
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(1) Select the Conflux with the aid of Conflux/Single switch.

(2) On starting option operation, option operating pilot pressure switches option spool and is input to
low pressure sensor.
pump proportional valves, and P1 bypass cut proportional valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the
P1 valve of the control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the P1 bypass cut valve is
switched and P1 pump delivery oil confluxes P2 pump delivery oil.
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61.5.2 MECHATRO CONTROLLER

61.5.2.1 SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
(1) Controls
(2) Gauge cluster
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(3) Screen selection by work mode select switch

The mode after the engine starting is always the start from "S" mode.
The work mode is switched in order of "S" -> "H" each time the work mode select switch is pressed.
Select proper work mode shown below according to the work condition and the purpose.
For the selected work mode, refer to the table shown below.
・ S mode: For standard excavating work

・ H mode: For heavy duty excavating work
S mode
"S mode" is suitable for standard digging and
loading works and is in saving fuel consumption
and is in good balance to the workload. 61
H mode
"H mode" is suitable for heavy duty digging
work which gives priority to the workload at
the high speed.
61-101
(4) Screen selection by attachment mode select switch (SE Asia : Option)
This switch is used for switching the attachment
mode.
The screen is changed from "Digging" to
"Nibbler" to "Breaker" each time the attachment
mode switch (3) is turned to respective position.
Depending on the attachment employed, select
the applicable mode from "Digging", Nibbler",
and "Breaker".
Before the working, confirm whether
appropriate attachment had been selected.
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(5) Pump flow rate adjustment (Nibbler mode / Breaker mode)

According to some kind of attachment, it is required to change the flow rate for service circuit. Change
the flow rate in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 370L/min. The
adjustment (increase or decrease) of flow rate is changeable by 10L/min step.
1: Screen Change Switch

2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Select Switch
9: Attachment Mode Select Switch
(SE Asia : Option)
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1. Turn starter key switch on and display main screen (a).

2. The screen is changed from "Digging" to "Nibbler" to "Breaker" each time the attachment mode
select switch (9) is turned when the main screen (a) is displayed.
3. Turn the switch (9) to "B", and "Nibbler mode" screen is displayed. Or turn the switch (9) to "A",
and "Breaker mode” screen is displayed.
4. When the nibbler/breaker select screen (b) or (c) is displayed, press the select switch (8) and the
value of flow rate reverses to black, and the screen is changed to (d). To increase flow, press the
up arrow (4) (washer switch), or to decrease flow, press the down arrow (5) (washer switch).
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the
desired value.
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(6) MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the
end of recommended replacement/change
interval specified for filter/oil.
After turning starter key switch ON or starting

engine, the screen is changed in order of "Time
for engine oil change" --> "Time for fuel filter
replacement" --> "Time for hydraulic oil filter
change" --> "Time for hydraulic oil change" -->
"Main screen" each time the screen change
switch (2) is pressed.
With this menu, the time range to the
recommended change time for the filter and oil
in use can be identified.
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
ASIA 2,000 Hr
Hydraulic oil
OCEANIA 5,000 Hr
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.
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2.
Remaining time display to the coming fuel filter
replacement
coming engine fuel filter replacement.
3.
Remaining time display to the coming hydraulic
oil filter replacement
coming hydraulic oil filter replacement.
4.
Remaining time display to the coming hydraulic
oil change
coming hydraulic oil change.
-The display automatically changes to the main screen, if switch is not operated for 30 seconds.
-For the setting procedure of maintenance time to be performed to the coming oil change in each
type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.
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61-105
(7) 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.
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.
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display
function.
1.4 Machine condition display :

Displays machine operating condition.
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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.
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61.5.2.2 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
(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.
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61.5.2.3 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.
Buzzer stop switch
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 to No.30

・ Mode No.2 : Screen No.1, Screen No.31 to No.40
・ Mode No.3 : Screen No.1, Screen No.41 to 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.
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(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
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61-111
61-112

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61-113
61-114
(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 to 2.0 M C-1 P1-PRES 0.2 to 2.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
D-1 P1-UL(BPC) 300 mA D-1 P1-UL(BPC) 300 mA
D-2 P2-UL(BPC) 300 mA D-2 P2-UL(BPC) 300 mA 61
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 1820 to 1880 G-3 ENG SPEED 1820 to 1880
POWER SHIFT 0 mA POWER SHIFT 0 mA
Operation No.3: Operation No.4:

Boom up in full lever operation & relief Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.31 BOOM No.31 BOOM
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 600 to 750 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
61-115
Operation No.5:
Boom down in full lever operation & in operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 5.0 to 9.0 M
C-2 P2-PRES 0.2 to 2.0 M
E-1 P1-PSV 650 to 681 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 300 mA
D-2 P2-UL(BPC) 300 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1800 to 2000
POWER SHIFT 0 mA

Arm-in in full lever operation & relief Arm-in in full lever operation & in operation
61-116

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
* Measure the values after a lapse of 5 minutes or after release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
C-2 P2-PRES 24.0 to 33.5 M C-2 P2-PRES 3.0 to 10.0 M 61
E-2 P2-PSV 500 to 750 mA E-2 P2-PSV 750 mA
61-117

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
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
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
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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
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 to 2.6 M B-17 P2 OPT 2.0 to 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 * Conflux switch is OFF. Relief set pressure is
value of shipping. value of shipping.
Operation No.18: Operation No.19 :

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 7.0 to 13.0 M C-1 P1-PRES 0.2 to 2.0 M 61
B-9 TRAVEL(R) 2.0 to 2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0 to 2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
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61.5.2.4 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.
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.
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61.5.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display
which allows confirmation of remaining time to
the coming replacement/change time of engine
oil, fuel filter, hydraulic oil filter and hydraulic
oil, therefore when the remaining time reaches
to Zero (0), replace or change engine oil, fuel
filter, hydraulic filter, hydraulic oil, etc. and
perform the initial setting by the following order.
Interval of replacement of parts is mentioned below.

-Engine oil: 500 Hr
-Fuel filter: 500 Hr
-Hydraulic filter: 1,000 Hr
-Hydraulic oil: 2,000 Hr (ASIA)
-Hydraulic oil: 5,000 Hr (OCEANIA)
61
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.
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61.5.2.6 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
1) Auto idling stop
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.
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2) Clock Adjustment Switches
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch 61
(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).
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3) Contrast Adjustment Switches
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).
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(2) Function for service

Following items are provided for adjustment of service function.
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of Does left rotation pedal use?
option attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Setting of optional Optional flow rate limitation, relief pressure limitation, combination of return selector
equipment adjustment.
Engine speed ON/OFF of engine rpm display
Auto acceleration Adjustment the type of the engine speed of auto deceleration runs up abruptly.
Change of starter mode Change of start mode
Low temperature mode Low temperature mode release
forcible release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
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61-125
61.5.2.7 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view
2) List of connectors
61-126
61
61-127
61-128
61
61-129
61-130
(2) Gauge cluster (symbol C-2)

1) General view
2) Connector CN-600 (Harness side)

No. Item name Wire color No. Item name Wire color
Gauge cluster --> Mechatro
GND source (+24V Battery direct
1 controller (RS232C White 5 Yellow / Black
connection)
communication)
Mechatro controller --> Gauge
2
cluster (RS232C communication)
Red 6 GND Black 61
3 Reserved - 7 Source (+24V starter switch ON) White
4 Reserved - 8 GND (RS232C communication) Black
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 120X168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 -
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch
8 Back light LED
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(3) Relay & fuse box (symbol E-1)

1) General view
61-132
2) Circuit diagram
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61-133
61-134
61
61-135
(4) High pressure sensor: LS52S00015P1
(5) Low pressure sensor: LC52S00019P1
61-136

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61.6 HYDRAULIC SYSTEM
61.6.1 HYDRAULIC CIRCUIT AND MODEL NUMBERS

61.6.1.1 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM
61-138
61
61-139
61.6.1.2 SEPARATE BOOM WITH ROTARY N&B,

BASIC JIB CYLINDER SPEC.
61-140
61
61-141
61.6.1.3 SEPARATE BOOM WITH ROTARY N&B,

LARGE DIAMETER JIB CYLINDER SPEC.
61-142
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61-143
61.6.2 EXPLANATION FOR HYDRAULIC

CIRCUIT OF LMN & SEPARATE
BOOM
Only different function between LMN & Separate
circuit and Standard backhoe circuit is explained here.
(1) Neutral circuit (LMN)

(2) Travel circuit: Hydraulic VLC (Only case of
SK500DLC-8 model)
(3) Bucket circuit (LMN)
(4) Boom circuit
(5) Jib circuit (LMN)
(6) Arm circuit (LMN)
(7) Motor circuit: For N&B rotation
(8) Crusher (Nibbler) circuit
(9) Breaker circuit: (Separate boom)
(10) Neutral circuit, Arm circuit, Jib circuit: (Separate
boom)
(1) Neutral circuit (LMN)

[Electric]
1. LMN/BH switching (SW-18) operation
In case that you change the work from the
backhoe work to LMN work, you need the
switching operation of LMN/BH. For safety
reasons, we change the switching procedure
from the one-touch switch type to the replacement
of connector type.The connector is located on
the rear left of operator's seat. Select either 1FA
female connector of LMN or BH, and connect
the connector you need to 1MA male connector.
For detail, refer to "Electric system, harness
LS13E0115P1".
2. When switching to LMN, ground signal is input
into controller (C1), and the mechatro-signal is
changed.
[Mechatro]
1. Switching of Arm IN/OUT solenoid valve (63)
(SV-8).
2. Attachment boost function cut
(The attachment boost function is not available
because the attachment boost switch is replaced
to release switch of bucket stroke end restriction.)
3. Function of bucket digging restriction solenoid (64)
(SV-16) is on.
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61
LMN NEUTRAL CIRCUIT: Switching operation of LMN/BH (Mechatro change)
61-145
(2) Travel circuit: Hydraulic VLC (Only case of similar steps to right piping. But in case of right
SK500DLC-8 model) crawler, the position of quick joint of lower frame
[Electric] is located on the right front of crawler. Therefore,
Switch the expansion or the retraction by using slew the upper frame 180 degrees against the
hydraulic VLC switch (SW-78) located on the undercarriage.
instrument panel. {For detail, refer to "Electric (6) When performing the extension of right crawler,
system, upper harness (Hydraulic VLC)"}Then crawler perform the similar steps to extend left crawler.
expansion SOL (SV-40) or crawler retraction SOL (7) When performing the retraction of right and left
(SV-41) is energized, solenoid valve (90) is switched. crawlers, perform the similar steps to extend the
Consequently, the signal that the solenoid valve was crawler.
switched is transferred to mechatro-controller (C-1).
[Mechatro]
P1 bypass cut proportional valve is energized by
switch signal of hydraulic VLC switch (SW-78), and
proportional secondary pressure is output. And
minimum flow rate delivery command for pump is
output.
[Pilot circuit]
Proportional secondary pressure is output from A7 port
of P1 bypass cut proportional valve (PSV-D), it
enters into 4Pc2 port of C/V (2), and switch the
bypass cut valve.
[Main circuit]
(1) In case of extending extension/retraction cylinder
of left crawlerSlew the upper frame 90 degrees
against the undercarriage, and connect 2 hoses to
quick couplers located on the left rear of the
upper frame. And connect the other end of hose
to quick coupler located on the rear of lower
frame.
(2) Switch the hydraulic VLC switch (SW-78) from
neutral to extension side, and pressurized oil is
supplied to head (H) side of cylinder (91) from
C/V (2) PO port through P-A port of solenoid
valve (90). Consequently, the left crawler is
extended.
(3) Return oil from cylinder enters into RS1 port of
C/V (2) from B-T port of solenoid valve (90), and
it returns to tank.
(4) When the extension of cylinder is finished, release
your hand from hydraulic VLC switch (SW-78).
The switch returns to neutral automatically, and
solenoid (SV-40) becomes non-energized
condition. Consequently, the spool of solenoid
valve (90) returns to neutral too.
(5) In case of extending extension/retraction cylinder
of right crawlerConnect the quick coupler in the
61-146
61
RETRACTABLE CRAWLER CIRCUIT: SK500DLC-8 Hydraulic VLC
61-147
(3) Bucket circuit (LMN); Bucket cylinder stroke end

prevention function 3. During the operation of bucket digging, when
[Electric] bucket stroke reaches nearly end, bucket stroke
This LMN machine has stroke end detection switch end detect switch (SW-32) is on. And bucket
(SW-32) located on the arm top, and this switch restriction valve (64) is switched and secondary
detects the position of idler link. When bucket pressure for bucket digging is cut.
cylinder reaches nearly to position of stroke end,
switch (SW-32) is actuated, and ground signal is input [Main circuit]
into the mechatro-controller (C-1). 1. P1 pump flow rate is delivered from 4B2 port of
C/V (2) to bucket cylinder (H).
[Mechatro] 2. When bucket restriction SOL valve (64) is
1. When connecting LMN switch connector to LMN switched, operation pressure for bucket digging is
side, P2 bypass cut proportional valve becomes cut. And bucket spool returns to neutral and
non-energized condition, and bucket digging and delivery oil to bucket cylinder (H) side is cut.
dump become conflux cut. At this time, pump flow Consequently, overload of bucket cylinder is
is controlled too. avoided.
2. When the output voltage of low pressure sensor
(SE-1) is input into mechatro-controller, the
controller judges that is bucket digging. And
attachment boost SOL (SV-2) is energized.
3. When the stroke end detection switch (SW-32) As for the release of the bucket stroke end restrict
becomes ON, bucket restriction relay (R-10) is ion: When LMN is operated, yellow button (SW-20) on t
switched by mechatro command. Consequently, he right control lever is release switch for bucket
bucket restriction solenoid (SV-16) is energized stroke end restriction. (When using this machine wit
and the solenoid valve (64) is switched. h bucket, this button is used for attachment boost s
witch.)During holding down switch (SW-20), a signal i
[Pilot circuit] s input into mechatro-controller. While the input is
1. When bucket digging is operated, secondary continuing , if the stroke end detection switch (SW -
pressure for bucket digging flows from port (1) of 32) is on, bucket restriction SOL (SV-16) is non-ene
right P/V (10), and it acts on low pressure sensor rgized, and bucket operation can be operated.
(SE-1). And it flows through P-A port of bucket
restriction SOL valve (64) and it acts on 4Pb2
port of C/V (2). Consequently, bucket spool is
switched.
2. At that time, attachment boost SOL (SV-2) is
switched, it acts on PC port of C/V (2), and it
boosts main relief pressure up to 34.3MPa.
Simultaneously, it acts on 4PC3 port and
restricts the stroke distance of bucket spool.
The purpose of above-mentioned control is prevention

from cavitation. When the bucket digging is operated
using crusher, this function restricts the stroke di
stance of bucket spool, and avoids the cavitation. R
eally, the boost function is not needed, but base ma
chine equips this function originally. So, this func
tion is left.
61-148
61
BUCKET CIRCUIT: Overload prevention function at bucket digging and cylinder stroke end
61-149
(4) Boom circuit; Boom down operation and

Holding valve function
[Pilot circuit]
When boom down is operated, secondary pressure for
boom down flows from ATT P/V (4) port, and
secondary pressure for boom down acts on PL port of
holding valve (70) and (71), and selector valve in
H/V is switched. And lock valve poppet spring
chamber in H/V communicates to low pressure side of
A port by switching selector valve. Consequently, the
lock valve poppet is fully opened.
[Main circuit]
1. When the lock valve poppet is fully opened,
head side of boom cylinder communicates to A
port of H/V (70) and (71), and oil returns to tank
from 4A3 port of C/V (2) through boom spool.
2. When boom spool is neutral or piping is broken,
the lock valve of H/V is shut to prevent falling of
boom. But if the head pressure of boom cylinder
rises higher than the relief pressure of H/V (70)
and (71), the relief valve is actuated, and boom
lowers to avoid the breakage of cylinder tube.
61-150
61
BUCKET CIRCUIT: Function of boom holding valve at boom down operation
61-151
(5-1) Jib circuit (LMN); Jib OUT (raise) operation

[Pedal control and jib motion]
P/V (59) C/V (2)
Left pedal Jib motion
Discharge port Inlet port
Front
B 4Pao OUT (raise)
(Pressing tiptoe)
[Pilot circuit]
When tiptoe side of jib control pedal is pressed, jib
control secondary pressure flows from B port of pilot
valve (59). And this pressure oil enters into P port of
jib extension inverse proportional valve (PSV-F) (65)
and flows out from A port, and enters into 4Pao port
of C/V (2). And this pressure oil switches jib spool
and acts on low pressure sensor (SE-20) located on
the JIB P/V (59).
[Mechatro]
1. Output voltage of low pressure sensor (SE-20) is
input into mechatro-controller, and secondary
pressure flows out from P1 bypass cut solenoid
proportional valve (PSV-D) by the command
current of mechatro-controller. Consequently, P1
bypass cut spool is switched.
[Main circuit]
P1 pump oil flows out from 4AO port of C/V (2) by
switching of bypass cut spool in the course of pilot
circuit. And this oil enters into head side of jib
cylinder (56) through restrictor (68), and operates jib
OUT.
Meanwhile, return oil from jib cylinder R side returns
to tank from 4BO port of C/V (2) through jib spool.
61-152
61
JIB CIRCUIT (LMN): Jib OUT (raise) operation
61-153
(5-2) Jib circuit (LMN); Jib IN (lower) operation

[Pedal control and jib motion]
P/V (59) C/V (2)
Left pedal Jib motion
Discharge port Inlet port
Rear
A 5Pbo IN (lower)
(Pressing heel)
[Pilot circuit]
When heel side of jib control pedal is pressed, jib
control secondary pressure flows from A port of pilot
valve (59). And this pressure oil enters into P2 port of
jib extension inverse proportional valve (PSV-G) (65)
and flows out from A2 port, and enters into 4Pbo port
of C/V (2). And this pressure oil switches jib spool
and acts on low pressure sensor (SE-20) located on
the JIB P/V (59).
[Mechatro]
1. Output voltage of low pressure sensor (SE-20) is
input into mechatro-controller, and secondary
pressure flows out from P1 unload solenoid
proportional valve (PSV-D) by the command
current of mechatro-controller. Consequently, P1
bypass cut spool is switched.
[Main circuit]
1. P1 pump oil flows out from 4BO port of C/V (2)
by switching of P1 unload spool in the course of
pilot circuit. And this oil enters into rod side of
jib cylinder (56), and operates jib IN.
2. Jib lowering speed is adjusted, because the flow
out oil from jib cylinder H side is restricted by
variable restrictor (68). Returned oil to 4AO port
of C/V (2) returns to tank through jib spool.
61-154
61
JIB CIRCUIT (LMN): Jib IN (lower) operation
61-155
(6-1) Arm circuit (LMN); Arm IN (lower) operation 3. Arm lowering speed is adjusted, because the
[Electric: LMN/BH switching] flow out oil from arm cylinder H side is restricted
1. Select the LMN connector from the connector for by variable restrictor (68) located in course of
changing LMN/BH to operate the LMN. Then piping for attachment.
connect it. And the arm reversing solenoid valve 4. The returned oil from arm cylinder head enters
(63) is switched. into 5B5 port of C/V (2), and returns to tank
2. When this solenoid valve (63) is switched, pilot through arm 2 spool.
signal for arm is switched too. And when the
control lever is pulled, arm moves inward. (Arm is
lowered.) This motion coincides with backhoe
motion.
The control valve moves in reverse direction of the

backhoe, because the pilot signal of arm was replace
d.
[Pilot circuit]
When the arm IN is operated, secondary pressure for
pilot operation flows out from port (7) of left pilot
valve (10) and it acts on low pressure sensor (SE-7).
At that time, this oil enters into B port of arm
reverse solenoid valve (63) and flows out from P port,
and it acts on 5Pa5 and 4Pb4 ports of C/V (2).
Consequently, arm 1 spool and arm 2 spool are
switched.
[Mechatro]
1. The output voltage of low pressure sensor (SE-7)
is input into mechatro-controller. And it processes
a signal same process as arm OUT operation of
backhoe.
2. When the LMN/BH connector is placed in LMN
side, hydraulic circuit flow is in conflux condition,
but P1 pump flow is controlled by signal of
mechatro-controller.
[Main circuit]
1. The delivery oil of P2 pump flows into P2
parallel circuit of C/V (2). And this oil opens load
check valve and passes through arm1 spool.
Then it opens arm lock valve by free flow and it
enters into cylinder rod from 5A5 port of C/V (2).
2. The delivery oil of P1 pump passes through
arm2 spool of C/V (2). And this oil flows
together with arm1 circuit in the C/V, and it is
delivered to arm cylinder rod from 5A5 port of
C/V (2).
61-156
61
ARM CIRCUIT (LMN): Arm In operation, Matching function of Arm movement of BH/LMN & Holding function are added
61-157
(6-2) Arm circuit (LMN); Arm OUT (raise) operation 2 spool of C/V (2). And this oil flows together
[Electric: LMN/BH switching] with arm 1 circuit in the C/V, and it is delivered
1. Select the LMN connector from the connector for to arm cylinder rod from 5B5 port of C/V (2).
changing LMN/BH to operate the LMN. Then 3. The delivery oil of P1 pump flows together with
connect it. And the arm reversing solenoid valve arm 1 spool through arm 2 spool. Then it flows
(63) is switched. out from 5B5 port and enters into cylinder head.
2. When this solenoid valve (63) is switched, pilot 4. The returned oil from arm cylinder rod enters
signal for arm is switched too. And when the into 5A5 port of C/V (2), and opens arm lock
control lever is pulled, arm moves outward. (Arm valve. Then it flows into arm 2 spool.
is raised.) This motion coincides with backhoe 5. Because the arm 2 spool is positioned the
motion. recirculation cut, this oil returns to tank through
arm 2 spool.
The control valve moves in reverse direction of the

backhoe, because the pilot signal of arm was replace
d.
[Pilot circuit]
1. When the arm OUT is operated, secondary
pressure for pilot operation flows out from port (8)
of left pilot valve (10) (refer to the case of
standard machine) and it acts on low pressure
sensor (SE-8). At that time, this oil enters into A
port of arm reverse solenoid valve (63) and
flows out from T port, and it acts on 5Pb5 of C/V
(2). Consequently, arm 1 spool is switched, and
arm lock valve selector is switched by 5PC1 port
action too.
2. Moreover, secondary pressure for pilot operation
flows out from P2 port of solenoid valve block
and enters into 4Pa4 port through electric
inverse proportional valve (PSV-A). Consequently,
the arm2 spool is shifted to the position of
recirculation cut.
[Mechatro]
The output voltage of low pressure sensor (SE-8) is
input into mechatro-controller. This time, hydraulic
circuit flow is in conflux condition, but P1 pump flow
is controlled by signal of mechatro-controller.
[Main circuit]
1. The delivery oil of P2 pump flows into P2
parallel circuit of C/V (2). And this oil opens load
check valve and passes through arm 1 spool.
Then it flows out from 5B5 port through restrictor
(68) and enters into cylinder head.
2. The delivery oil of P1 pump passes through arm
61-158
61
ARM CIRCUIT (LMN): Arm OUT operation, Matching function of Arm movement of BH/LMN is added
61-159
(7) Motor rotation circuit; Crusher (Nibbler) rotation

motor operation
[Electric; Switch operation of attachment control
lever grip]
Switch operation Rotation direction Pressure oil outlet
Pressing switch Left side of
Rightward
on the right lever attachment
Pressing switch Right side of
Leftward
on the left lever attachment
By turning on the switch of rotation (SW-33, SW-34)

located on the control lever grip, the left rotation or
right rotation SOL (SV-7 or SV-6) of solenoid valve
(62) is energized, and control valve is switched.
[Mechatro]
When controller detects the "ON" signal of the switch
of rotation (SW-33, SW-34), and the left rotation or
right rotation SOL (SV-7 or SV-6) of solenoid valve
(62) is energized. As a result, control valve (55) is
switched.
[Pilot circuit]
Pilot primary pressure flows into G port of the left
rotation or right rotation SOL (SV-7 or SV-6) and
flows out from A port or B port. Then it flows into
PA1 port or PB1 port of control valve (55), and it
switches spool for rotation.
[Main circuit]
1. In case of the left rotation
Delivery oil from 4th gear pump (51) which is
added to main pump flows into P port of control
valve (55). And it flows out from B1 port through
rotation spool and enters into B port of crusher
rotation motor. Consequently, this delivered oil
rotates crusher leftward.
2. Returned oil from rotary motor A port flows into A
port of control valve (55). And it connects with
makeup circuit of crusher slewing motor through
rotation spool. Consequently, it flows into PS1
port of C/V (2) and returns to tank through tank
circuit.
61-160
61
MOTOR CIRCUIT: Motor left rotation
61-161
(8) Crusher circuit; LMN & Separate boom in [Pilot circuit]

common 1. In case of Crusher closing
[Electric; Switch operation] When tiptoe side of crusher control pedal is
1. By selecting the "A mode" switch located on the pressed, crusher control pilot secondary pressure
monitor, this signal is input to mechatro-controller flows from B port of pilot valve (59). And this
(C-1). (When you work in LMN, "A mode" is pressure oil enters into 5Pb3 port of C/V (2) and
fixed.) this pressure oil switches crusher spool and acts
2. By selecting the "Conflux" from CONFLUX/SINGLE on low pressure sensor (SE-11) located on the
switch (SW-15), the grounding signal is input to side of P/V (59).
mechatro-controller (C-1). 2. In case of Crusher opening
When heel side of crusher control pedal is
[Mechatro] pressed, crusher control pilot secondary pressure
1. When "A mode" is selected, selector SOL (SV-13) flows from A port of crusher control pilot valve
of N/B electro-magnetic switching valve (53) is not (59). And this pressure oil enters into 5Pa3 port
energized. of C/V (2) and this pressure oil switches crusher
spool and acts on low pressure sensor (SE-11)
Monitor (Gauge cluster) N/B electro-magnetic and crusher open pressure switch (SW-29) located
[MODE] switching valve (53) under side of P/V (59).
A mode No switching
[Mechatro]
1. The output voltage of low pressure sensor
2. By the conditions of the switching of (SE-11) is input into mechatro-controller, and P1
CONFLUX/SINGLE switch (SW-15) and the and P2 pump flow rate are controlled by the
crusher open pressure switch (SW-29), the command current from mechatro-controller.
following electro magnetic proportional valves are 2. According to the situations of the crusher
energized by command current from controller opening pressure switch (SW-29), the
(C-1). CONFLUX/SINGLE switch (SW-13), and the
LMN/Separate select switch, either Conflux or
Single flow of pump is decided, and suitable one
is selected.
[Main circuit]
1. Delivery oil of P1 pump flows into load check
valve and opens it through travel straight valve,
and flows into parallel circuit of P2 side.Delivery
oil of P2 pump opens load check valve and
flows into parallel circuit.And pump flow rate of
P1 and P2 flow together, and this joined oil is
3. The setting of flow rate of crusher is set more supplied to crusher cylinder (H) side from 5B3
accurately by using gauge cluster. port of C/V (2) by switching of crusher spool. As
a result, the crusher is closed.
[Pedal of Crusher operation] 2. The returned oil from crusher cylinder (R) side
flows into C port of N&B electro magnetic
switching valve (53). And it passes through spool
and flows to A port. Then it flows to 5A3 port of
C/V (2) and returns to tank through crusher spool.
61-162
61
CRUSHER CIRCUIT: At crusher work “A mode”& At CONFLUX/SINGLE switch is in “CONFLUX”

, crusher closing operation
61-163
(9) Breaker circuit; Separate boom breaker (SE-11) is input into mechatro-controller, and P1
[Electric; Switch operation] and P2 pump flow rate are controlled by the
1. By selecting the "B mode" switch located on the command current from mechatro-controller.
monitor, this signal is input to mechatro-controller 2. Selector solenoid (SV-13) is energized by
(C-1). (When you work in LMN, "A mode" is switching the work mode switch to B mode.
fixed. Therefore, the mode does not change to "B 3. When the work mode of "B" is selected, spool of
mode".) N&B electro-magnetic switching valve (53) is
2. By selecting the "SINGLE" from switched and primary pressure of pilot line acts
CONFLUX/SINGLE switch (SW-15), the on pressure sensor (SE-29). And the confirmation
grounding signal is not input to mechatro-controller of switching of selector spool can be checked by
(C-1), because a switch is "OFF" condition. (Make this signal of sensor. If the switching is normal,
sure to use the breaker with single flow.) no display appears. But if the abnormal is found,
3. The setting of flow rate of breaker is set more "SELECTOR VALVE FAILURE" is indicated.
accurately by using gauge cluster.
[Main circuit]
[Mechatro] 1. In case of Breaker circuit, delivery oil of P2 pump
1. When "B mode" is selected, selector SOL (SV-13) flows into load check valve and opens it from
of N/B electro-magnetic switching valve (53) is parallel circuit. And it flows into parallel circuit,
energized. then it opens load check valve and it passes
breaker spool, and flows out from 5B3 port of
Monitor (Gauge cluster) N/B electro-magnetic C/V (2). As a result, the breaker starts blowing
[MODE] switching valve (53) work.
B mode Switching 2. The returned oil from breaker flows into C port
of N&B electro magnetic switching valve (53). And
it returns to tank directly from T port, because the
[Pedal of Breaker operation] spool of N&B electro magnetic switching valve
was shifted.
[Pilot circuit]
1. In case of Breaker blowing
When tiptoe side of breaker control pedal is
pressed, breaker control pilot secondary pressure
flows from B port of pilot valve (59). And this
pressure oil enters into 5Pb3 port of C/V (2) and
this pressure oil switches breaker spool and acts
on low pressure sensor (SE-11).
Selector solenoid (SV-13) of N&B electro-magnetic
switching valve (53) was switched, therefore, the
pilot primary pressure from PL port shifts spool
of selector valve, and at that time, this pressure
acts on low pressure sensor (SE-29).
[Mechatro]
1. The output voltage of low pressure sensor
61-164
61
BREAKER CIRCUIT: At breaker work of separate boom “B mode”

, At CONFLUX/SINGLE switch is in “SINGLE”
, breaker blowing operation
61-165
(10) Neutral circuit; Arm circuit, Jib circuit, and Jib LMN. But, when jib and bucket are worked at
circuit (Separate boom) one time, jib restriction function is actuated.
- Neutral circuit
[Electric]
When you use the "Machine with Separate boom", make

sure to switch the LMN/BH connector to BH side.
[Electric]
1. Change the LMN/BH connector (SW-18) to BH
side. For detail, refer to the previously described
section "LMN neutral".
2. Arm OUT/IN reverse SOL (SV-8) becomes [Mechatro]
unable to operate. And the grounding signal to 1. When the above-mentioned sensor (SE-20) and
mechatro-controller (C-1) disappears too. pressure switch (SW-43) are turned on at one
time, command of mechatro-controller actuates jib
[Mechatro] inverse proportional valve (PSV-F or PSV-G).
LMN function is released by command from controller 2. Output voltage of low pressure sensor (SE-20) is
(C-1), and the machine becomes usual backhoe input into mechatro-controller, and secondary
machine. pressure of P1 unload solenoid proportional valve
(PSV-D) (Refer to the case of standard
- Arm circuit machine.) is generated. As a result, P1 bypass
[Pilot circuit] cut spool is switched. And delivery flow rate of
Because Arm reversing solenoid valve is pump is controlled by command current for the
demagnetized, pilot secondary pressure flows through pump.
only reversing solenoid valve (63). Therefore, pilot
secondary pressure actuates the arm 1 spool of C/V [Main circuit]
(2) as well as standard machine. In case that bucket and jib are operated at one time,
only P1 pump works for both bucket and jib cylinder.
[Main circuit] Therefore, we restrict the operation of jib cylinder
Main circuit is same as circuit of standard machine. and give the priority to operation of bucket.
Arm falling speed is restricted, because return oil of
arm cylinder rod side is restricted by restrictor (68)
located on the midway of circuit.
- Jib circuit
1. Jib circuit is same as circuit of LMN basically. But
there are 2 kinds of cylinder, standard jib
cylinder and large diameter jib cylinder. The
purpose of large diameter jib cylinder is
reinforcement of rod side holding force.
Accordingly, output of head side is increased.
Therefore, to adjust the output of the large
diameter jib cylinder, we add relief valve (72) to
head side of the large diameter jib cylinder. By
this means, the output of the large diameter jib
cylinder keeps same output as the standard jib
cylinder.
2. Operation and function of circuit are same as
61-166
61
SEPARATE BOOM ROTARY N&B: Neutral circuit, Arm circuit & Jib circuit
61-167
61.6.3 HYDRAULIC LINES DRAWING

NUMBER LIST
61-168
61.7 ELECTRICAL SYSTEM
61.7.1 ELECTRIC CIRCUIT
61
61-169
61-170
61
61-171
61-172
61
61-173
61-174
61
61-175
61-176
61
61-177
61.7.2 ELECTRICAL EQUIPMENT
61-178
61
61-179
61.7.3 HARNESS LIST
61-180
61
61-181
61-182
61.7.4 OPERATOR'S CONTROLS
61
61-183
61.7.5 CONTROLLER INSTAL
61-184
61.7.6 INSTALLMENT PANEL ASSY

YN17M00046F1: WITH B/H STD AND DEMOLITION
MACHINE IN COMMON TYPE WITH MAIN BOOM
61.7.7 UPPER ELEC ASSY
LS03E00001F1: WITH B/H STD AND DEMOLITION
61.7.8 UPPER HARNESS ASSY
61
61-185
61-186
61
61-187
61-188
61.7.10 UPPER LUBRICATION LINES
61
61-189
61-190
61
61-191
61.7.11 HARNESS ASSY (ROTARY LIGHT)
61-192
61
61-193

(HYDRAULIC VLC)
61-194
61
61-195
61.7.13 ENGINE HARNESS ASSY

61.7.14 UPPER HARNESS ASSY (FLOOR)
61.7.15 CAB HARNESS ASSY
LC14E00023F1: WITH B/H STD AND DEMOLITION
61-196
61.7.16 CAB INSTALL
61
61-197
61-198
61
61-199
61-200
61.7.17 WASHER TANK ASSY

YN54C00002F1: WITH B/H STD AND DEMOLITION
61
61-201
61.7.18 ONE-WAY CALL ASSY
61-202
61.7.19 HARNESS ASSY (WATER

SPRINKLER)
61
61-203
61-204
61.7.20 BOOM HARNESS ASSY (STD.

ARM SPEC.)
61
61-205
61-206
61
61-207
61-208
61
61-209
61-210
61.7.21 BOOM HARNESS ASSY (LONG

ARM SPEC.)
61
61-211
61-212
61
61-213
61.7.22 BOOM HARNESS ASSY (BASIC &

LARGE DIAMETER JIB CYLINDER
SPEC.)
61-214
61.7.23 UPPER FRAME LIGHT INSTALL

LS80E00004F1 (WITH STD AND DEMOLITION
MACHINE IN COMMON TYPE WITH MAIN BOOM)
61
61-215
61.7.24 ANGLE SENSOR INSTALL (MAIN

BOOM)
61.7.25 ANGLE SENSOR INSTALL
(FRONT BOOM & INTER BOOM,
INTER BOOM & ARM)
61-216
61.7.26 STROKE END DETECTION SWITCH

INSTALL (ARM)
61
61-217
61-218
61.8 COMPONENTS
61.8.1 MAIN HYDRAULIC PUMP (PTO: FOR N&B ROTATION MOTOR)

(1) General view
61
LMN rotation & with common use type

LS10V00014F1
MAIN HYDRAULIC PUMP separate boom and Rotary N&B
LS10V00016F1 STD
No. NAME PARTS No. Q'TY REMARKS
1 HYDRAULIC PUMP LS10V00017F1 1 <--
2 REGULATOR LS10V01006F1 2 <--
3 SOLENOID VALVE YN35V00052F1 2 <--
4 GEAR PUMP LS10V00018F1 1 <--
5 GEAR CASE ASSY LS46W00001F1 - 1
61-219
(2) Constructions
PTO Sub gear casing assy
PTO SUB GEAR CASING ASSY: LS46W00001F1

No. NAME Q'TY REMARKS No. NAME Q'TY REMARKS
115 IDLE SHAFT 1 414 SOCKET BOLT 3 M16X35
117 2nd GEAR 1 416 SOCKET BOLT 8 M12X35
118 3rd GEAR 1 709 O-RING 1
125 BEARING 2 710 O-RING 1
126 CYLINDER ROLLER BEARING 1 711 O-RING 1
128 BEARING CASING 3 825 LOCKING RING 1 RR-80
284 BEARING CASING 1 826 LOCKING RING 1 RR-35
316 COVER 1 886 PIN 2
326 GEAR CASING 1 901 EYE BOLT 1 EB-M10
409 SOCKET BOLT 2 M10X16
61-220
61.8.2 GEAR PUMP: YN10V00026F1 (N&B ROTATION)

(1) General view
(2) Specifications
Model SGP2A32F1H1-R382
Theoretical delivery rate 32.5 cm3
Rated pressure 24.5 MPa
Momentary maximum pressure 29.4 MPa
Rotation direction CW rotation seen from shaft end 61
Speed range 400～3000 min-1
Suction pressure -0.02~0.2 MPa
Mass 5.7 kg
61.8.3 RELIEF VALVE ASSY: LS22V00001F2 (1-OPT KIT)

(1) Installation procedure for 1-OPT: Set pressure 24.5 MPa
(In case that customer does not require anything about pressure.)
61-221
(2) Constructions
61.8.4 CONTROL VALVE FOR OPTION (JIB SPECIFICATION)

(1) Installation procedure
(2) General view: LS30V00004F7
61-222
(3) Specifications
(4) Tightening torques of ports
(5) Constructions
61
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
5 SLEEVE 1 17 O-RING ; 1B P31 1
6 GUIDE 2 18 BACKUP RING 1
7 CAP 1 19 RESTRICTOR VALVE 1
8 COVER 1 20 SPRING 1
9 COVER 1 21 SEAL 1
10 CAPSCREW ; M12X30 4 147±10 (108±7) 22 SET SCREW ; M14X110 4
11 O-RING 2 23 WASHER 4
13 SPRING 1 24 O-RING 3
14 RELIEF VALVE 2 25 PISTON 1
16 CAP 1
61-223
61.8.5 SELECTOR VALVE

(1) Installation: Upper hydraulic lines
LMN rotation & with common use type separate boom
UPPER HYDRAULIC LINES LS03H00051F1
and Rotary N&B
1 SELECTOR VALVE LS30V00010F1 1 N/B
5 TUBE LS03H01323P1 1 ø34Xt4.0 TO C/V
7 TUBE LS03H01325P1 1 ø42.7Xt3.5 RETURN TO TANK
19 SEMS BOLT ZM73C12025 2 M12X25, T=83~110N-m(61.2~81.1 lbf-ft)
20 SEMS BOLT ZM73C12030 2 M12x30, T=83~110N-m(61.2~81.1 lbf-ft)
61-224
(2) General view: LS30V00010F1
61
(3) Specifications
Item Specifications
Standard flow rate 280 L/min
A to C or C to A 740 L/min
Maximum flow rate at working
C to T 370 L/min
Maximum pressure (A, C port) 34.8 MPa
Allowable pressure of T port (A from/to C) 0.8 Mpa or less
Rated voltage DC24V
Electric specification
Rated power consumption 17W or less
(4) Tightening torque for port side

Items Name Size Tightening torque N･m (lbf･ft)
A C/V port 4-M12 83~110 (61.2~81.1)
C N&B return port 4-M14 140~180 (103~133)
DR Drain port PS 1/4 34~39 (25.1~28.8)
PL Pilot port PS 1/4 34~39 (25.1~28.8)
PS Pressure sensor port PS 1/4 34~39 (25.1~28.8)
T Tank port 2-M12 83~110 (61.2~81.1)
SOL. Opposing flats 12 6.9~7.9 (5.09~5.83)
Electric
Emergency manual adjusting thread 2.0 after contact with bottom
61-225
(5) Constructions
101 CASING 1 301 SPOOL 1
111 PLATE 1 321 SPRING 1
161 O-RING ; 1B G55 1 ELECTRO-MAGNETIC
162 O-RING ; 1B P9 1 601 PROPORTIONAL 1
163 O-RING ; 1B G30 1 REDUCING VALVE
164 O-RING ; 1B P15 1 48~65(35.4~48.0) 701 CAPSCREW ; M10X25 2

201 SPRING COVER 1 5.8~7.9(4.28~5.83) 702 CAPSCREW ; M5 2
PLUG ; 1/16 PLATE 98~120(72.3~88.5) 703 CAPSCREW ; M12X105 3

7.8~9.8(5.75~7.23) 206 4
PROCESSING 98~120(72.3~88.5) 704 CAPSCREW ; M12X80 1
61-226
61.8.6 CONTROL VALVE (N&B ROTATION)

(1) Installation
UPPER HYDRAULIC LINES LS03H00054F1 Rotary motor for N&B
1 CONTROL VALVE YY30V00008F1 1 N&B rotation
2 HOSE ; PF1/2 L=46 ZM32M08046 1 To slewing motor M port
4 TUBE ; ø22Xt3 LS03H01432P1 1 Right rotation
5 TUBE ; ø22Xt3 LS03H01367P1 1 Left rotation
12 SEMS BOLT ZM73C08035 3 M8X35
61
61-227
(2) General view
CONTROL VALVE ASSY: YY30V00008F1

Tightening
Q'T Q'T
torque No. NAME PARTS No. No. NAME PARTS No.
Y Y
N-m (lbf-ft)
19 (14.0) 1 NUT ZN18C08007 4 8 CONTROL VALVE YT30V00027F1 1

2 CONNECTING ROD BOLT 2436R378S1 2 9 RELIEF VALVE 2436R1119F5 1
46 (33.9) 3 NUT 2436U424S9 2 10 RELIEF VALVE YT22V00006F3 2
4 CONNECTING ROD BOLT 2436U880S8 1 11 PLUG YR30V00014S010 4
5 HYDRAULIC VALVE YR20V00001F1 1 12 PLUG 2436U2937S18 2
6 OUTLET, SUCTION ASSY 2436R329F1 1
(3) Specifications
Item Specifications
Model KVS-65-1
Maximum flow rate 57 L/min
Normal pressure 20.6 MPa
Main relief valve set pressure 20.6 MPa
A1 port relief set pressure 22.6 MPa
B1 port relief set pressure 22.6 MPa
(4) Tightening torque and each port size

Items Name Size Tightening torque N･m (lbf･ft)
A1, B1 Main port PF1/2 108±10 (79.7±7.38)
P Hydraulic pressure port PF1/2 108±10 (79.7±7.38)
T Tank port PF1/2 108±10 (79.7±7.38)
Pa1, Pb1 Pilot port PF1/4 36.3±2 (26.8±1.48)
61-228
61.8.7 PILOT VALVE: YN30V00080F1 (JIB), YN30V00080F1 (N&B, BREAKER)
61
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

1 SHIM t=0.1 2 12 SHIM t=0.2 2 23 RIVET 2
2 SHIM t=0.2 2 13 SHIM t=0.1 2 24 PIN 2
3 SEAT 1 14 CAM 1 25 BALL 1
5 SLEEVE 2 15 BOOT 1 26 BALL 3
6 COVER 1 16 PIN 1 27 O-RING; 1A P10 2
7 PISTON 2 18 PLUG; PF1/4 1 28 O-RING; 1B P11 1
8 BODY 1 19 SOCKET BOLT; M12X20 1 29 O-RING 2
9 SPRING (LARGE) 2 20 FLANGE BOLT; M4X8 2 31 PISTON ASSY 2
10 SPRING (SMALL) 2 21 SETSCREW; M8X8 2 32 SPOOL 2
11 NAME PLATE 1 22 WASHER 2
61-229
61.8.8 SOLENOID VALVE: LC35V00004F3 (CRUSHER ROTATION)

(1) General view
61-230
(2) Specifications
Items Specifications
Operating pressure MPa 4.9
Rated flow L/min 7
Rated voltage V DC24
Consumption power W 12
Coil resistance Ω 49
Leak amount (P to T) mL/min 100 at 4.9MPa
Each port size (All ports are PF1/4 with O-ring)
Weight kg 2
(3) Tightening torque of each screw part

Tightening torque
Items
N･m (lbf･ft)
Each port PF1/4 16.7 (12.3)
Solenoid installation bolt M10 21.6 (15.9)
(4) Constructions
Tightening torque
No. NAME Q'TY
N-m (lbf-ft)
1 SPRING 2
2 SPOOL 2
3 BODY 1
61
5 SOLENOID: AMP MARK II 2
26.5 (19.5) 7 PLUG; PF1/4 2
3.9 (2.88) 8 SOCKET BOLT; M5X12 4
10 O-RING; 1A P16 2
11 O-RING; 1A P11 2
61-231
61.8.9 SOLENOID VALVE: ARM IN & OUT REVERSE OPERATION (2436U3045F2)
No. NAME PARTS No. Q'TY

1 SOLENOID VALVE 2436U3063F1 1
2 SUB PLATE 2436U3045S2 1
61-232
61.8.10 SOLENOID VALVE: BUCKET PROTECTION (LE35V00001F2)
61
No. NAME Q'TY No. NAME Q'TY

1 PLUG 1 6 SOLENOID 1
2 BODY 1 8 SOCKET BOLT; M5X10 2
3 SPRING 1 10 O-RING; 1A P10 1
4 SPOOL 1 11 O-RING; 1A P16 1
61-233
61.8.11 SOLENOID VALVE: LS35V00006F1 (INVERSE PROPORTIONAL VALVE

FOR JIB)
(1) General view
(2) Specifications
Item Unit Specifications
Model - 2KWE5G-30/G24R-262
Rated pressure MPa P1, P2 port 0~5.0
Maximum rated flow L/min 10L/min
3
Drain flow (When no applying current) cm /min 2000 or less at P port 5.0MPa
A1,A2,P1,P2,T port radius inch PF1/4
Each port of Tightening torque N-m 36±2
Weight kg 3.2
Electric specifications (Rated current) mA 700
Range of electro-magnetic proportional reducing valve
MPa 0~2.9
secondary pressure
61-234
(3) Constructions
Tightening torque
No. NAME Q'TY
N-m (lbf-ft)
101 CASING 1
7±1 (5.16±0.74) 171 CAPSCREW; M5X0.8 4
601 ELECTRO-MAGNETIC PROPORTIONAL REDUCING VALVE 2
61
61-235
61.8.12 SOLENOID VALVE: LS35V00008F1 (HYDRAULIC RETRACTABLE VLC)

(1) General view and constructions
61-236
(2) Specifications
Model - DE6P-20-210-WD24-G68
MPa P,A,B port 31.5
Maximum operation pressure
MPa T port 16.7
Maximum flow rate L/min 65 (10MPa), 10 (25MPa)
Voltage DC24V
Electricity spec. Power 26.5W
Insulation H type
Weight kg 12.2
(3) Constructions
No. NAME Q'TY No. NAME Q'TY
1 CASING 1 17 LEAD HARNESS 2
2 SPOOL 1 21 O-RING ; 1B P18 2
3 SPRING SEAT 2 22 O-RING ; 1B P9 4
6 SPACER 2 23 SOCKET BOLT ; M5X45 4
7 SPRING 2 24 SLEEVE 4
15 SOLENOID 2
61
61-237
61.8.13 SEPARATE JIB H SIDE INSTALLING VALVE ASSY: YN22V00026F3

(1) General view
No. NAME Q'TY REMARKS

1 CASING 1
2 BALANCE TYPE RELIEF VALVE 1 SET PRESSURE 20.6MPa
(2) Specifications
NAME MODEL USE
RELIEF VALVE RPIC-LAN SEPARATE BOOM LARGE DIAMETER JIB
61-238
61.8.14 RELIEF VALVE FOR HYDRAULIC VLC RETRACTABLE CYLINDER:

LS22V00014F1
(1) General view
61
(2) Specifications
Model - PREX-LWN-FBX/S-210/50A-270/50B
Maximum operation pressure MPa 35
Maximum flow rate L/min 95
MPa 20.6 A PORT SIDE
RELIEF VALVE SET PRESSURE
MPa 26.5 B PORT SIDE
(3) Constructions
No. NAME Q'TY
1 CASING 1
2 SEAL PLATE 1
3 O-RING 4
4 PIN 1
5 BALANCE TYPE RELIEF VALVE 2
61-239
61.8.15 HOLDING VALVE (FOR BOOM CYLINDER)

LH: LS28V00009F1(SEE THE FIG. BELOW), RH: LS28V00008F1
(1) General view
(2) Specifications
Items Unit Specifications
LS28V00009F1 - KHCV25P-A104-1.0/370-EV
Model
LS28V00008F1 - KHCV25P-A103-1.0/370-EV
Maximum pressure MPa 42
Rated flow L/min 360 (A-B)
PA=0.04 (A port is pressurized)
Cracking pressure MPa
PPL=0.8 (PL port is pressurized)
3
Leak volum (total) cm /min 5 at 50 degC (B port 10MPa is pressurized)
Weight kg approx. 10
61-240
(3) Constructions
61
101 CASING 1 34~39(25~29) 204 PLUG; ROH-1/4 1
161 O-RING; 1B P38 1 LOCTITE #241
206 RESTRICTOR; TR-M6 2
162 O-RING; 1B P28 1 5.8~7.9(4.3~5.8)
163 O-RING; 1B P29 1 69~88(51~65) PLUG; ROH-3/8 LH 3

207
164 O-RING; 1B P11 1 69~88(51~65) PLUG; ROH-3/8 RH 2
165 O-RING 1 7.6~9.8(5.6~7.2) 208 PLUG; NPTF 1/16 COAT 7
166 O-RING 1 271 SPRING SEAT 1
167 O-RING 1 311 POPPET 1
169 O-RING; 1B P14 LH 3 321 SPRING 1
O-RING; 1B P14 RH 2 322 SPRING 1
170 O-RING; 1B G35 1 323 SPRING 1
260~310(192~229) 201 PLUG; M42X1.5 1 511 SPOOL 1
200~250(148~184) PLUG; M30X1.5 LH 1 541 BUSHING (1) 1
202'
200~250(148~184) PLUG; M30X1.5 RH 0 542 BUSHING (2) 1
200~250(148~184) PLUG; M30X1.5 LH 0 69~88(51~65) 601 RELIEF VALVE 1
202"
200~250(148~184) PLUG; M30X1.5 RH 1 631 PISTON (1) 1
470~510(347~376) 203 PLUG; ROH-1 1 632 PISTON (2) 1
61-241
61.8.16 BOOM CYLINDER COMMON USE WITH LMN & SEPARATE BOOM
CYLINDER: LS01V00055F1 (COMMON WITH STD)
LMN JIB CYLINDER: LS01V00055F1 (COMMON WITH BOOM CYLINDER)
61.8.17 LMN ARM CYLINDER: LC01V00007F2

(1) Constructions

1 CYLINDER TUBE 1 13 CUSHION BEARING 1 24 BUSHING 1
2 PISTON ROD 1 14 SEAL 1 25 RING 2
3 CYLINDER HEAD 1 15 PISTON 1 26 BUSHING 1
4 BUSHING 1 16 SEAL RING 1 27 WIPER RING 2
5 SNAP RING 1 17 BACKUP RING 2 28 BAND ASSY 1
7 U-RING 1 18 RING 2 29 BAND 1
8 BACKUP RING 1 19 RING 2 30 CAPSCREW: M10X35 2
9 RING 1 20 SHIM 1 31 WASHER 2
10 O-RING; 1B G145 1 21 NUT: M75X2 1 32 BUFFER RING 1
11 BACKUP RING 1 22 SET SCREW: M14X2 1
12 CAPSCREW; M20X2.5 12 23 BALL 1
(2) Specifications
Cylinder bore / Rod Center distance of pins
Stroke Dry weight
Use Dia. Full extend B / Full retract A Cushion
mm (ft-in) kg (lbs)
mm (ft-in) mm (ft-in)
Bucket 130 dia./90 dia. 1,208 3,004 / 1,796 With cushion
206 (454)
Cyl. (5.12"/3.54") (4'-0") (9'-10" / 5'-11") on rod side
61-242
61.8.18 LMN BUCKET CYLINDER: LB01V00008F3

(1) Constructions
61
1 TUBE ASSY 1 12 CAPSCREW 12 22 STEEL BALL 1
2 PISTON ROD 1 13 BEARING 1 23 BUSHING 1
3 ROD COVER 1 14 PISTON 1 24 RING 4
4 BUSHING 1 15 SEAL RING 1 25 BAND ASSY 1
5 RETAINING RING 1 16 BACKUP RING 2 26 BAND 1
7 U-RING 1 17 RING 2 27 CAPSCREW 2
8 BACKUP RING 1 18 RING 2 28 LOCK WASHER 2
9 RING 1 19 SHIM 1 29 BUFFER RING 1
10 O-RING 1 20 NUT 1 30 BUSHING 1
11 BACKUP RING 1 21 SET SCREW 1
(2) Specifications
Stroke Dry weight
mm (ft-in) kg (lbs)
Bucket 130 dia./90 dia. 1,208 3,004 / 1,796 With cushion
206 (454)
Cyl. (5.12"/3.54") (4'-0") (9'-10" / 5'-11") on rod side
61-243
61.8.19 SEPARATE BOOM BASIC JIB CYLINDER: LS01V00056F1 (COMMON WITH

STD ARM CYLINDER)
SEPARATE BOOM ARM CYLINDER: LS01V00056F1 (COMMON WITH STD)
61.8.20 SEPARATE BOOM LARGE DIAMETER JIB CYLINDER: LS01V00039F1

(1) Constructions

1 CYLINDER TUBE 1 9 THRUST RING 1 17 SLIDE RING 2
2 PISTON ROD 1 10 WIPER RING 1 18 NUT 1
3 CYLINDER HEAD 1 11 O-RING 1 19 SET SCREW 1
4 BUSHING 1 12 BACKUP RING 1 20 STEEL BALL 1
5 SNAP RING 1 13 SOCKET BOLT 8 21 PIN BUSHING 2
6 BUFFER RING 1 14 PISTON 1 22 WIPER RING 4
7 U-RING 1 15 SEALING ASSY 1 23 AIR BREATHER 1
8 BACKUP RING 1 16 SLIDE RING 2 24 PLUG 1
(2) Specifications
Stroke Dry weight
mm (ft-in) kg (lbs)
240 dia./160 dia. 1,855 4,600 / 2,745
Jib Cyl. Without 991 (2185)
(9.45"/6.30") (6'-1") (15'-1" / 9'-0")
61-244
61.8.21 SEPARATE BOOM BUCKET CYLINDER: LS01V00057F1 (COMMON WITH

STD)
61.8.22 SK500DLC-8 HYDRAULIC RETRACTABLE CRAWLAR CYLINDER:
LS01V00071F1
(1) Constructions
61

1 CYLINDER TUBE 1 8 ROD PACKING 1 15 SET SCREW 1
2 PISTON ROD 1 9 BACKUP RING 1 16 CIRCLIP 1
3 CYLINDER HEAD 1 10 DUST SEAL 1 17 SPERICAL BUSHING 2
4 PISTON 1 11 O-RING; 1B G40 1 18 SNAP RING 1
5 BUSHING 1 12 O-RING; 1B G125 1 19 GREASE NIPPLE 2
6 RING 2 13 BACKUP RING 1
7 SPG PACKING 1 14 O-RING 1
(2) Specifications
Stroke Dry weight
mm (ft-in) kg (lbs)
Retractable 130 dia./60 dia. 355 1,099 / 744
Without 63 (139)
cyl. (5.12"/2.36") (14.0") (7'-27" / 29.3")
61-245
61.9 DISASSEMBLING & ASSEMBLING
61.9.1 DISASSEMBLING AND ASSEMBLING OF ATTACHMENT

・ General precautions
It is recommended that the following service work be done by a qualified service professional.
Specialized product knowledge and training is important to successfully perform this service.
Contact the dealer/distributor to obtain qualified service.
Decide working method and procedure, and have them well-known to person connected, and
designate a supervisor for work and perform the work under command of supervisor.
When meeting pin to pin hole, do not put fingers into pin hole, but meet them visually.
Use the slinging tools applicable to the weight of object.
Do not enter in the area under the attachment hoisted by the crane to prevent being caught between
them.
1. Select hard and level ground, and also the area where the main body, boom, arm, etc. can be
arranged and crane, etc. can be placed around for assembly and disassembly.
2. When assembling or disassembling works are performed, appoint the supervisor for the work in
advance. And all workers should follow the instruction of the supervisor.
3. The disconnected hydraulic pipe and hose should be plugged without fail to prevent the entry of
dust, etc.
4. The removed shim should be placed in a set, be tagged and be stored for reference to enable
their assembly to the former positions.
5. Check on dust seal, O-ring etc. for possible damage when assembling and disassembling, and
replace the damaged one.
61.9.2 CAUTIONS TO BE TAKEN FOR SLINGING WORK

・ Determination of how to signal and agreement with signalman
Determine how to signal to be made between operator and signalman.
Assign one signalman and follow his signal.
Assign the one signalman to prevent confusion and accident.
・ Protector (flexible thing) to be provided
When slinging wire rope, apply protector to slung part to prevent the damage.
・ Precautions before slinging
1. The crane hook should be equipped with a properly functioning retainer latch.
2. Use the slinging wire rope and slinging chain which have the specified strength.
3. Crane loads do not pass over the heads of workmen nor in any way endanger their safety.
4. Do not enter under the lifted load.
・ Maintenance of wire rope
Repair the twisted and bent wire rope in good condition after usage and return it in position.
61-246
61.9.3 GENERAL CAUTIONS TO BE TAKEN WHEN OPERATING MACHINE

1. Start the engine only from the operator's seat.
2. Pay attention to the safety around the machine, and alert the bystander by sounding horn in
starting engine and swinging machine.
3. When visibility is poor, post signalman and leader.
Signalman and leader must be always stayed within view of operator.
4. Make the meanings of all signals understood perfectly.
And assign supervisor of signalman and leader.
5. Do not enter a person and obstacle into the working range.
61.9.4 SAFETY TRAVELING

1. Pay attention to the safety around the machine in traveling.
2. In traveling, confirm the location of travel motor and check the traveling direction before operating
control lever.
61
61-247
61.10 DISASSEMBLING & ASSEMBLING OF ATTACHMENT
61.10.1 DISASSEMBLING & ASSEMBLING OF ULTRA LONG ATTACHMENT

Tools needed
1. Pedestal
Pedestal should have the enough strength to bear the component parts.
2. Wire
3. Slinging wire rope
4. Wood block
5. Tools
Accessory tools: Spanner (opposing flat 95 mm)
Spanner (opposing flat 115 mm)
General tools: Large hammer, driving pin
6. Oil pan to receive oil when removing hose
7. Cap, plug, etc. on the hose removing parts
8. Crane
61.10.1.1 DISASSEMBLY
(1) Remove Crusher
1. Direct the jaw of the crusher to this side,
and place the crusher on the level ground
stably.
2. Remove crusher attaching pin and idler
link attaching pin.
3. Stop engine, press crusher control pedal
several times, or open the crusher beam,
or return it slightly in the reverse direction
from the close end, and release pressure
remaining in the pipe.
4. Close the stop valve on the side of the
arm, disconnect a hydraulic hose, and
attach the plugs.
5. Raise the boom slowly, and remove the
crusher.
To avoid falling down of the unstable crusher, use the wood block to support the crusher.
61-248
(2) Removing Arm

1. Lower the ultra long demolition attachment, and receive the inter boom and boom by pedestal.
2. Stop the engine, release the remaining pressure in the pipe connected to the bucket cylinder and
the arm cylinder by operating the control lever several times, and close the stop valves other
than that for inter boom cylinder installed on the insert boom and main boom.
3. Disconnect hydraulic hoses of bucket cylinder and arm cylinder and plug the disconnected hoses.
4. The rod of bucket cylinder should be fixed to arm with wire to prevent extending.
5. Remove arm cylinder.
6. Disconnect the coupler of proximity switch located at the arm top position. And disconnect the
coupler of the harness for potentio meter located at the inter boom top position. Then remove the
potentio meter.
Do not damage the harness for potentiometer.
7. Lift the arm by hooking the hook on the upper face of arm and he crusher attaching hole with
wire rope, remove nut with accessory spanner (opposing flat 95 mm), and pull out the arm
mounting pin.
8. Remove the arm.
61
Removing of arm
(3) Removing Inter Boom

1. Remove the pin on the jib cylinder rod side, retract the rod, and fix it to the boom with wire.
2. Close the stop valve on the pipe for the inter boom on the upper face of insert boom and main
boom.
3. Disconnect the hydraulic hose of jib cylinder, and plug the disconnected hydraulic hoses.
4. And disconnect the coupler of the harness for potentio meter located at the front boom top
position. Then remove the potentio meter.
Removing of Inter Boom
61-249
5. Lift the inter boom slightly hooking the hook on the upper face of inter boom with wire rope,
remove nut with the accessory spanner (opposing flat 95 mm), and pull out the inter boom
mounting pin.
6. Remove inter boom.
(4) Removing Front and Insert Boom
The connections of front boom, insert boom and main boom is provided with concave guide to
receive respective mating pin to make positioning of each pin easier.
1. Lower the boom assembly, and remove

the front boom supporting the front boom
with wood blocks as shown in the figure.
2. Remove nut with accessory spanner
(opposing flat 85 mm and 115 mm) and
pull out the connection pin.
3. Move the machine backward lowering the
main boom and the inter boom slightly.
4. Remove the insert boom by the same
procedure as that described above.
Removing of front boom
61-250
(5) Removing main boom

When the machine is transported by trailer, the removal of main boom is not required, but when
transported by truck, etc. the removal of the main boom is required, so remove it in the procedure
shown below.
1. Put suitable pedestal to the front side of

the main boom to support boom.
2. Stop engine, release the pressure remaining
in the pipe, etc. to boom cylinder by
operating the control lever several times,
and disconnect hydraulic hose.
3. And disconnect the coupler of the harness
for potentio meter located at the main
boom foot position. Then remove the
potentio meter.
4. Hook wire rope to the boom cylinder, lift
slightly by crane, remove pin on the boom
side first and then head side, and remove
the cylinder.
61
When lifting up the cylinder, the cylinder should be bound with a rope to prevent slipping and to
ensure safety. And when moving the cylinder, fix it with wire to protect the rod from extending out of
the cylinder.
5. Put wire rope through the hook on the main boom, and lift slightly, then lift up slightly after
removing the boom foot pin, move the machine back and remove the main boom.
61.10.1.2 ASSEMBLING ATTACHMENT

Assemble attachment by the reverse procedure of the disassembly. After assembly, make sure to
check the following points.
1. Check that each pin section is fully lubricated.

2. Check the level gauge of hydraulic oil tank, and refill oil if the level is low.
3. Repeat operations of the boom, inter boom, arm and crusher at low speed of the engine, and
bleed air in each cylinder and pipes.
4. Check that each hydraulic pipe and hydraulic hose for oil leakage.
61-251
61.10.2 DISASSEMBLY AND ASSEMBLY OF SEPARATE BOOM ATTACHMENT

61.10.2.1 DISASSEMBLING PROCEDURE
(1) Removal of crusher (nibbler)
1. Turn the opening of crusher to the
machine, and lay the crusher (nibbler) on
the ground.
2. Remove the pins (arm tip and bucket link
tip) attaching the crusher (nibbler).
3. Stop engine, and press the crusher
(nibbler) control pedal several times or open
the beam of crusher (nibbler). Or return the
beam a little from the closed end to
release the remaining pressure in the
hydraulic line.
4. Close the stop valve on the arm side,
disconnect hydraulic hose and plug up
holes.
5. Raise boom slowly and remove the crusher
(nibbler).
When placing the crusher (nibbler) on the ground, lay the crusher on the wood blocks to prevent
turning over, because the crusher (nibbler) has unstable shape. And store the crusher indoors.
(2) Removal of attachment

1. Extend the front attachment for the
separate boom machine fully, and lower the
arm tip to the ground.
2. Remove the lubrication hose for the jib

cylinder rod pin.
3. Hold the jib cylinder with nylon sling and
pull out the jib cylinder rod pin.
4. Retract the jib cylinder fully, sling up the

cylinder until the jib cylinder comes in
contact with stopper and fix it by using a
chain block and wire.
5. Close the stop valve located on the main
boom. And disconnect the piping.
61-252
6. Hook the wire to the idler link and the

lifting eye of front boom, and sling them up
by crane. And pull out the front boom foot
pin in this condition.
7. Sling up the attachment by crane and

remove them from the main boom.
8. Put the attachment on the wooden support.
(3) Removal of the main boom

Remove it by the same procedure as ultra long attachment. (See 61.10.2.1(5))
61.10.2.2 ASSEMBLING PROCEDURE

Assemble it by the reverse procedure of disassembly. After assembly, give particular attention to the
following.
61
1. Make sure that enough lubrication is applied to each pin section.
2. Check the oil level of hydraulic tank and make up the shortage, if necessary.
3. Start the engine at low speed, and operate boom, inter boom, arm, and crusher (nibbler) slowly
to bleed air from each cylinder and piping. And repeat these operations several times.
4. Check that each hydraulic pipe and hydraulic hose is free from oil leak.
61-253
61.10.3 JIB CYLINDER ROD LUBRICATION HOSE CONNECTING PROCEDURE

The jib cylinder rod lubrication hose connecting procedure differ according to the presence or absence
of jib cylinder. Connect it by the following procedure.
1. When jib cylinder is not provided (Ultra

long attachment, back-hoe, main boom)
Connect lubrication hose (1) to lubrication
hose (2).
Do not plug the lubrication hose (2).

There is the danger of damaging auto lubrication distributor.
2. When jib cylinder is provided (Separate

boom)
Connect lubrication hose (3) to lubrication
hose (2).
Connect lubrication hose (1) to connector
which fixes the hose on the main boom.
61-254
61.10.4 REMOVING AND INSTALLING

61.10.4.1 ATTACHMENT ASSY
Front attachment and position
61.10.4.2 BUCKET
A. REMOVING BUCKET
(1) Put the machine in position to remove
bucket.
61
Position to remove bucket
(2) Removing pin (2)

Loosen nut (2) of capscrew M20X180 (1),
and remove capscrew (1) from pin.
Tools: Spanner: 30mm
Removing pin (2)
61-255
(3) Removing bucket attaching pin (K)

Lift up bucket, position it so that bucket
attaching pin (K) is not loaded, adjust
bucket link, and pull out bucket attaching
pin (K).
Removing bucket attaching pin
(4) Removing bucket drive pin (J)

Put bucket on the ground, position it so
that the bucket drive pin (J) is not loaded,
adjust bucket link, and pull out pin (J).
Store the removed pin (J) in original
position again.
Removing bucket drive pin
B. ATTACHING BUCKET
(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then
continue in the reverse procedure of
removing.
Attaching bucket
-When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
-Check the seals for damaged and replace as necessary.
-When inserting the pin, coat the shaft with grease.
61-256
C. PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm
(1) Shift O-ring (3A) toward the bucket boss,

using a spatula. (a-->b)
(2) When adjusting clearance (B), bring the
non-adjusting side of the bucket in contact
with the arm.
(3) Measure clearance (B) and check that it is
within 1.0mm (0.04in).
(4) Adjust clearance (B) where it is more than
1.0mm (0.04in).
(5) An average of 5 shims (10) of 1mm
(0.04in) thickness are set in the plate (7)
fixed by the three capscrews (9). The Adjusting clearance between bucket and arm
clearance can be decreased by 1mm
(0.04in) if one shim is removed.
Tools: Socket: 30mm,
Tightening torque : 314N-m (232 lbf-ft)
(6) After adjustment, tighten the capscrews
evenly.
-The gap exceeding the specified dimension
causes early wear.
(7) Operate the bucket and confirm that the
total sum of both clearance is within 1.0mm
(0.04in). 61
(8) Replace O-ring (3A) on its original position.
- When shifting O-ring (3A) by means of a spatula, use care so as not to damage O-ring (3A).
- Remove shims (10), push out bushing (6) rightwards by means of three capscrews (9) and adjust
clearance (B) so it settles within the standard value evenly all round.
61-257
61.10.4.3 ARM
A. REMOVING ARM
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket
cylinder and bring the arm down on the
ground.
Position to remove arm
(2) Disconnecting piping of bucket cylinder

Release pressure of hydraulic tank, place
oil pan to prepare for oil leaking, and
disconnect pipes.
When the removal of bucket cylinder is
not required, skip to procedure (6).
Disconnecting piping of bucket cylinder
Plug both end of disconnected pipes.

Plug:
Tools section 11.5.2-(5)
(3) Removing bucket cylinder rod pin (H)

Loosen nut (9), remove capscrew M20X180 (8), and push out pin (H).
Detail of bucket cylinder rod pin (H)
61-258
(4) Removing cylinder head pin (G)

Loosen nut (3), remove capscrew
M20X180 (2), and push out pin (G).
Detail of bucket cylinder head pin (G)
(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon
sling, and remove it.
Bucket cylinder weight : 364 kg (803 lbs)
Slinging bucket cylinder
(6) Removing arm cylinder rod pin (E)

Put a wooden block between the arm cylinder and the boom.
Loosen nut (3), remove capscrew M20X200 (2), and push out arm cylinder rod pin (E).

61
Retract arm cylinder rod, and return pin (E) to the original position (hole).
Detail of arm cylinder rod pin (E)
61-259
(7) Removing boom top pin (F)

Loosen capscrew M20X40 (2), and pull
out boom top pin (F).
Insert pin (F) into the original hole.
Detail of boom top pin (F)
(8) Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight : 1553 kg (3,424 lbs)
Slinging arm assy
B. ATTACHING ARM
Instal the arm in the reverse order of removing, paying attention to the following:
1. When aligning the pin holes, do not put

your finger in the pin holes, but align them
visually.
2. Check the seals for damage and replace
as necessary.
3. When inserting the pin, coat the shaft with
grease.
4. Pin lock nut handling procedure
5. When installing the arm and the cylinder,

inspect the clearance in the thrust
direction of the pins and decide the
thickness of shims by referring to the
Maintenance Standard.
6. Tightening torque
61-260
61.10.4.4 BOOM
A. PREPARATION FOR REMOVING AND ATTACHING BOOM
When removing and attaching boom in the position shown in below Fig. to remove and attach boom
foot pin (A), removing and attaching of cab and guard are required.
B. REMOVING BOOM
(1) Put the machine in position to remove
boom.
Place top end of boom down on block, etc.
giving attention for arm cylinder rod not to
be extended.
Position to remove boom
(2) Lifting up boom cylinder temporarily

Remove the right and left boom cylinders
one side by one side according to the
following procedure:
Lift up boom cylinder temporarily to
prevent it from dropping.
61
Lifting up boom cylinder temporarily
(3) Press the boom cylinder rod pin (C)

At the one side of pin (C), loosen nut (5),
remove capscrew (4) (M16X150), and
remove boss (3). And push pin (C) to the
end of boom boss.

(4) Preparing for disconnecting cylinder pipes
Retract the above mentioned cylinder rod,
and place one side of cylinder on stand.
(See right Fig.)
Detail of boom cylinder rod pin (C)
61-261
(5) Disconnecting the arm cylinder and bucket

cylinder pipings
Release pressure from arm and bucket
circuit and bleed air in hydraulic tank, and
then disconnect pipe at (A1), (A2), (A3),
(A4) and hose (A7), (A8), (A9), (A17).
Tools: Allen wrench: 8, 12, 14mm
After disconnection of pipe, plug every pipe.

Half clamp plug : See Tools 11.5.2-(5)
Boom piping disconnection
(6) Lifting up boom assy temporarily

Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded.
Weight of single boom : 3,640 kg (8,026 lbs)
(7) Removing boom foot pin (A)

1. Remove capscrew (3) M24X60 and plate
(2).
2. Draw out pin (A).
Details of boom foot pin (A) section
61-262
(8) Hoisting boom assy

Hoist and remove boom assy.
Weight of single boom : 3,700 kg (8,160 lbs)
(9) Completion of removal of front attachments

When the removing and attaching of cylinder are not required, the work is finished.
(10) Removing and installing arm cylinder
1. Lift up arm cylinder (2) with nylon sling so

that the head of cylinder is not loaded. 61
2. Disconnect hose (F1) and (F2) at position
A. After disconnection of hose, plug both
ends of hose.
Plug : TOOLS
11.5.2-(5) Plugs for half clamp
Tools: Allen wrench: 12, 14 mm
3. Removing arm cylinder head pin (D)
Loosen nut (3), remove capscrew
M20X200 (2) and pull out pin (D).
4. Removing arm cylinder (2)
Weight of arm cylinder : 591kg (1,303 lbs)
Removing arm cylinder
61-263
(11) Removing and installing boom cylinder
1. Release pressure from boom circuit and

bleed air in hydraulic tank.
2. Sling boom cylinder (2) using nylon sling
temporally not to act the weight of cylinder
upon the cylinder head.
3. Disconnect each four hoses (C2). And
plug their both ends.
Plug :
TOOLS 11.5.2-(4) Plugs for ORS fitting
Tools: Spanner: 36,41mm
Removing and installing boom cylinder
4. Removing boom cylinder foot pin (B)

(See right Fig., below Fig.)
Loosen nut (5), remove capscrews
M20X200 (4) and pull out pin (B).
5. Remove boom cylinder (2).
Weight of boom cylinder : 396 kg (873 lbs)
6. Remove another boom cylinder the same
way.
Removing and installing boom cylinder head

pin (B)
C. ATTACHING BOOM
(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the boom assy.
Attach it in the reverse procedure of removing, paying attention to the following points.
1. When aligning the pin holes, do not put

your finger in the pin holes, but align them
visually.
2. Check that the dust seals is not damaged
and replace as necessary.
3. When inserting the pin, coat the shaft with
grease.
4. Refer to paragraph 32.1.3.2 about installing
of jam nut.
5. When installing boom and cylinder, check
the clearance of mounting section in thrust
direction, and decide the thickness of shim
according to the maintenance standard.
Install plastic shim first, and insert iron Boom foot pin (A)
shim into remaining gap. Regarding the
position of shim, refer to details of boom
foot pin (A) section.
61-264
61.10.5 DISASSEMBLING AND ASSEMBLING

61.10.5.1 CYLINDER
A. PREPARATION BEFORE DISASSEMBLY
Before assembly, secure a dustfree workshop and necessary equipment and facilities.
A.1 WORK AREA

The following working area is required for disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn
out. For this reason, the first condition is that the working area is long enough for the work. In
terms of width, it is also necessary to keep sufficient space to disassembly, cleaning and
measuring equipment are placed and the work can be performed.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of
rubber and plastic materials. For this reason full care should be exercised so the hydraulic cylinder
is free from dust, dirt, and in particular, such hard particles as sand, metal chips, and weld slag
(spatter). If the hydraulic cylinder is assembled with hard particles adhered on such components
as the cylinder tube and the piston rod, the tube inner surface and the rod surface are scratched
as the cylinder operates, consequently disabling it in worst cases. Damage to the piston seals
and the rod seals will result in oil leaks. For this reason, grinding and welding operation should
not be performed in the neighborhood of the working area to keep it clean.
A.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane 61
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must
also be capable of making level and liner movement under load for retracting and extending the
piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of
the cylinder in its most retracted condition and of withstanding the repulsive force of the
tightening torques of the cylinder head and the piston nut. Since a vise is attached to the bench,
the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be
damaged as the rod bushing and the piston are twisted due to the weight of the rod. A stand is
required to support the rod to prevent damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut
and for oil leak tests after completion of assembly.
(5) Jet air source: It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also
necessary.
61-265
A.3 NECESSARY TOOLS

Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table below as a
guideline. For the details of special tools and jigs, refer to the back pages of this manual.
List of Tools and Jigs

Tool/Jig Remarks Tool/Jig Remarks
Hammer 1. Steel hammer Spatula Metallic one with smooth corners.
2. Wooden or plastic hammer
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in
place of a gimlet.
Chisel Flat chisel Special jig 1. For removing and press-fitting bushing.
(A), (D), (C)
2. For press-fitting wiper ring. (D)
3. For inserting and reforming seal ring.
(E),(F),(G),(H)
(See para 61.10.5.1-I for detail)
Vise One having an operation wide enough to Rust
hold cylinder head O.D. and tube remover
mounting pins (clevis)
Wrench 1. Eye wrench Measuring 1. Slide caliper
2. Allen wrench instruments 2. Micrometer
3. Extension pipe for wrenches 3. Cylinder gauge (Fig. "Cylinder gauge")
4. V-block
A.4 EXTERNAL CLEANING

The cylinder taken off the excavator has dust
and foreign matter, and grease is usually
adhered to the clevis part. For this reason,
Cylinder gauge
remove external soil and contamination from the
cylinder with water and steam before bringing
it into the workshop.
-The following describes the construction of
boom cylinder. When disassembling and
servicing the cylinder, confirm the construction
of cylinder referring to Parts Manual.
A.5 DISCHARGING OIL

Place a wooden-block on the work bench and
place the cylinder on it to prevent it from
rotating. Charge air into ports A and B
alternately to actuate the piston rod till the
hydraulic oil in the cylinder is drained out. At
this time, connect a suitable hose to each port
so that the hydraulic oil may not gush out.
Preparation
61-266
B. CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)
61
Construction of general cylinder
P/No LS01V00056F1
No. PARTS Q'ty No. PARTS Q'ty No. PARTS Q'ty
1 CYLINDER TUBE 1 12 O-RING : 1B G180 2 23 SETSCREW : M8 1
2 PIN BUSHING 1 13 BACKUP RING 2 24 CUSHION PLUNGER 1
3 PISTON ROD 1 14 O-RING 1 25 STOP RING 1
4 PIN BUSHING 1 15 CUSHION RING 1 26 SOCKET BOLT : M18 20
5 ROD COVER 1 16 PISTON 1 27 CHECK VALVE 1
6 BUSHING 1 17 SLIPPER SEAL 1 28 SPRING 1
7 RETAINING RING 1 18 WEAR RING 3 29 SPRING SUPPORT 1
8 BUFFER SEAL 1 19 DUST RING 2 30 O-RING : 1B P14 1
9 U-PACKING 1 20 O-RING : 1B G115 1 31 PLUG : PT3/8 1
10 BACKUP RING 1 21 BACKUP RING 2 32 WIPER PIN 4
11 DUST WIPER 1 22 PISTON NUT 1
61-267
C. DISASSEMBLY
・ When disassembling and servicing the cylinder, check the construction and the availability of
service parts as well as necessary tools and jigs on separate Parts Manual.
・ The figures in parentheses after part names correspond to those in Fig. "construction of general
cylinder"
・ The following explanation and quantities are for a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined, the construction differs from separated type, refer
to the sentence in parenthesis.
C.1 REMOVING ROD COVER AND PISTON ROD

(1) Hold the clevis section of the tube in a vise.
Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use
of the outside piping as a locking means.
(2) Pull out piston rod (3) about 200 mm

(8in). Because the piston rod is heavy,
finish extending it with air pressure after the
above-mentioned oil draining operation.
(3) Loosen and remove socket bolts (26) of the

rod cover in sequence.
Cover the extended piston rod (3) with cloths to prevent it from being accidentally damaged during
operation.
(4) Strike the corner of the rod cover flange by means of a plastic mallet till rod cover (3) comes off.
61-268
・ At this time, the weight of piston rod (3)

is loaded on rod cover (5). Therefore, lift
the top end of the piston rod with a hoist
to the extent that only the rod weight may
be held.
Drawing out piston rod assy (2).
(5) Draw out the piston rod assy from cylinder

tube (1).
Method of drawing out the piston rod assy
Since the piston rod assy is heavy in this case, lift the tip of the piston rod (3) with a hoist and
draw it out. However, when piston rod (3) has been drawing out to approximately two thirds of its
length, lift it in its center to draw it completely. However, since the plated surface of piston rod (3) is
lifted, do not use a wire rope which may score the surface, but use a strong cloth belt or a rope. 61
(6) Place the removed piston rod on a
horaizontal wooden V-block.
-Cover a V-block with cloths.
Method of placing the piston rod
(7) Remove slide ring (18) and dust ring (19)

from piston (16).
Remove slide ring (18) and (19)
61-269
C.2 REMOVING PISTON ASSY

(1) Fix piston rod (3) by holding its clevis
section in a vise. Fix the piston rod (3)
securely as piston nut (22) is tightened to
a high torque.
How to loosen piston nut (22)
-Note that the tightening torque differs with the type, the working pressure and the mounting method of
the piston (16), though the rod diameter remains the same.
-It is also necessary to place a suitable supporting block near the piston (16). In case a V-block is
used, put cloths or something over the rod to prevent it from damage.
(2) Scrape off the caulked part of setscrew

(23) of piston nut (22) by means of a hand
drill and loosen setscrew (23).
Removing setscrew (23)
(3) Loosen and remove piston nut (22).
How to loosen piston nut (22)
Since piston nut (22) is tightened to a high torque, use a hook wrench suitable for the outside
diameter of piston nut (22) . Use care so the hook of the wrench is positively fixed in the groove of
the piston nut perimeter.
61-270
(4) Loosen piston (16) with a pin wrench as

shown in right Fig., utilizing the two holes
in the side face of the piston. If the O-ring
(20) section comes off, the piston may be
turned easily by hand. When removing the
last thread of the piston, hold the piston
by hand to receive the weight.
Removing piston (16)
If the piston is dropped with a bang, the O-ring seal face on the piston interior may be damaged with
the threads.
(5) After removing cushion ring (15), separate

rod cover (5) from piston rod (3). If it is
too hard to slide it, knock the flanged part
of rod cover (5) with a plastic mallet. But
when drawing it out, lift rod cover (5) by
hoist and pull it straight horizontally.
Removing rod cover (5) 61
Take care so rod bushing (6) and the lip of packings (8,9,10,11) may not be damaged by thread of
the piston rod (3).
61-271
C.3 DISASSEMBLING PISTON ASSY

(1) Remove piston seal (17).
Removing piston seal (17)
Cut the seal ring (17-1) by tapping it with a screwdriver or a chisel. Take care not to strike it too
hard, otherwise the groove may be damaged.
(2) Separate O-ring (20) and back-up ring (21)

from piston (16).
After removing two back-up rings (21),
remove O-ring (20). The back-up ring (21)
comes off easily if the slit on its
circumference is extended. O-ring (20) can
be taken off by stretching it with an
earpick-like spatula.
Removing back-up ring (21) and O-ring (20)
C.4 DISASSEMBLING ROD COVER ASSY

(1) Remove O-ring (12) and back-up ring (13).
Remove back-up ring (13) and O-ring (12)
in that order. Remove back-up ring (13)
and O-ring (12) by pulling and stretching
them with an spatula like earpick.
Removing the outer circumferential seal of

rod cover (5)
61-272
(2) Remove buffer seal (8), rod-picking (7)

and back-up ring (10). Each seal is fixed in
the groove on the bore and removing in
flawless is impossible.
Stab each seal with a gimlet and pull it out
of the groove.
Removing the inner circumferential seal of

rod cover (5)
Take care in this operation not to damage the grooves.
(3) Remove dust seal (11). When taking out

dust seal (11), fix rod cover (5) in a vise.
61
Removing wiper ring (11)
(4) Remove circlip (7) and rod bushing (6).

After taking out snap ring (7) in the same
way as mentioned above, remove rod
bushing (6). Rod bushing (6) is impossible
to remove as it is press fitted in rod cover
(3). Machine the bushing thin on a lathe,
insert a steel spatula hard into the gap
at the chamfered edge of the remaining
bushing and pry it up.
Removing rod bushing (6)
Center the work on a lathe sufficiently so the bushing may be shave on a lathe as thin as possible.
61-273
C.5 REMOVING PIN BUSHING

(1) Apply driver to wiper ring (32) of cylinder
tube (1) and piston rod (3), and strike it
by hammer lightly.
(2) Push out pin bushing (4) press fitted in
cylinder tube (1) and piston rod (3) with
press.
Drawing out pin bushing (4)
D. CLEANING
(1) After disassembly the cylinder, wash all parts with commercial detergent.
Never use benzene(gasoline, thinner, etc.) because it may be damage the rubber, etc.
(2) Do not use the used oil seal, O-ring, back-up ring, etc. even if they are not damaged after
inspection.
(3) After cleaning, dry all parts by compressed air, and put them on the working bench taking care
not to damage them.
E. ASSEMBLING PIN BUSHING

Start assembling the following sub assy
-Cylinder tube assy
-Piston assy
-Rod cover assy
E.1 ASSEMBLING PIN BUSHING

(1) Press fit pin bushing (4) in cylinder tube (1)
and piston rod (3) respectively with press.
(2) Press fit wiper ring (32) in the upper and
lower sides of cylinder tube (1) and piston
rod (3) respectively with press.
Press fitting of pin bushing (4)
-Before press fitting, apply grease on wiper ring and boss hole.
-Before press fitting the pin bushing, align the position of oil hole.
61-274
E.2 ASSEMBLING OF PISTON ASSY

(1) Fit back ring (17-2) of piston seal as if it
slips in with driver the corner is rounded.
(2) And fit seal ring (17-1) with fitting jig.
Attaching seal ring (17-1)
Since it is hard to deform seal ring (17-1) in room temperature, immerse and soften it in hydraulic oil
heated about 150 to 180 C degrees. Therefore slip it in piston seal groove quickly with fitting jig so as
not to be cooled.
To avoid burn, wear gloves when fitting the heated seal ring (17-1), and fit it quickly. And the
hydraulic oil must be heated with electric heater. (Do not use fire. There is a danger.)
(3) Shrink the seal ring (17-1) to the original

size using correcting jig.
(4) Fit back-up rings (17-3) to both sides of
seal ring.
61
Correction of seal ring (17-1)
Make sure about the fitting direction of back-up ring.
(5) Fit O-ring and back-up ring (2 places) to

the bore side.
Direction of components
E.3 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (6) in rod cover (5) with
bushing press-fitting jig. Then, fit snap ring
(7) in the groove. Apply hydraulic oil on
internal surface of rod cover (5).
61-275
The snap ring (7) can not be fitted when the bushing (6) is not press-fitted fully to the stop end.
(2) Apply grease to dust seal (11), or the

hole of rod cover (5), and fit dust seal
(11) to the bottom of the hole. At this
moment, press the metal ring of dust seal
(11) with a jig.
Pressing in rod bushing (6)
(3) Fit buffer seal (8), back-up ring (10) and rod packing (9) in their grooves in that order. Before
setting packings, coat them with hydraulic oil (or vaseline if not available). If you forget the
coating, the packings may be scored. When attaching seals, deform them in a heart shape as
illustrated.
Inserting a seal into the inner circumference

of rod cover.
How to fit rod-packing (9)
-Rod-packing (9) is harder than other packing and it would be difficult to deform them in a heart
shape. In such a case, put a U-ring in the groove obliquely by hand as deep as possible and push
in the last part with a push bar till it is set with a click.
-Buffer seal (8) should be fitted taking care of the fitting direction. The reverse fitting may cause
deformation, damage, etc. of the piston due to high pressure generated between the buffer ring and
rod-packing.
-If rod-packing (9) is set upside down, the lip may be damaged. Check that it is positioned correctly.
-Attach back-up ring (13) on the open air side of O-ring (12). (See above Fig.).
61-276
E.4 INSERTING ROD COVER ASSY TO PISTON ROD

Inserting rod cover (5) to piston rod assy by the following procedure.
(1) Fix piston rod assy on working bench.

(2) Install rod cover (5) on piston rod (3) with
inserting guide jig (I) as shown in right
Fig. paying attention for the lip section of
U-ring not to be caught on the stepped
section.
Inserting rod cover (5)
-For the rod the outer diameter of piston installing section is small, insert spacer on the faucet
section of rod first, and attach inserting guide jig.
-Apply hydraulic oil on the inserting guide jig and outer surface of piston rod lightly to make the
insertion smooth.
61
61-277
E.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD

(1) Insert cushion ring (15). Then install the
piston assy in piston rod (3).
(2) Apply hydraulic oil or grease to the inside
of the piston assy and to the piston
mounting part of piston rod (3). Then install
the piston assy as shown in right Fig.,
exercising care not to damage O-ring (20)
and the seal.
Always tighten the piston to a specified
torque.
Tightening piston assy
(3) Turn in piston nut (22) till it gets tight.

Always tighten the piston nut (22) to a
specified torque.
(Refer to G.3).
Tightening piston nut (22)
Always correct the threads of the tapped hole in piston nut (22) before fixing piston nut, using a tap.
(4) Screw in and set setscrew (23).
Tools: Allen wrench: 4mm

After tightening the setscrew to a specified
torque of 15N-m (11ft-lbs), caulk the two
places of the thread of the piston nut side
to secure the setscrew.
Attaching setscrew (23)
(5) Attach two wear rings (18) and dust rings

(19). Take off vinyl tape wound around the
perimeter of piston (16), apply high-quality
grease (or vaseline) to wear ring (18) and
dust ring (19) and attach the wear rings in
a manner that they may be coiled around
the groove. Set the wear rings about 90
degrees apart with each other so that the
slits may not point to the same direction.
Attaching wear ring (18)
61-278
E.6 OVERALL ASSEMBLY

(1) Place a V-block on a work bench (A wooden V-block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar through the clevis pin hole to lock the assy.
(2) Insert the piston rod assy into the cylinder tube assy, while lifting and moving the piston rod assy
with a hoist. In this operation, apply hydraulic oil (or vaseline) to the inner surface of the tube
mouth and the circumference of the piston. Align the center of the piston rod assy with the
center of the cylinder tube assy and put it in straight forward. When inserting, make sure that
wear rings (18), dust ring (19) on the perimeter of the piston is not out of the groove.
(3) Tighten socket bolt (26). Match the bolt holes of the rod cover flange to the threaded holes in
the cylinder assy, and screw in socket bolts (26) one by one. Tighten the bolts to a specified
torque, taking care so the bolts may not be tightened unevenly. See para. G.3 for torque.
Tools: Allen wrench: 14mm
Inserting piston rod assy

Tightening socket bolts (26)
61
Take care so as not to damage the rod surface by accidentally slip a wrench. Covering the rod
surface with cloth is recommended to prevent damage to it.
61-279
F. INSPECTION AFTER ASSEMBLY

(1) No-load functional test
Place the cylinder level at no load,
operate the piston rod 5 to 6 strokes by
the directional valve and make sure that it
operates without failure.
External leak test
-Do not raise the hydraulic pressure above the maximum pressure of 34.3MPa (4975psi) for the
cylinder of the machine.
-Grease coated on the O-rings and the seals of the rod cover may come out. Wipe it off and retest
the cylinder in such a case.
(2) Leak test
1. Apply a test pressure to the retracting and extending sides of the cylinder for three minutes
independently, and check that the rod section and the welds have external leaks and permanent
deformation. For an internal leak test, connect the cylinder with a test unit as shown in below Fig.
2. After completing the test, apply a plug to each port and store the cylinder. (Below Fig.)
・ For storage, place the cylinder on wooden V-blocks and bring the cylinder to the most retracted
condition.
How to store the cylinder
Internal leak test
61-280
G. MAINTENANCE STANDARDS
G.1 INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are
detrimental to use are not present.
(1) Inspection Item

Parts Name Inspecting Portion Inspection Item Remedy
1. Neck of rod pin Presence of crack Replace
2. Weld on rod hub Presence of crack Replace
3. Stepped part to which
Presence of crack Replace.
piston is attached
4. Threads Presence of seizure Recondition or replace
Measure degree of bend (See Refer to Table "Example of
5. Bend
Fig. "Measuring method") measurement"
6. Plated surface Check that:
Piston rod
1) Plating is not worn off to 1) Replace or replate
base metal
2) Rust is not present on 2) Replace or replate
plating.
3) Scratches are not present. 3) Recondition, replate or
replace.
Recondition, replate or
7. Rod Wear of O. D.
replace.
8. Bushing at mounting part Wear of I. D. Replace
1. Weld on bottom Presence of crack Replace
61
2. Weld on head Presence of crack Replace
Cylinder tube 3. Weld on hub Presence of crack Replace.
4. Tube interior Presence of damage Replace if oil leak is seen.
5. Bushing at mounting part Wear on inner surface Replace
1. Bushing 1) Wear on inner surface 1) See para. 61.10.5.1-G.2
Rod cover 2) Flaw on inner surface 2) Replace if score is
deeper than coating.
(2) Repair method

Check all seals and parts to see that they do not show excessive damage and wear. For correction of
scores on the piston rod, observe the following procedure:
1. Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so
deep as may be caught by your nail.
2. In case of a smooth indention, recondition by removing the sharp area around the indention with
an oilstone. If the score or the indention is excessive, replace or replate the damaged part.
・ Always regrind after replating. The thickness of the plating must be maximum 0.1 mm (0.004 in).
・ In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to
replate the surface.
61-281
G.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear on the sliding surfaces of the cylinder tube and the rod
that have no such damage as may degrade the sealing effect.
(1) Clearance between piston rod and rod bushing

Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25mm
(0.01in).
(2) Bend of piston rod
The allowable bend of the rod is maximum 1mm / 1m (0.04"/3'3"). For measurement, support
both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center
between the two V-block turn the piston rod, and read the difference between the maximum and
minimum deflection on the dial indicator.
Table shows an example of measurement.
Measuring Method
Even if the bend is within the above limit, the cylinder may not operate smoothly because of localized
bend. Beware of it during function test after assembly. Replace the rod if the cylinder makes a
squeaking noise or dose not operate smoothly.
G.3 TIGHTENING TORQUE
G.4 VOLUME OF OIL LEAK

The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION
AFTER ASSEMBLY 61.10.5.1-F(2).
Cylinder Volume of Internal Oil Leak

Boom 5.95 cc (0.36 cu-in) or below / 10 min
Arm 6.65 cc (0.41 cu-in) or below / 10 min
Bucket 5.00 cc (0.31 cu-in) or below / 10 min
61-282
H. TROUBLESHOOTING
61
61-283
I. TOOLS AND JIGS LIST

The tool and jig list provides the materials and the dimensions of tools and jigs so that they may be
utilized in manufacturing in a service shop. Follow the directions given below in selecting,
manufacturing and using the tools and jigs.
(1) For the rod cover, piston nut and others that require large tightening torques, use eye wrenches
as much as possible.
The tools and the jigs are so designed dimensionally that they can withstand the maximum
tightening torques even if material SS400 (JIS) is used. However, the hook of the tool may be
distorted if struck with a hammer. If such occurs, apply reinforcement weld and finish it by grinding.
(2) The pin section of pin wrenches and pin hook wrenches is loaded with large shearing force.
Therefore, take care when selecting pin material and welding the pin to the body. It is
recommended to use the shank section of disused drills (Below Fig.)
I.1 ALLEN WRENCH (FOR ROD COVER SOCKET BOLT)
I.2 DUST SEAL PRESSING JIG (FOR ROD COVER)
Dust seal pressing jig
61-284
I.3 EYE WRENCH (FOR PISTON NUT)
Eye wrench
I.4 WRENCH (FOR PISTON)

61
Wrench
61-285
I.5 ROD COVER INSERTING JIG
Rod cover inserting jig
I.6 PISTON (SLIPPER) SEAL FIXING JIG
Piston (slipper) seal fixing jig
61-286
I.7 SLIPPER SEAL HOLDING-DOWN JIG
Piston seal holding-down jig
I.8 BUSHING PRESS-FITTING JIG
61
Bushing press-fitting jig
61-287
I.9 BUSHING PRESS-FITTING JIG
Bushing press-fitting jig
61-288
61.11 DISASSEMBLY AND ASSEMBLY OF UPPER SLEWING

STRUCTURE
61.11.1 INSTALLATION AND REMOVAL OF ADD-ON (LAYER TYPE)
COUNTERWEIGHT (SK500DLC-8)
Extend the track crawler before installation of counterweight. The installation of counterweight with the
track crawler retracted causes machine tip-over sideways.
Do not enter under the lifted counterweight.
61.11.1.1 INSTALLATION OF COUNTERWEIGHT

1. Park the machine on hard and level
ground, direct the track crawler forward and
hold the main boom in horizontal position.
If the ground is soft, reinforce the ground in
good condition by covering the ground
with iron plates and so on.
2. Sling up the casing (1) of counterweight 61

by crane and place the counterweight to
the installing position of frame.
61-289
3. Sling up the counterweight casing (1) at 4

points.
Do not use these fittings for slinging up the main body.
4. Install the counterweight with 4 mounting

bolts M45 (5) (width across flat 70mm)
and 4 washers (6) (Outside diameter
92mm).
5. And sling up the counterweight (2) and

put it in the casing.
61-290
6. And then, sling up the counterweight (3)

and put it in the casing.
7. Sling up the counterweight (3) at 2 points.

Use 2 lifting eyes on the front side of the
counterweight.
8. Tighten 8 bolts M24 (7) with washer (8)

(outer diameter 62mm) from the upper
thread holes of the counterweight. 61
When combining counterweights (1), (2), and (3), and slinging them up as one piece, sling it up at 4
points.
Use the 4 lifting eyes provided on the counterweight (3).
61-291
Do not use these fittings for slinging up the main body.
61.11.1.2 REMOVAL OF COUNTERWEIGHT

Remove the counterweight by the reverse procedure of installation.
61-292
61.12 DISASSEMBLING & ASSEMBLING OF TRAVEL SYSTEM
61.12.1 EXTENSION AND RETRACTION OF HYDRAULIC ADJUSTABLE TYPE

CRAWLER (SK500DLC-8)
The undercarriage is required to extend (spread out) crawler in operation and to retract in
transportation.
Do not operate machine with crawler frame retracted.
Tools needed
Accessory tools
Specified grease
61.12.1.1 EXTENSION OF CRAWLER

1. Hold main boom in horizontal position as
shown in the figure.
2. Swing the upper structure until the cab
comes to the front of extended crawler as 61
shown in the figure. And stop the engine.
3. Hydraulic hose connecting procedure
a. Connect the hose between the coupler

which is attached to the upper frame
(under air cleaner) and the coupler which is
attached to the left crawler.
b. After extending left crawler
And, connect the hose between the
coupler which is attached to the upper
frame (under air cleaner) and the coupler
which is attached to the right crawler.
c. Insert coupler to the end, and lock it
securely by rotating the sleeve.
61-293
When the pressure is not completely released, do not force to insert coupler. There is the danger of
damaging O-ring and backup-ring.
The insufficient insertion could result in slipping out of coupler during operation and oil spraying out.
4. Pull out the spring pin (1) and remove pin

(2), and put it in next hole.
Two pins on the rear side of machine are
located inside of the cover. Loosen wing
bolt (3), open cover (4) and similarly
replace the pins by the same procedure.
5. Start engine and hold it in low idling.

6. Press "Extend" side of retractable crawler
select switch, and crawler retraction cylinder
extends and the crawler is extended.
61-294
When it is hard to shift, increase the engine speed close to the medium speed (1500min-1) and try the
retracting operation again.
7. The pins (2) drop into the fastening holes

by itself at the time when the crawler is
fully extended.
Insert spring pins (1) and fix pins (2).
8. Stop engine, disconnect coupler and disconnect hose.
Oil remained inside is spilled by disconnecting coupler. Prepare oil pan and waste cloth to prevent oil 61
from scattering.
9. Similarly, extend the crawler frame on the other side by the same procedure as the above
procedure 2 to 8.
10. After completion of work, apply a dust cap to connecting hose and store it in the room behind the
guard for the next use.
Disconnect the hose and clean the dust and dirt thoroughly, and attach the dust cap to the mouth of
fitting to prevent from entering contaminations.
When the ring of coupler is tight and is hard to move, tap the edge lightly with wooden hammer. Do
not use iron hammer.
61-295
11. After extension of crawler, install the pipe

covers (1) and (2) to working position in
order to prevent the entering of sand and
dirt.
61.12.1.2 INSERTION OF SHIM

1. Swing upper structure to get the largest
space which is located between crawler
and axle in No.1 position.
2. Insert the stamped "1" shim (3) and fix
the shim with pin (4).
3. Similarly, insert shims in No.2, No.3 and
No.4 positions and fix them with pin.
61.12.1.3 RETRACTION OF CRAWLER

1. Retract the track crawler by the reverse
procedure of the track crawler extension.
61-296
Before retraction of the track crawler, clean sliding surface of the car body and sliding hole of the
crawler thoroughly and apply grease (Multipurpose Grease with Extreme Pressure).
2. After removing the shims, keep them with

pins facing in the opposite direction.
Do not extend and retract the track crawlers when the shims remain insertion.
There is the danger of damage of the car body and the track crawler.
61
61-297
61.13 TROUBLESHOOTING
61-298
61
61-299
BH with
Trouble and Symptom LMN separate Cause Remedy
boom
When machine uses Poor connection of switching

Connect switching harness to LMN side.
ultra long attachment, harness.
maximum working ○ Switching harness is

radius is not indicated unconnected.
on the display. Failure of switching harness. Check and replace failed harness if necessary.
When machine uses Failure of buzzer Check and replace gauge cluster if necessary.
ultra long attachment,
○ Check, repair and replace failed angle sensor
tip-over alarm buzzer Failure of angle sensor
if necessary.
does not sound.
When machine uses Failure of initial adjustment Perform initial adjustment.
ultra long attachment,
Check, repair and replace failed angle sensor
the indicated working Failure of angle sensor
○ if necessary.
radius and boom-
angle are different from Failure of arm length selection. Perform initial adjustment.
realistic values.
Noise is generated Lack of grease Lubricate it with grease.

○ ○
from pin. Scratching of pin and bushing Replace pin and bushing
Lack of grease in cartridge. Replace cartridge with new one.
Failure of setting of lubrication

Reset the interval.
interval.
Failure of automatic lubricator Check and replace failed controller if

controller. necessary.
Attachments are not
○ ○ Failure of automatic lubricator Check and replace automatic lubricator pump
lubricated.
pump. if necessary.
Failure of distribution valve

Adjust distribution valve.
adjustment.
Connection failure of lubrication Check and replace lubrication piping if

piping. necessary.
Boom works slowly. Setting failure of relief pressure. Adjust relief pressure or replace it if necessary.
Boom does not work. Failure of slow return valve

Adjust slow return valve opening.
Boom has low-power ○ ○ opening.
and it cannot keep Check and replace holding valve if necessary.
position. Failure of holding valve.
Check pilot pressure.
Setting failure of relief pressure. Adjust relief pressure or replace it if necessary.
Failure of slow return valve

Adjust slow return valve opening.
opening.
Jib works slowly.
Failure of stop valve opening. Open stop valve fully.
Jib does not work.
Jib has low-power ○ ○ Setting failure of left pedal
Cancel left pedal rotation function.
and it cannot keep rotation function.
position. Failure of jib inverse Check and replace jib inverse proportional
proportional valve. valve if necessary.
Harness failure of jib inverse Check and replace harness of jib inverse
proportional valve. proportional valve if necessary.
Mistake of separate boom

When separate boom Select the correct specification.
selection.
is used and jib and
Failure of jib inverse Check and replace jib inverse proportional
bucket are operated ○
proportional valve. valve if necessary.
simultaneously, bucket
does not move. Harness failure of jib inverse Check and replace harness of jib inverse
proportional valve. proportional valve if necessary.
61-300
BH with
Trouble and Symptom LMN separate Cause Remedy
boom
Arm works slowly. Setting failure of relief pressure. Adjust relief pressure or replace it if necessary.
Arm does not work.
Failure of slow return valve
Arm has low-power ○ ○ Adjust slow return valve opening.
opening.
and it cannot keep
position. Failure of stop valve opening. Open stop valve fully.
Poor connection of switching

harness.
When ultra long Switching harness is
attachment is used, unconnected.
○
in/out operation of the
Failure of switching harness. Check and replace failed harness if necessary.
arm is reversed.
Failure of arm reverse solenoid. Check and replace failed solenoid if necessary.
Failure of solenoid harness. Check and replace failed harness if necessary.
Bucket works slowly. Setting failure of relief pressure. Adjust relief pressure or replace it if necessary.
Bucket does not work.
Bucket is low-power ○ ○
and it cannot keep Failure of stop valve opening. Open stop valve fully.
position.
Bucket cylinder stroke Failure of proximity switch

Adjust proximity switch distance.
restriction does not ○ distance.
work. Failure of restriction solenoid. Check and replace failed solenoid if necessary.
Bucket works
slowly.Bucket does not Failure of harness. Check and replace harness if necessary.
work.
Crusher has low-power. Setting failure of relief pressure. Adjust relief pressure or replace it if necessary.
61
Crusher does not work. Failure of stop valve opening. Open stop valve fully.
○ ○
Or crusher works
Failure of N&B flow rate
slowly. Adjust N&B flow rate.
adjustment.
Crusher does not Failure of lever switch. Check and replace lever switch if necessary.
rotate.
Failure of harness. Check and replace harness if necessary.
Or crusher rotates ○ ○
slowly. Failure of solenoid for rotation. Check and replace solenoid if necessary.
Crusher has low-power. Failure of stop valve opening. Open stop valve fully.
Wrong connection of piping. Check and correct piping.
Hydraulic VLC does Failure of solenoid for

○ ○ Check and replace solenoid if necessary.
not work. retractable cylinder.
Shim had been left. Remove shim.
Connection failure of coupler. Check and replace coupler if necessary.
Water spray system Check and replace water spray solenoid if

Failure of water spray solenoid.
does not work and necessary.
○ ○
also water does not
flow out.
61-301
61.14 SAFETY EQUIPMENTS
61.14.1 OUTLINES
Alarm and Safety equipments
Alarms and safety devices configurate the safety equipments.
(1) Buzzers for alarm

1. Stability alarm
When the attachments exceed the safety zone, this buzzer sounds.
2. Bucket cylinder stroke-end alarm
When the cylinder rod extends and reaches within 75mm to the end, this buzzer sounds.
(2) The followings are safety equipments.

1. Bucket cylinder protector
To prevent damage of bucket cylinder rod, this protector is equipped.
2. Debris redirector
To avoid the debris falling from back of boom, this stopper is equipped.
3. LMN/BH switch
The switching connector to select the works LMN or BH is located on the left rear cover of
operator's seat.
4. Specialized demolition cab
To protect the operator from falling debris, this cab equips front guard and skylight guard.
5. Skylight wiper
To keep the visibility from roof skylight, skylight wiper is equipped.
6. One-way call
During working, to communicate with the person who is out of cab, this microphone and speaker
are equipped.
61-302
61.14.2 FUNCTIONS
When LMN/BH switching connector is switched to LMN side, the following controls are actuated.
(1) "A" mode start is selected and it is fixed. But when the machine is in "A" mode condition, engine
speed control is same as "H" mode.
(2) Solenoid valve is switched to match the Arm-in/out operation to BH.
(3) Timing of swing parking break release is changed from Arm-in to Arm-out.
(4) Display on the gauge cluster (Monitor)
1. The working radius and the boom angle are displayed at one time on the display.
2. Display is changed as shown below each time you press the screen change switch.
"WORKING RADIUS AND BOOM ANGLE" to "ENGINE OIL" to "FUEL FILTER" to "HYD. OIL"
to "WORKING RADIUS AND BOOM ANGLE"........
While the starter key switch is turned off, the last display is stored. And it is restored when the
starter key switch is turned on.
3. When the tip-over alarm control is not adjusted, the display of "WORKING RADIUS AND BOOM
ANGLE" is not indicated.
(5) Bucket cylinder stroke-end control
1. When the bucket cylinder reaches to stroke-end, the stroke-end detect switch is turned on. And
this alarm buzzer sounds for 1 second and the stroke-end restriction relay is turned on.
2. When the stroke-end detect switch is turned off, and the stroke-end restriction relay is turned off.
3. To cancel the alarm buzzer, turn off the stroke-end detect switch or turn on the buzzer stop
switch. 61
4. The attachment boost switch is switched to bucket cylinder stroke restriction release switch
function. When this release switch is turned on, restriction release relay is turned off. And the
bucket cylinder moves to the stroke-end. (At this time, attachment boost function is not actuated.)
(6) When attachment enters in warning zone, the tip-over alarm sounds intermittently. And when
attachment enters in danger zone, the tip-over alarm sounds continuously, and "CAUTION
TIPPING" is indicated on the display. And this indication is displayed until the attachment gets
out of danger zone.
(7) Judgment of boom length
These switches (SW-22) and (SW-79) judge the length of insert-boom.
Wire No. Length of attachment

Switch No.
(Wire color) Longest Longest-2.68m Longest-3.98m Shortest
SW - 22 566 (G/R) OPEN OPEN Grounding Grounding
SW - 79 569 (L/R) OPEN Grounding OPEN Grounding
61-303
(8) Following conflux controls are not available.
1. Arm sequence conflux

2. Bucket conflux
Position of angle sensors
Position of proximity switch
61-304
61.14.3 LMN SEPARATE BOOM INITIAL ADJUSTMENT

The following two initial adjustments are necessary for the machine that uses LMN and Separate-boom.
The procedure for each adjustment is described below.
(1) Adjustment of LMN stability alarm
61
61-305
(2) Choice of separate boom jib cylinder

The separate boom has 2 types the large diameter jib cylinder and the basic jib cylinder. And the
valve control for each specification is different. Therefore, at first, confirm the specification of machine.
The followings are procedures for check.
61-306
61.15 AUTOMATIC LUBRICATION EQUIPMENT
61.15.1 CONFIGURATION
Auto grease lubricator is the device which consists of the following devices.
1. The grease pump (including grease

cartridge) is located on the right front side
of the swing frame.
2. The controller is located on the left wall of
the inside of cab.
3. The distributors are installed to boom, arm,
and the right front side of the swing frame.
a. Grease cartridge tank
b. Grease pump assembly
c. Distributor (Boom cylinder head side)
d. Wiring harness
e. Controller
f. Distributor (Boom)
g. Distributor (Arm)
61
61.15.2 OPERATION
A. AUTOMATIC START
1. Start the engine.
2. The controller is activated and the all lamps light up for several seconds.
3. A part of indicators are flickered, and the indicators other than the power lamp go out. And the
controller begins to count the lubrication interval.
4. At the pre-set lubrication time, the grease pump starts automatically. And the lubrication system
proceeds "Pressurizing", "Holding pressure (Grease)", and "Depressing (for next lubrication depress
pressure from distributor).
5. During lubrication pre-set time the lubrication system works automatically, and at the pre-set time,
it stops.
B. MANUAL START
1. When manual operation is selected, you can activate the controller switch anytime.
2. The controller works 1 cycle of lubrication regardless of the accumulating time and stops the cycle.
3. In this case, the operating interval during counting is once canceled, and the new counting starts
again after the pump stops automatically.
61-307
61.15.3 LUBRICATION CONTROLLER

Lubrication controller is installed to left wall of the inside of cab. And this controller has the following
functions.
1. Switching of "Auto start" and "Manual start"

2. Setting of "Lubrication interval", "Lubricating time", and "Limitation of lubrication frequency"
Initialization of this machine is described on the page 2-11.
1. Indicator
2. Power (LED)
3. Drive (LED)
4. Alarm (LED)
5. Set (LED)
6. Level key
7. Item key
8. Start/Set key
9. Reset/Escape key
10. Fuse (Blade type 10A)
In the condition of pressure holding, the controller indicates "0" on the indicator (1).
In case of auto lubrication, smaller amount of grease is fed than manual lubrication, but this does
not affect performance.
In the event of failure of the auto lubrication system, it is possible to lubricate manually from the
grease nipples located on each distributor.
Only when the following mode settings are changed, use the "LEVEL" key or "ITEM" key. Contact
our dealer/distributor when you change "LEVEL" or "ITEM".
1. Lubrication interval
2. Lubricating time
3. Limitation of lubrication frequency
When controller is normal, the lamp in the lower right of the indicator flickers after the engine starts.
61-308
61.15.4 PARTS NAMES AND FUNCTIONS

1. Indicator
2. Power (LED)
3. Drive (LED)
4. Alarm (LED)
5. Set (LED)
6. Level key
7. Item key
8. Start/Set key
9. Reset/Escape key
10. Fuse (Blade type 10A)
1. Indicator
At function is set: Symbol of set item and Level code are indicated.
Lubrication interval is accumulated -- Small lamp is flickering.
At pressurized -- Rotate clockwise.
At pressure holding -- Rotation stops.
At depressurized -- Rotate counterclockwise.
When the lubricating frequency becomes less than nine times -- Remaining frequencies are
indicated (Countdown starts). 61
When abnormality is occurred -- "E" and "Error code" are indicated.
2. Power (LED): When applying current, lamp lights (Pilot lamp).
3. Drive (LED):
When pump is working -- Lamp flickers.
At pressure holding -- Lamp flickers slowly.
At depressurized -- Lamp flickers quickly.
4. Alarm (LED): When abnormality is occurred -- Lamp flickers.
5. Set (LED): When each item is set -- Lamp flickers.
6. Level key: Represented by (6) key hereafter
At function is set -- Switching key to step to select "LEVEL (Setting item)"
7. Item key: Represented by (7) key hereafter
At function is set -- To select "ITEM"
Press select keys (6), (7) simultaneously, the mode is changed to setting mode.
8. Start/Set key: Represented by "SET" hereafter
At function is set -- "SET" key, after set the "Level code No." by each item"SET"
At manual drive -- When press the Start/Set key, one cycle operation is driven. In this case, the
operating interval during counting is once canceled, and the new counting starts again after the
pump stops automatically.
9. Reset/Escape key: Represented by "ESC" key hereafter
At function is set -- After all items are set, releasing key of computer setting mode.
At abnormality is occurred -- Alarm releasing key.
Cartridge -- Press "ESC" key for 5 seconds or more, the memory of lubrication frequency is reset.
61-309
61.15.5 SETTING ITEM AND SETTING PROCEDURE

To actuate the centralized lubricating system by controller, there are next 2 procedures.
A. AUTOMATIC OPERATION (CONTROLLED WITH TIMER)

The lubricator starts and stops lubrication
automatically with controller built-in timer.
If you need the change of set value, contact our dealer/distributor.
B. MANUAL OPERATION
The lubricator starts and stops lubrication
manually with controller start switch.
When manual operation is selected, press the
start key. And one cycle lubrication is
performed regardless of the counting time.
(1) Contents of set items

According to the working condition of
excavator, ambient temperature, and kind of
grease, you can select the next items.
This machine is set the right table as an initial
setting.
(2) Set items and level codes numbers.
Do not use the columns which were lined diagonally.

The code numbers can be entered into each item.
61-310
(3) Setting procedure
・ In case of setting
Before setting, put the controller into "Setting mode" by pressing required keys. In this situation,
the setting can be entered.
・ In case of completion of setting
Release the controller from "Setting mode" by pressing required keys. And the system returns to
usual operation mode which is the situation of lubrication interval counting time.
1. Start engine, and turn power on.

2. Press (level) key and (item) key
simultaneously, and the set mode is
selected. And the setting LED is flickering.
(See right diagram.)
3. When the (Item) key is pressed, the
setting items (a, b, and c) on the
controller are changed in turn as shown in
the right diagram.
61
61-311
(4) How to set (Exercise)

Install the initial setting value for the Ultra Long Attachment Demolition Machine.
See the right table and decide the level codes, and enter the values of lubrication interval, lubrication
time, and lubrication limit frequency is 1.5 hour, 15 minutes, and 150 times.
1. Press "LEVEL" key and "ITEM" key

simultaneously.
2. Select and set the required item by
pressing "ITEM" key. In case of the
exercise, press "ITEM" key until "a" is
appeared.
3. While "a" flickers, press "LEVEL" key and
"a" to "0" to "a" to "0" flicker by turns.
Then, code number (number portion) is
moved up for every pressing "ITEM" key.
It changes as follows. "a" to "0" to "a" to
"1" "a" to "2" to "a" to "9"
4. For exercise, input "2" in the level code
No. of the Table to set 1.5 hour.
When "a" to "2" flickers, press "SET" key.
Now 1.5 hour has been set to "a". And
"b" to "0" to "b" to "0" flickers for next
setting item. So, for exercise, input "6" in
the Table to set 15 minutes. When "b" to
"6" to "b" to "6" flickers, press "SET" key.
5. For the following setting, since the "c" to
"0" flickers, input code "5" in the Table
when "c" to "5" flickers.
When "c" to "5" to "c" to "5" flickers,
press "SET" key, and "a" and "2" are
flickered alternately.
6. After setting every item for "a" "b" "c"
Press "ESC" key for 3 seconds or more
to release the setting mode. Immediately
after pressing "ESC" key, the counting of
lubrication interval is started, and the
flicker at a part of indication segment
proves the execution of counting.
After setting, the set value is stored even if
the power is off.
If the cartridge is replaced with new one, press the "ESC" key for 5 seconds or more. When release
your finger from key, figure "0" flickers several times on the indicator, and it shows the reset of
lubrication frequency.
61-312
61.15.6 NORMAL OPERATION DISPLAY LIST

The condition of the lubrication system can be known by 7 segments LED of the control panel and the
display contents of LED. This list is useful to judge whether the operation is normal or abnormal after
the initial setting and the installation.
A. NORMAL OPERATION UNDER NORMAL OPERATION
61
61-313
B. ERROR LIST
4 kinds of the lubrication system error are shown by alarm LED, and the error contents and the
display are indicated by error code. However, the power LED does not light up when the fuse is
blown.
61.15.7 AUTOMATIC LUBRICATING POINTS

Automatic lubrication points are shown below.
Excluding these lubrication points, lubricate the other points with conventional grease gun according to
the instruction on page 5-13 in this manual.
Lubricate the marked points (Bucket, link, and crusher area) with grease gun.
Lubricate the bucket area every 50 hours and lubricate the crusher area every 8 hours.
In the event of malfunction of automatic lubricating system, use the grease gun and lubricate the
grease from the grease nipples located on each distributor.
61-314
A. DEMOLITION BACKHOE
No. Lubricating points Q'ty No. Lubricating points Q'ty
1 Boom foot (Right) 1 6 Boom cylinder rod (Left) 1
2 Boom foot (Left) 1 7 Arm cylinder head 1
3 Boom cylinder head (Right) 1 8 Boom point 1
4 Boom cylinder head (Left) 1 9 Arm cylinder rod 1
5 Boom cylinder rod (Right) 1 10 Boom cylinder head 1
61
61-315
B. 3-PIECE DEMOLITION MACHINE

1 Boom foot (Right) 1 9 Inter boom foot (Right) 1
2 Boom foot (Left) 1 10 Inter boom foot (Left) 1
3 Boom cylinder head (Right) 1 11 Arm cylinder head 1
4 Boom cylinder head (Left) 1 12 Arm foot (Right) 1
5 Boom cylinder rod (Right) 1 13 Arm foot (Left) 1
6 Boom cylinder rod (Left) 1 14 Arm cylinder rod 1
7 Jib cylinder head 1 15 Bucket cylinder head 1
8 Jib cylinder rod 1
61-316
C. SEPARATE BOOM MACHINE

1 Boom foot (Right) 1 8 Main boom top pin 1
2 Boom foot (Left) 1 9 Arm cylinder head 1
3 Boom cylinder head (Right) 1 10 Jib cylinder head 1
4 Boom cylinder head (Left) 1 11 Arm cylinder rod 1
5 Boom cylinder rod (Right) 1 12 Front boom top pin 1
6 Boom cylinder rod (Left) 1 13 Bucket cylinder head 1
7 Jib cylinder rod 1
61
61-317
61.15.8 REPLACEMENT OF CARTRIDGE

A. INDICATION OF REPLACING TIME
The total greasing amount of every section for
time of this auto lubricating system is set
about 4cc by the distributor, and the lubricating
frequency until the cartridge, 1000cc, is
emptied is memorized 200 times by the
controller.
When the remaining greasing times reduces to
10 times or less, the indicator of controller
counts down like 9, 8, 7... 3, 2, 1 and when
reaches to "0" the error code "E"-"0" goes on
and off alternately on the indicator to tell the
replacement.
If the error code "E"-"0" should be missed, the
cartridge can afford to lubricate further and
when reaching to the following greasing time
the grease is automatically lubricated. Replace
the cartridge within the given time the error
code "E"-"0" is indicated. The operation the
error code "E"-"0" is left indicated might cause
inadequate lubricating pressure and so on
because the cartridge is emptied.
B. REPLACING PROCEDURE
1. Turn cartridge cover counterclockwise
slightly and remove cover. At this time, take
care that the built in spring for pressure is
jumped out of the cover.
2. Remove spring and spring retainer giving
attention to the spring retainer direction.
3. Remove empty cartridge and install the new
cartridge.
After the grease is pushed out a little,
screw the cartridge into the inlet securely to
prevent the entering of the air.
4. Install the spring and the spring retainer
paying attention to the spring retainer
direction and tighten the cartridge cover
securely.
5. After replacement of cartridge, keep
RESET/ESC switch pushing for 5 seconds
or more and the memory of lubricating
frequency is reset.
61-318
Before installing new cartridge, remove inner lid (cap) of cartridge.

Prevent air and dust from entering into grease.
Be sure to use recommended grease. See the table at the previous page.
61.15.9 AIR BLEEDING FROM GREASE PUMP

1. Remove the air-bleed plug located on the
side of pump using 5 mm Allen wrench.
2. Press the switch marked START/SET, and
start pump, then continue the running of
pump until the containing air-bubbles grease
is completely removed.
Check that the only pure grease comes out
continuously from air bleeding hole.
3. Stop the pump and install the air-bleed
plug in original position.
61
Do not reuse the used cartridge refilled with new grease, to avoid the trouble of grease pump. Use
the genuine cartridge of parts number 2421Z512.
61-319
61.15.10 CAUTIONS IN LOW AND HIGH TEMPERATURE CONDITIONS

・ In low temperature condition
The grease in cartridge is abruptly
contracted in the event of sudden
temperature drop. In this case, the grease
volume discharged by distributor can not
cover the shortage due to contraction of
grease volume. There is a case that one
operation might not be enough to discharge
grease to pins.
In this case, try to operate it several times
manually and it is lubricated.
・ In high temperature condition
The grease in piping from distributor to pins
is expanded in the event of the increase
of temperature, and the discharge to pins
by one operation is a little increased. But
the greasing volume is stabilized with
repetition of operation.
・ Adjustment of grease discharge
The grease discharge is adjusted before
shipping and set to the proper condition
by each distributor, but if the adjustment is
required, remove vinyl cap of distributor and
turn adjusting screw with Allen wrench
(3mm).
The one rotation of adjusting screw in clockwise reduces about 0.1cc of discharged grease volume.
61.15.11 MAINTENANCE AND CHECK

The maintenance and checking of the automatic lubrication system must be carried out every 2 weeks
according to the items shown in the Table below.
Checking items
Does controller work normally.
1 1. Is the power lamp lit during engine operation?
2. Is error not indicated?
2 Is the pump area free from leak of grease?
3 Is the distributor valve free from leak of grease?
Is grease fed to each pin surely?
4 It is less than the ordinary amount of grease, but does grease come out by
bit?
5 Are attaching bolts of controller, pump and distributor free from loosening?
6 Are attaching bolts of hose, tube and so on free from loosening?
61-320
61.15.12 GREASING PROCEDURE AT THE TIME OF REMOVAL OF ATTACHMENT

When pin on the greasing section is removed
to remove attachment, lubricate grease until
the grease comes out of the boss end.
61
61-321
61.15.13 TROUBLESHOOTING
When this lubrication system fails, the
corresponding error code on the controller
display flickers.
Check the system for the cause of failure and
take a corrective action.
61-322

Sk480 Sk500dlc 8 Shop Manual

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Sk480 Sk500dlc 8 Shop Manual

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DEMOLITION MACHINE WITH

COMMON USE TYPE MAIN BOOM

Book Code No. S5LS6111E01

61. DEMOLITION MACHINE WITH

61.1 FOREWORD ……………………………………………………………………………………………………61-3

Book Code No. S5LS6111E01

Issue Data of Issue Applicable Machines Remarks

・ 3-Piece demolition ultra long attachment (LMN)

61.1.1 CHANGED MAJOR PARTS FROM STANDARD MACHINE

(2) Main control valve

(5) Classification of appearance according to attachments

(6) Classification of connector for attachment

61.1.2 CHANGED PIPING PARTS FROM STANDARD MACHINE

Regarding the electric circuit, refer to electric system section.

61.1.3 OUTLINE FOR MACHINE

For the working details, refer to Section 3 Machine Operation.

61.1.3.2 FRONT/REAR AND RIGHT/LEFT OF MACHINE

61.1.3.3 RUNNING-IN PERIOD

Perform running-in using care especially the following points.

・ Do not work with heavy load and high speed.

61.2 GENERAL VIEW

B. 3-PIECE DEMOLITION TYPE (LONG ARM SPEC.)

C. SEPARATE BOOM TYPE

61.2.1.3 CRUSHER (NIBBLER)

B. DEMOLITION CRUSHER FOR FERROCONCRETE BUILDING (KR1200PR) AUTO ROTARY TYPE:

61.2.2 MACHINE DIMENSIONS

Track crawler Track crawler hydraulically

Track crawler Track crawler hydraulically

Track crawler Track crawler hydraulically

Track crawler Track crawler hydraulically

Track crawler Track crawler hydraulically

Track crawler Track crawler hydraulically

Jib cylinder standard

Large diameter jib cylinder

Track crawler Track crawler hydraulically

I. 4.5M Main boom

Track crawler Track crawler hydraulically

61.2.3 SPECIFICATION SHEET

Model SK480DLC-8 (Fixed track gauge[Retractable track gauge])

The units in this table are shown "International system of units".

Model SK500DLC-8 (Hydraulic retractable track gauge)

The units in this table are shown "International system of units".

A. Length and Weight of Front attachment (Ultra Long Attachment)

B. Length and Weight of Front attachment (Separate boom)

Front boom 4.7 3,690 [4,110]

C. Length and Weight of Front attachment (Demolition Backhoe)

61.2.4.2 MAJOR DIMENSIONS OF SK480DLC-8/SK500DLC-8 FOR TRANSPORTATION

With main boom and without counterweight

Without counterweight and attachments

Bolt size of counterweight mounting bolt: M45

Add-on counterweight specifications

Main boom specifications Insert boom specifications

Insert boom specifications Front boom specifications

Inter boom specifications Arm specifications

Front boom specifications 61

Long arm specifications

Arm + Inter boom + Front boom specifications

Long arm + Inter boom + Front boom specifications

Front boom specifications Front boom specifications

Front boom specifications

Arm + Front boom specifications Arm + Front boom specifications

Front boom specifications

Front boom + Arm specifications (For demolition back-hoe)

Standard jib cylinder specifications Large diameter jib cylinder specifications