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MAINTENANCE SPECIFICATIONS
SHOP
MANUAL model SK210LC-10
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
GENERAL SAFETY INFORMATION 3) CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in mi-
nor or moderate injury. It may also be used to
alert against possible damage to the machine
Do not operate or perform any maintenance on this and its components and is represented as fol-
machine until all instructions found in the OPERA- lows:
TOR’S MANUAL and this MANUAL have been thor-
oughly read and understood.
Improper operation or maintenance of this machine (4) It is very difficult to forecast every danger that may
may cause accidents and could result in serious in- occur during operation. However, safety can be en-
jury or death. sured by fully understanding proper operating pro-
Always keep the manual in storage. cedures for this machine according to methods
If it is missing or damaged, place an order with an recommended by Manufacturer.
authorized our Distributor for a replacement.
(5) While operating the machine, be sure to perform
If you have any questions, please consult an autho-
work with great care, so as not to damage the ma-
rized our Distributor.
chine, or allow accidents to occur.
(1) Most accidents, which occur during operation, are (6) Continue studying the manual until all Safety, Oper-
due to neglect of precautionary measures and safe- ation and Maintenance procedures are completely
ty rules. Sufficient care should be taken to avoid understood by all persons working with the ma-
these accidents. Erroneous operation, lubrication chine.
or maintenance services are very dangerous and
may cause injury or death of personnel. Therefore
all precautionary measures, NOTES, DANGERS,
WARNINGS and CAUTIONS contained in the man-
ual and on the machine should be read and under-
stood by all personnel before starting any work with
or on the machine.
(2) Operation, inspection, and maintenance should be
carefully carried out, and safety must be given the
first priority. Messages of safety are indicated with
marks. The safety information contained in the
manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
(3) Messages of safety appear in the manual and on
the machine : All messages of safety are identified
by either word of "DANGER", "WARNING" and
"CAUTION".
1) DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury and is represented as
follows:
0-2
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SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.
0-3
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(13)Always use the proper tools that are in good condi- (19)Loose or damaged fuel, lubricant and hydraulic
tion and that are suited for the job at hand. Be sure lines, tubes and hoses can cause fires. Do not bend
you understand how to use them before performing or strike high pressure lines or install ones which
any service work. have been bent or damaged. Inspect lines, tubes
(14)Reinstall all fasteners with the same part number. and hoses carefully. Do not check for leaks with
Do not use a lesser quality fastener if replacements your hands. Very small (pinhole) leaks can result in
are necessary. a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
(15)Repairs which require welding should be per-
cause personal injury. Use card-board or paper to
formed only with the benefit of the appropriate ref-
locate pinhole leaks.
erence information and by personnel adequately
trained and knowledgeable in welding procedures. (20)Tighten connections to the correct torque. Make
Determine type of metal being welded and select sure that all heat shields, clamps and guards are in-
correct welding procedure and electrodes, rods or stalled correctly to avoid excessive heat, vibration
wire to provide a weld metal strength equivalent at or rubbing against other parts during operation.
least to that of the parent metal. Make sure to dis- Shields that protect against oil spray onto hot ex-
connect battery before any welding procedures are haust components in event of a line, tube or seal
attempted. failure must be installed correctly.
(16)Do not damage wiring during removal operations. (21)Do not operate a machine if any rotating part is
Reinstall the wiring so it is not damaged nor will be damaged or contacts any other part during opera-
damaged in operation of the machine by contacting tion. Any high speed rotating component that has
sharp corners, or by rubbing against some object or been damaged or altered should be checked for
hot surface. Do not connect wiring to a line contain- balance before reusing.
ing fluid. (22)Be careful when servicing or separating the tracks
(17)Be sure all protective devices including guards and (crawlers). Chips can fly when removing or install-
shields are properly installed and functioning cor- ing a track (crawlers) pin. Wear safety glasses and
rectly before starting a repair. If a guard or shield long sleeve protective clothing. Tracks (crawlers)
must be removed to perform the repair work, use can unroll very quickly when separated. Keep away
extra caution and replace the guard or shield after from front and rear of machine. The machine can
repair is completed. move unexpectedly when both tracks (crawlers)
are disengaged from the sprockets. Block the ma-
(18)The maintenance and repair work while holding the
chine to prevent it from moving.
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
The copyright of this manual belongs to KOBELCO CONSTRUCTION MACHINERY CO., LTD.
Copy, reproduction, distribution, and delivery (including these actions on the Internet) of all or part of this
manual are prohibited without permission of KOBELCO CONSTRUCTION MACHINERY CO., LTD.
This manual is intended to provide instructions for repair, maintenance, and adjustment of the machine, sold
directly or indirectly by KOBELCO CONSTRUCTION MACHINERY CO., LTD. or Kobelco Construction
Machinery U.S.A Inc. and any use other than that purpose will not be allowed.
Also, all or part of this manual cannot be transferred, sold, or lent to a third person without permission of
KOBELCO CONSTRUCTION MACHINERY CO., LTD.
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
North America INDEX SK210LC-10
Index
Distribution Year–Month Title 1
No. 17 9
MAINTENANCE SPECIFICATIONS
2015-06 OUTLINE 1
2015-06 SPECIFICATIONS 2
DISASSEMBLING 13 5
DISASSEMBLING
2015-06 12
& ASSEMBLING
2015-06 ATTACHMENT 13
2015-06 BY TROUBLE 17
_
15 7
_
2016-04 ENGINE 18
_
16 8
_
0-5
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NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.
• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
0-6
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[1. OUTLINE]
1. OUTLINE
1.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................1-3
1.2 GENERAL PRECAUTIONS FOR MAKING REPAIRS .................................................................1-4
1.2.1 PREPARATION BEFORE DISASSEMBLING ..........................................................................1-4
1.2.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING .........................................................1-4
1.2.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .........................................1-5
1.2.4 ELECTRICAL EQUIPMENT....................................................................................................1-7
1.2.5 HYDRAULIC PARTS..............................................................................................................1-7
1.2.6 WELD REPAIR ......................................................................................................................1-8
1.2.7 ENVIRONMENTAL ISSUES ...................................................................................................1-8
1.3 INTERNATIONAL UNIT SYSTEM ..............................................................................................1-9
1-1
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[1. OUTLINE]
1-2
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[1. OUTLINE]
1-3
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[1. OUTLINE]
Cleaning machines
Clean machines of soil, mud, and dust before carrying into the service shop.
Carrying a soiled machine into the service shop, causes making less efficient work and damage of parts.
Inspecting machines
Confirm the disassembling section before starting work, determine the disassembly procedure taking the conditions
in work shop into account, and request to procure necessary parts in advance.
Recording
Record the following items to keep contact and prevent malfunction from recurring.
• Inspecting date, place
• Model name, Serial number and Record on hour meter
• Trouble condition, place, cause
• Visible oil leak, water leak and damage
• Clogging of filters, oil level, oil quality, oil contamination and looseness.
• Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour
meter.
WARNING
Safety
• Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
• Attach "Don't operate" tag to control lever, and begin a meeting before starting the work.
• Before starting inspection and maintenance stop the engine.
• Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure
and ambulance to prepare for accidents and fire.
• Choose a hard, level and safe place, and put attachment on the ground without fail.
• Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more).
• Use proper tools, and change or repair defective tools.
• Machine and attachment required to work in the lifting condition should be supported with supports or blocks
securely.
1-4
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[1. OUTLINE]
1
Removing hydraulic equipment assy
• Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank,
and take out the filter.
• Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.
• Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
• Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before
putting them on working bench.
Inspecting parts
• Check that the disassembled parts are free from adherence, interference and uneven working face.
• Measure the wear of parts and clearance, and record the measured values.
• If an abnormality is detected, repair or replace the parts.
1-5
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[1. OUTLINE]
Im p o r t a n t im fo r m a t io n
LEVEL GAUGE
Oil level of hydraulic oil tank.
If the indicator is within
level marks, the oil quantity
is acceptable.
1-6
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[1. OUTLINE]
O-ring
• Check that O-ring is free from flaw and has elasticity before fitting.
• Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections, the rubber
hardness also differs according to the pressure force, and also the quality differs depending on the materials to
be seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and bend.
• Floating seal should be put in pairs.
1-7
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[1. OUTLINE]
1-8
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[1. OUTLINE]
1-9
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[1. OUTLINE]
1-10
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[2. SPECIFICATIONS]
2. SPECIFICATIONS
2.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................2-3
2.2 BASIC COMPONENTS OF THE MACHINE................................................................................2-4
2
2.3 GENERAL DIMENSIONS..........................................................................................................2-6
2.3.1 SK210LC-10 [5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m3(1.05cu·yd)
Bucket Shoe]...................................................................................................2-6
2.4 WEIGHT OF COMPONENTS.....................................................................................................2-7
2.5 SPECIFICATIONS FOR TRANSPORTATION .............................................................................2-8
2.5.1 DIMENSIONS AND WEIGHT OF ATTACHMENT/EQUIPMENT ................................................2-8
2.6 GENERAL SPECIFICATIONS .................................................................................................2-10
2.6.1 SPEED AND CLIMBING CAPABILITY ..................................................................................2-10
2.6.2 ENGINE ..............................................................................................................................2-10
2.6.3 HYDRAULIC COMPONENTS ...............................................................................................2-10
2.6.4 WEIGHT ..............................................................................................................................2-10
2.7 TYPE OF CRAWLER .............................................................................................................. 2-11
2.7.1 SK210LC-10 TYPE OF CRAWLER ....................................................................................... 2-11
2.8 TYPE OF BUCKET .................................................................................................................2-12
2.9 COMBINATIONS OF ATTACHMENT .......................................................................................2-13
2.10 ENGINE SPECIFICATION .....................................................................................................2-14
2.10.1 SPECIFICATIONS..............................................................................................................2-14
2.10.2 ENGINE CHARACTERISTIC CURVE (HINO J05E-UM) .......................................................2-15
2-1
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[2. SPECIFICATIONS]
2-2
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[2. SPECIFICATIONS]
2-3
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[2. SPECIFICATIONS]
33
34 8
20
6
35 Indicate the right side
30
36
18
37 31
7
11
38
21
39
24
25
26
29
23
26 12 22
27
41
40 19 16
17
Inside the left side door 14
13 15 30
2-4
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[2. SPECIFICATIONS]
2-5
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[2. SPECIFICATIONS]
45 (1.77”)
R2
(9 9
’7 ” 1 0
)
9600 (31’6”) 2850 (9’4”)
2900 (9’6”) 1460 1380
(4’9”) (4’6”)
3060 (10’0”)
2740 (8’12”)
2980 (9’9”)
1060* (3’6”)
450*
(17.7”)
4450 (14’7”) 790
(31.1”)
5130 (16’10”) 3180 (10’5”)
2-6
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[2. SPECIFICATIONS]
2-7
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[2. SPECIFICATIONS]
2.5.1.3 Arm
Item / Type 2.94m (9ft-8in) Arm
2-8
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[2. SPECIFICATIONS]
2.5.1.4 Bucket
Type Hoe bucket
Length X Height X Width 1.37 x 1.26 x 1.16
L X H X W: m (ft-in) (4'6" x 4'2" x 3'10")
Õ Hoe bucket
2-9
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[2. SPECIFICATIONS]
2.6.2 ENGINE
Engine model HINO J05E-UM
Water-cooled, 4 cycle 4 cylinder
Type
direct injection type diesel engine with inter cooler turbo-charger
Rated output / Engine speed 124kW (166 hp) / 2,000 min-1 (rpm) (ISO 14396 : Without fan)
Maximum torque / Engine speed 660 N·m (487 lbf·ft) / 1,600 min-1(rpm) (ISO 14396 : Without fan)
Starter 24 V / 5.0kW
Alternator 24 V / 60A
2.6.4 WEIGHT
Fully equipped weight kg (lbs) 22,300 (49,170)
Lower machinery
kg (lbs) 8,070 (17,790)
(790 mm {31.1in} grouser shoe)
Attachment
3,740 (8,250)
5.65m (18ft-6in) Boom+2.94m kg (lbs)
0.8 m3 (1.05cu·yd) Bucket
(9ft-8in) Arm+Bucket
2-10
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[2. SPECIFICATIONS]
Use 600mm (23.6in) grouser shoes on rough ground (areas covered with rocks and gravel).
If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly
(link, roller, etc.)
Grouser shoe
600 (23.6) 2,990 (9'10") 45 (6.5)
46 LINKS
2-11
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[2. SPECIFICATIONS]
0.80
0.59 1,160 1,060 660
(1.05) 5 W YES
(0.77) (3'10") (3'6") (1,460)
STD
2-12
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[2. SPECIFICATIONS]
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
2
• The marks listed below are specified as follows.
◎Standard: combination
○General: operation Excavation or loading of sand, gravel, and clay
△Light operation: Mainly loading of loose gravel (e.g., cultivation or loading of sand or gravel)
×Prohibited combination: Do not use this combination because this is not included in the warranty.
• When installing the attachment to this machine, install the genuine or KOBELCO recommended attachment.
Note that if a failure occurs in this machine or the attachment because of installation of an attachment other than
the specified attachment, it is not included in the manufacturer warranty.
STD
Hoe bucket 0.59 (0.77) ◎
0.80 (1.05)
Breaker ― ― ○
2-13
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[2. SPECIFICATIONS]
Maximum torque (ISO 14396 : Without fan) 660 N·m (487 lbf·ft) at 1,600 min-1 (rpm)
Thermostat action Start 344 K (160F degrees) / Full open 358 K (185F degrees)
Firing order 1 -3 -4 -2
Specific fuel consumption (at rated power) 208 g / kw·h (155 g / hp·h)
2-14
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[2. SPECIFICATIONS]
{N.m(lbf.ft)}
800(590)
(kW) 600(443)
2
140 400(295)
200(148)
Torque
120
Out put
100
80
60
40
2-15
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[2. SPECIFICATIONS]
2-16
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[3. ATTACHMENT DIMENSIONS]
3. ATTACHMENT DIMENSIONS
3.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................3-3
3.2 BOOM......................................................................................................................................3-4
3.2.1 BOOM DIMENSIONAL DRAWING..........................................................................................3-4
3.2.2 BOOM MAINTENANCE STANDARD ......................................................................................3-5
3.3 ARM ........................................................................................................................................3-8
3.3.1 ARM DIMENSIONAL DRAWING.............................................................................................3-8
3.3.2 ARM MAINTENANCE STANDARD .........................................................................................3-9 3
3.4 BUCKET ................................................................................................................................3-12
3.4.1 BUCKET DIMENSIONAL DRAWING ....................................................................................3-12
3.4.2 BUCKET DIMENSIONAL TABLE..........................................................................................3-12
3.4.3 LUG SECTION DIMENSIONAL DRAWING ...........................................................................3-13
3.4.4 BOSS SECTION DIMENSIONAL DRAWING .........................................................................3-14
3-1
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[3. ATTACHMENT DIMENSIONS]
3-2
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[3. ATTACHMENT DIMENSIONS]
3-3
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[3. ATTACHMENT DIMENSIONS]
3.2 BOOM
3.2.1 BOOM DIMENSIONAL DRAWING
d2
J
SECTION X-X
3-4
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[3. ATTACHMENT DIMENSIONS]
A
C
B
3
Unit:mm (in)
+ 0.250 + 0.290
0
Boom cylinder ø 85 (+0.0098) (+0.0114)
B YN02B02457P1 - 0.040
(Head side) (3.3465) + 0.050 + 0.050
(-0.0016) Replace
(+0.0020) (+0.0020) 2.0 2.5
bushing
+ 0.020 + 0.250 + 0.270 (0.08) (0.1)
or pin
Boom cylinder ø 85 (+0.0008) (+0.0098) (+0.0106)
C YN02B01721P1
(Rod side) (3.3465) - 0.020 + 0.050 + 0.030
(-0.0008) (+0.0020) (+0.0012)
3-5
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[3. ATTACHMENT DIMENSIONS]
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
3-6
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[3. ATTACHMENT DIMENSIONS]
Unit:mm (in)
3-7
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[3. ATTACHMENT DIMENSIONS]
3.3 ARM
3.3.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
DIMENSION DIMENSION
Code NAME Code NAME
mm (ft-in) mm (ft-in)
D Distance between pins of boss and bracket R874 (34.4") N Bracket inner width 126 (4.96")
G Height between pins of boss and bracket 665.5 (26.2") d2 Pin dia. ø70 (2.76")
H Height between pins of boss and bracket 312 (12.3") d3 Pin dia. ø85 (3.35")
K Arm top end boss width 325 (12.8") d4 Pin dia. ø90 (3.54")
L Arm link section boss width 323 (12.7") d5 Pin dia. ø80 (3.15")
3-8
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[3. ATTACHMENT DIMENSIONS]
C
G
+ 0.284 + 0.324
Idler link 0
ø70 (+0.0112) (+0.0128)
C (Connecting YN12B11605P1 - 0.040
(2.7559) + 0.099 + 0.099
part of arm) (-0.0016)
(0.0039) (+0.0039)
3-9
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[3. ATTACHMENT DIMENSIONS]
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X3 L3 PL5
X6 L6
X5 L5
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D SECTION G-G
3-10
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[3. ATTACHMENT DIMENSIONS]
Unit:mm (in)
323 2.5
Idler link Arm 0.5
C-C L3 (12.72) 1.0 (0.04) (0.10) PL3
(Arm connection)
Link side —
(0.02)
3
Bucket link Rod side —
D-D (Idler link L4 323 428
connection) Link side (16.9)
(12.72) 0.6 to 1.0
(0.02 to 2.0 (0.08) Shim
105 PL4
Rod side 0.04) adjust
Bucket link (4.13)
ment
D'-D' L4'
(Rod side) Bucket 11 1
link (4.37)
105
Head side
Bucket cylinder (4.13) 227
E-E L5 PL5
(Head side) 11 1 (8.9)
Arm 0.6 to 2.0
(4.37) 4.0
(0.02 to 3.0 (0.12)
120 (0.16)
Rod side 0.08)
Arm cylinder (4.72) 252
F-F L6 PL6
(Rod side) 126 (9.9)
Arm
(4.96)
342
Arm
(13.46) 0.5 2.5 508
G-G Arm foot L7 1.0 (0.04) PL7
347 (0.02) (0.10) (20.0)
Boom
(13.66)
3-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[3. ATTACHMENT DIMENSIONS]
3.4 BUCKET
3.4.1 BUCKET DIMENSIONAL DRAWING
Hoe bucket
B Distance between bucket pin and tooth end H Bucket outer width of front side
Part No. —
A R430 (16.9")
B R1,440 (4'9")
C 1,005 (3'4")
D 399 (15.7")
E 327 (12.9")
F 1,159 (3'10")
G 865 (34")
H 1,057 (3'6")
I 224 (8.82")
IO 224 (8.82")
d1 ø95 (3.74")
d2 ø80 (3.15")
3-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[3. ATTACHMENT DIMENSIONS]
X B
J
A
bb
F
N
D E
Unit:mm (ft-in)
3-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[3. ATTACHMENT DIMENSIONS]
H 5
(0.197" )
- G
I
m 0 .2 0 8 "
.0 0 . x
(0 R a
R 0 .0
ax
08 2
m
(
")
.0 .5
- A - B - C- D
(0 -C 0
")
)
20
30r
2
15 (0.591")
DETAIL bb
E
Unit:mm (ft-in)
øB 84 (3.31")
øC 105.5 (4.15")
øD 111.5 (4.39")
E 23 (0.91")
F 38 (1.50")
øG 17 (0.669")
H 13 (0.512")
I 2.5 (0.098")
3-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
4. TOOLS
4.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................4-3
4.2 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ..........................................................4-4
4.3 SCREW SIZE AND NOMINAL SIZE OF TOOL ...........................................................................4-6
4.3.1 CAPSCREW (HEX HEAD BOLT) ............................................................................................4-6
4.3.2 CAPSCREW (HEX HEAD SOCKET BOLT) .............................................................................4-6
4.3.3 SET SCREW (HEX HEAD SOCKET SET SCREW) ..................................................................4-6
4.4 TIGHTENING TORQUE FOR HOSE AND FITTING ....................................................................4-7
4.4.1 JOINT (O-RING TYPE)...........................................................................................................4-7
4.4.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) ..........................................................................4-7
4.4.3 ORS FITTNIG ........................................................................................................................4-7
4.4.4 SPLIT FLANGE .....................................................................................................................4-7
4.5 TIGHTENING TORQUES FOR NUTS AND SLEEVES ................................................................4-8
4.6 PLUG.......................................................................................................................................4-9 4
4.6.1 PLUG FOR BYTE TYPE TUBE FITTING .................................................................................4-9
4.6.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................................................4-10
4.7 SPECIAL SPANNER FOR TUBE .............................................................................................4-12
4.8 SPECIAL TOOLS....................................................................................................................4-13
4.9 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND....................4-15
4.10 SUCTION STOPPER ............................................................................................................4-16
4.10.1 COMPONENTS..................................................................................................................4-16
4.10.2 DIMENSION.......................................................................................................................4-16
4.11 COUNTER WEIGHT LIFTING JIG..........................................................................................4-17
4.12 ENGINE MOUNTING PEDESTAL ..........................................................................................4-18
4.13 MUFFLER ASSY LIFTING JIG ..............................................................................................4-19
4.14 WHIRL-STOP JIG OF DEF TANK FIXING BAND....................................................................4-20
4.15 TRACK SPRING SET JIG .....................................................................................................4-21
4-1
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
4-2
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
4-3
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
Strength
4.8T 7T 10.9T
classification
Size
Use No Oil No Oil No Oil
classification lubrication lubrication lubrication lubrication lubrication lubrication
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
(3.2±0.4) (2.7±0.3) (7.1±0.7) (6.0±0.6) (12.8±1.3) (10.8±1.1)
4-4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
Strength
4.8T 7T 10.9T
classification
Size
Use No Oil No Oil No Oil
classification lubrication lubrication lubrication lubrication lubrication lubrication
11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1
(8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9)
4-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
M6 10 M36 55
M8 13 M42 65
M10 17 M45 70
d
M12 19 M48 75
(M14) 22 M56 85
M16 24 (M60) 90
(M18) 27 M64 95 B
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
M6 5 (M27) 19
M8 6 M30 22
B
M10 8 M36 27
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10
4-6
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
3/4 36 162±9.8(119±7)
1 41 255±9.8(188±7)
1 41 137±15 (101±11)
36 177±18 (131±13)
1 3 / 16-12 UN
41 206±21 (152±15)
41 206±21 (152±15)
1 7/ 16-12 UN NUT
46 206±21 (152±15)
4-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
Nippon A.M.C. 29.4 (4270) ø18 X 2.5 (0.709 X 0.098) 32 147±15 (110±11)
Ihara Science 29.4 (4270) ø35 X 5.0 (1.38 X 0.197) 55 441±44 (330±33)
SLEEVE NUT
B
d
d
6 ZF96S06000 — 6 14 ZF96N06000 —
8 ZF96S08000 — 8 17 ZF96N08000 —
10 ZF96S10000 ZA93S10000 10 19 ZF96N10000 ZA93N10000
12 ZF96S12000 — 12 22 ZF96N12000 —
15 ZF96S15000 ZA93S15000 15 27 ZF96N15000 ZA93N15000
18 ZF96S18000 ZA93S18000 18 32 ZF96N18000 ZA93N18000
22 ZF96S22000 ZA93S22000 22 36 ZF96N22000 ZA93N22000
28 ZF96S28000 ZA93S28000 28 41 ZF96N28000 ZA93N28000
32 ZF96S32000 — 32 50 ZF96N32000 —
35 ZF96S35000 ZA93S35000 35 55 ZF96N35000 ZA93N35000
38 ZF96S38000 — 38 60 ZF96N38000 —
4-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
4.6 PLUG
4.6.1 PLUG FOR BYTE TYPE TUBE FITTING
Cap nut (Joint plug)
Applicable Opposing
tube Cap nut parts No. T screw flats
O.D:A H1 H
6 ZF83H06000 M12 X 1.5 14 14
A
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
H1 T s cre w H
Applicable
tube Plug parts No.
O.D:A 4
6 ZF83P06000
8 ZF83P08000
A
10 ZF83P10000
12 ZF83P12000
15 ZF83P15000
18 ZF83P18000 S le e ve Nut
Type
22 ZF83P22000
joint body
28 ZF83P28000
Nut
Applicable
Opposing
tube Nut parts No. d screw
flats
O.D:A
6 ZF93N06000 M12 X 1.5 14
8 ZF93N08000 M14 X 1.5 17
10 ZF93N10000 M16 X 1.5 19
12 ZF93N12000 M18 X 1.5 22
A
d s cre w
15 ZF93N15000 M22 X 1.5 27
18 ZF93N18000 M26 X 1.5 32
22 ZF93N22000 M30 X 1.5 36
28 ZF93N28000 M36 X 1.5 41
32 ZF93N32000 M42 X 1.5 50
35 ZF93N35000 M45 X 1.5 55
38 ZF93N38000 M48 X 1.5 60
4-9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
PF
Plug parts No. B mm O-ring parts No. Nominal O-ring B
screw O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PT screw
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
PF3/4 2444Z2729D4 27 36
PF1 2444Z2729D5 36 41
Opposing Oppos ing
PF1 1/4 2444Z2729D6 40 50 flats F flats E
4-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
Male
Opposing
Screw Applicable O-ring Nominal
Plug parts No. flats
size A hose O.D parts No. O-ring
(HEX)
Female
Applicable Opposing
Screw size A Plug parts No.
hose O.D flats (HEX)
25.53 to
1/2 ZE12Q08000 38.10 17.48 9 45Z91D2
25.40
31.88 to
3/4 ZE12Q12000 47.63 22.23 11 ZD12P02600
31.75 C
39.75 to
1 ZE12Q16000 52.37 26.19 11 ZD12P03400
39.62
44.58 to
1 1/4 ZE12Q20000 58.72 30.18 11 ZD12P03800 D
44.45
25.53 to
1/2 ZE13Q08000 40.49 18.24 9 2445Z831D1
25.40 G
31.88 to
3/4 ZE13Q12000 50.80 23.80 11 ZD12P02600
31.75
39.75 to
1 ZE13Q16000 57.15 27.76 13 ZD12P03400
39.62
44.58 to
1 1/4 ZE13Q20000 66.68 31.75 15 ZD12P03800
44.45
4-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
70(2 .76)
16 8 PART-No. 22
15 (0.591) 2421T160 27 (0.3 15)
(0.6 30) (0.8 66)
HEX27
40(1 .57) 12.7
(0.500 )
70(2 .76)
42(1 .65)
70(2 .76)
11.5 (0.453)
HEX50
HEX55
4-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
Allen wrench
ZT22A10000 Pump
1 Nominal
suction
B:10, C:11.3
Spanner or socket
2 General tools Pump install
Nominal size:17
CUT
Com merc ia l tool oute r width (D) - cut le ngth = Re quire d le ngth
81 (3.19") - 16 (0.63") = 65 (2.56")
Additiona l M10 X 22
ta pping
4
for M10 e ye bolt
For slinging
Plug ZE72X12000
4 the swing
PF3/4
motor
PF3/4 O-ring
M12
M8 Eye bolt
Plug ZF83P22000
(Nominal size 22)
6 Reference Re fe re nce nut Flare hose
Eye bolt ZS91C00800
Nut ZF93N22000
M8 X 18
Addtiona l ta pping
4-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
M8 Eye bolt
M8 X 18
Additional
threading
Plug YN01H01001P1
Nominal 1-14UNS
7 HEX 27 Flare hose
Eye bolt ZS91C00800
1-14UNS
M8 X 18 M8 Eye bolt
Additional
threading
Plug
YN01H01002P1
Nominal 1 3/16-
8 12UN HEX 36 Flare hose
ZS91C00800
Eye bolt
1 3/16-12UN
Plug ZE25F08000
PF1/2 We ld For slinging
9
Coupling the swivel joint
half Coupling ha lf
PF 1/2
5.49
TORX driver
For instrument
(with tamper proof) Point shape
10 — panel cover
T30
(RH)
(For M6)
4-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
High
#271 1305
strength
(Manufacturer ; Loctite)
Sumitomo
Chemical Co., Cyano Bond P0-1 Swing bearing and seal
Ltd.
Shell petroleum Shell Alvania EP2 New Molyknock Grease 2 Grease bath of swing bearing
4-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
2
3
4.10.2 DIMENSION
50
(1.97")
R
(1 8 O113 (4.45")
.3
15" 2
) M8 NUT (0.08")
O8 (1.315")
600 (23.6")
+0.5
M8 O100 0
(0.787")
(3.94 +0.0197
0 )
O108
20
(4.25")
ROD COVER
4-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
M8 15 ZS91C00800 80 (176)
L
M30 45 ZS91C03000 1500 (3310) dd
4-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
6 1
175(6.89)
375 (14.8)
2
400 (15.7)
240 (9.45)
(4.72) (4.72)
750 (29.5)
120 120
375 (14.8)
175(6.89)
6 6
744 (29.3) 100
(3.94)
945 (37.2)
6 6
275 300
(10.8) (11.8)
352 (13.9)
250(9.84)
0
213(8.39)
750 (29.5)
R5 .0)
200(7.87)
t 50 (2
(2.0) t 24 (0.95)
t 24 (0.95)
5 X 1 piece
3 X 1 piece 670 (26.4)
400 (15.7) 120
(4.72)
200 (7.87) 945 (37.2)
55 145
352 (13.9)
(2.2) (5.71)
6 X 5 pieces
R5
352 (13.9)
100(3.94)
(2. 0
(3.5)
10(0.39)
90
t 24 (0.95) 0)
t 24
10(0.39)
(7.48)
(0.95)
190
t50
(2.0)
Engine stand
4-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
2 COUPLING 6 ELPG7-10
3 HOOK 1 SWL750LBS
4 CHAN 2
(3 ft
970 )
s
2 in
s
t
t
n)
(3 f 8 0
t
t 7i
10
s
(3 ft 1 in
940
)
s
s
4-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
19 (0.75")
36 +10 (1.42")
48 (1.89")
(0.94")
24
40 (1.57") 28 (1.10")
80 (3.15") 284 ( 11.2")
4-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
Retainer plate
)
.6"
(12
(27.6")
Stand
(15.0")
Hydraulic jack
Base 4
Track spring set jig
4-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[4. TOOLS]
4-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-1
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-2
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-3
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5.2 PREFACE
Working Conditions
• Workers:
More than one worker shall be 1st class service technician (having five years or more of field experience and
having received training in the operation).
• Equipment:
Jigs, tools, apparatuses and testers used in field service work shall be available commercially.
The maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for
specific self inspection activities.
• Place:
A flat land where work may be performed and to which a service car or a truck crane is accessible.
5-4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
The time required for works specified in this Chapter shows the total time for maintenance.
04 Travel system
5-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5.3.1 Attachment(01)
Group Work to be Unit:
Location Unit Remarks
No. done Hour
See Paragraph "BUCKET" in
00 Bucket related parts
Chapter "ATTACHMETNTS"
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.1
14 • Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.1
16 • Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.1
17 • Boom top pin Detach/attach 1 pc. Include wire stop pin 0.1
34 • Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.2
5-6
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
42 • Arm cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.1
5-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
129 Swivel joint O/H 1 set Removing and installing guard 3.6
5-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
Other necessary works Detach/attach 1 set Removing and installing guard 0.6
5-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
01 Track link ASSY Detach/attach One side Include adjustment of tension 1.5
5-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
61 Pipe on swivel joint travel side Detach/attach 1 pc. Include bonnet assy removing 0.6
and installing.
5-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
Light
5-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
Solenoid
SV-1 Swing parking sol. Replace 1 0.5
5-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[5. STANDARD MAINTENANCE TIME TABLE]
5-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-1
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-2
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-3
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Terminology
• Standard values; Values to be used to condition or assemble a new machine. Where special notes are not given,
these values represent standard specifications (machine with standard attachments and standard shoes).
• Reference values for remedy; Values at which readjustment is required. In order to ensure performance and
safety it is strictly prohibited to use the machine over the specified values.
• Service limit; This is the limit value at which reconditioning is impossible without replacement of parts. If the
value is expected to exceed the service limit before next inspection and correction are performed, replace the
parts immediately. The operation over the specified values causes increase of damage and requires the down
time of machine, and also causes safety problems.
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
When turning on the power, the work mode is set at the H mode (for North America) or S mode (for Europe).Unless
otherwise specified, measure the inspection items by the H mode.
C la s s
NAS 8
Cle a nline s s of hydra ulic oil Hydra ulic oil in ta nk — — — S a mpling
S ta n d a rd Me a s u rin g c o n d itio n
or le s s
Surface temperature
Hydraulic oil temperature near relief valve of 50 (12 2) + 5 (41) - 5 (23) Atmos phe ric te mp
conrol valve °C — 50°C~-10°C
Water temperature Upper tank surface of 75 (167) + 15 (59) - 15 (5) (°F) (122°F~14°F)
radiator
H mode Lo idle 1000 + 30 - 30 LOW throttle
E n g in e s p e e d
n o t re q u ire d
Ad ju s tm e n t
H mode Hi idle Me a s ure the e ngine 2000 + 30 - 30 Full throttle (HI idle )
De ce l s pe e d a t multi dis pla y on 1050 + 30 - 30 min -1
P e rform a ll
S mode Hi idle the ga uge clus te r. 1800 + 30 - 30 me a s ure me nt with the
a ir-conditione r "OFF".
Eco mode Hi idle 1800 + 30 - 30
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 P R1 HI idle
va lve p re s s u re
P1 a1
Ma in re lie f
Arm a2
H P F1/4 37.8 (5480) + 0.5 (+73) - 0.5 (-73) MP a OR7 Arm in
R 37.8 (5480) + 0.5 (+73) - 0.5 (-73) (ps i) OR2 Bucke t dump
Bucket a1
H 39.7 (5760) + 0.5 (+73) - 0.5 (-73) OR1 Bucke t digging
RH 29.0 (420 5) + 2.5 (+363) - 0.7 (-100) OR6 S wing RH
S wing a2
LH 29.0 (420 5) + 2.5 (+363) - 0.7 (-100) OR5 S wing LH
FW —
RH a1 34.3 (497 0) + 1.7 (+247) 0 S imulta ne ous
6
Tra ve l
RV —
ope ra tion of tra ve l
FW —
LH a2 34.3 (497 0) + 1.7 (+247) 0 RH a nd LH
RV —
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Sta nda rd
Ins pe ction ite m Unit
va lue
Sprocke t re volution 1s t s pe e d 26.9 to 30.1
min -1
(RH,LH) 2nd s pe e d 45.3 to 50.1
Up 2.5 to 3.1
Boom
Down 2.2 to 2.8
O p e ra tin g s p e e d
90 to 110 de gre e
bra ke 180° full s pe e d s wing
P e rforma nce of S wing
15 de gre e gra die nt 0 mm (inch)
pa rking bra ke
Tip of the bucke t tooth 96 (3.8)
7.2 (0.28) mm / 5 min
ATT a mount of drift Boom cylinde r (At no loa d)
(inch / 5min)
Arm cylinde r 5.4 (0.21)
30 to 50
Amount of horizonta l pla y a t the bucke t tooth mm (inch)
(1.18 to 1.97)
The port re lie f va lve s No.OR1~OR8 on the control s e ction a re a djus te d to the following ope ra tion numbe rs in
a dva nce .
(1) Bucke t digging, (2) Bucke t dump, (3) Boom up, (4) Boom down
(5) S wing le ft, (6) S wing right, (7) Arm in, (8) Arm out
6-6
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-7
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OFF
F
MODE HM
ATT MODE BRK
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V
6-8
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
a1
6-9
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
MACHINE
FRONT
MACHINE
FRONT
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
A3
a3
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
PB
PA
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
2 1
H E X 2 2
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-13
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
Hydraulic oil temperature:
45 to 55C degrees (113 to 131F degrees)
Crawler on the right and left sides are tensioned evenly.
Preparation
Attach the reflection panel with a magnet to the travel
motor cover. REFLECTION
PANEL
Swing the swing frame through 90C degrees as shown
in Fig. "One side lifted position" and make the crawler on
one side take off the ground, using the attachment.
Measurement
Sprocket revolution Unit 8 min -1
Engine revolution: Hi idle Standard Reference value Service
Measurement item value for remedy limit
2-speed travel switch: 1st speed and 2nd speed
RH H mode 1st speed 30.1 to 26.9 23.5 to 21.0 19.1 or less
Measuring points: Right and left &
Method, example 1: LH H mode 2nd speed 50.1 to 45.3 39.1 to 35.3 32.0 or less
Measure revolution with a stroboscope
Method, example 2:
Measure the revolutions per minute visually.
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Measuring method
Measurement
Tra ve l de via tion Unit : mm (in) / 20m (66ft)
1. Measure the max. deviation distance of the circular Measuring
Standard value
Reference value
Service limit
position for remedy
arc in the 20 m (66 ft) length, excluding the
A 240 (9.45) or less 480 (18.9) 720 (28.4)
preliminary run of 3 to 5 m (10 to 16 ft).
2. Operate the travel lever at the same time.
6-15
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
15 degree slope
Preparation
Place an angle meter on the shoe plate and confirm that
it makes an angle more than 15 degree.
Hang a perpendicular in parallel with the guide frame rib
on the track frame and put a mark (matching mark) on
the shoe plate.
C ANGLE
GUIDE FRAME METER
Method of measurement
Measurement
Parking brake Unit : mm(in)/5min
Five minutes after the engine stops, measure the Measuring
Standard value
Reference value
Service limit
position for remedy
movement distance of the matching mark.
C 0 1 (0.04) 2 (0.08) or more
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
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.
Measurement : At Travel Lock Drain rate of travel motor Unit : L(gal )/30sec
Measuring Reference value
position Standard value for remedy Service limit
Drain rate 9 (2.4) 16 (4.2) 23 (6.1) or more
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.
Perform measurement on each side at the forward rotation for three times and the average value of the results
is the measurement value.
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
Hydraulic oil temperature:
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution: Hi idle
Preparation
Make the bucket empty and extend the boom, arm and
bucket cylinders fully. (Minimum reach) Swing speed measuring position (at the min.
reach)
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
Hydraulic oil temperature:
45 to 55C degrees (113 to 131F degrees)
Firm, level ground, no load bucket
Engine revolution: Hi idle
Preparation
• Make the bucket empty, retract the arm cylinder fully ARM TOP
BOOM FOOT
and extend the bucket cylinder fully. And move the PIN
PIN
boom so that the arm top pin is positioned at same
height with the boom foot pin.
• Put a matching mark on the outer circumference of
the swing bearing of the upper frame side and of the
track frame side. Place two poles (flags) on the front
and back of the extended line of the matching mark.
Amount of deflection of
Swing drift matching marks [m (ft-in)]
angle (degrees) = Circumferential length of X 360
swing race [m (ft-in)]
degrees 6
Swing brake performance Unit : degree
Measuring Reference value
position Standard value for remedy Service limit
Swing 180 110 99 to 121 131 or more
6-19
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Put the
bucket empty, retract the arm cylinder fully and extend
the bucket cylinder fully. And move the boom so that the
arm top pin is positioned at same height with boom foot
pin.
MATCHING MARKS
ON INNER RACE
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Conditions
Hydraulic oil temperature:
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution: Hi idle
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.
Measurement : At Swing Lock
Drain rate of swing motor Unit : L(gal)/30sec
1. Start the engine and put the side faces of bucket Measuring
Standard value
Reference value
Service limit
position for remedy
against the inside of the right or left shoe plates.
Drain rate 2.1 (0.55) 5.2 (1.4) 6.2 ( 1.6 ) or more
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.
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Condition
3 0 c m (1 ft)
Hydraulic oil temperature:
45 to 55C degrees (113 to 131F degrees)
Measuring position for bucket digging and dump
Engine revolution: Hi idle
Operating time excluding the cushion stroke
Preparation C o n d itio n :
A r m c y lin d e r m o s t r e tr a c te d
Firm level ground with the bucket empty B u c k e t c y lin d e r m o s t e x te n d e d
6-22
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-23
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Condition
Firm, level ground
The swing bearing mounting bolts are not loosened.
The swing bearing is lubricated well, not making abnormal sound during turning.
Preparation
LOCATION OF BEARING
1. Install a dial indicator to the magnetic base and fix it MOUNTING BOLTS
to the lower frame.
2. Direct the upper swing body and the lower frame SWING BEARING
toward the travel direction, bring the probe of the A
dial indicator in contact with the bottom surface of
the outer race on the swing body side and set the
reading at zero. DIAL INDICATOR
3 0 c m (1 ft)
Measuring position I
ARM TOP
PIN BOOM FOOT
PIN
Measuring position II
6-24
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-25
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
C-8:
ENGINE
C-2: CONTROLLER
GAUGE CLUSTER
PUMP
PROPO RTIONAL
VALVE
S TARTER E-1:
SWITCH FUSE&REL AY BOX EMERGENCY E-27:
ACCEL
ACCEL DIAL ENGINE THROTTLE FOR
POTENTIO METER REDUNDANT MODE
INPUT / OUTPUT
6-26
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
2 4
Gauge cluster
PREPARATION
• Raise the oil temperature to about 50C degrees (122F degrees) to warm up the engine.
• Turn the air-con OFF.
• Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the adjustment data
is not entered.
A215, A225, A015, A025, A035
As the error codes other than those shown above may suggest failures of machine, repair the machine into the
ordinary operating condition according to Error Code List.
6
For machines equipped with lifting magnet, turn the generator OFF.
1. Turn starter key switch ON keeping the work mode MULTI DISPLAY
select switch on the gauge cluster pressed, and hold (EXAMPLE)
it for 5 to 10 seconds, and then release it. (If the S 12:15
6-27
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
ADJUST 0 CRANE
---
---
STEP
2040
P1 PUMP 350
P2 PUMP 350
P1 UNLOAD 750
P2 UNLOAD 750
P1 PRESSURE 250
P2 PRESSURE 11
STEP 0
pump proportional valve start working to increase ECU OUTPUT 360
P2 PUMP
390
390
P2 UNLOAD 360
PRESSURE", and the current (command value) of P1 PRESSURE 341
"P1 PUMP" and "P2 PUMP" proportional valves are P2 PRESSURE 340
displayed.
5. After detection of the engine rated speed, the
adjustment of pump is automatically completed. FINISH
PUMP
(Press the buzzer stop switch on gauge cluster
while this display is appeared and the adjustment is ENGINE 2040
STEP 0
completed. The unloading adjustment required later ECU OUTPUT 120
P2 PUMP
350
350
P1 UNLOAD 750
P2 UNLOAD 750
P1 PRESSURE 250
P2 PRESSURE 11
6-28
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
STEP 0
The "ENGINE" speed, "P1 PRESSURE" and "P2 ECU OUTPUT 360
P2 PUMP
390
390
P2 UNLOAD 360
valves are displayed. P1 PRESSURE 341
P2 PRESSURE 340
STEP 0
The speed is shifted to the speed corresponding to ECU OUTPUT 120
P2 PUMP
350
350
P2 UNLOAD 750
display of current of P1, P2 unloading proportional P1 PRESSURE 250
mA.
Stop the engine. (The adjusted data is automatically
stored.)
6-29
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
ADJUST LMN
---
---
ADJUST UNLOAD
FIN
FIN
STEP
2040
P1 PUMP 350
P2 PUMP 350
P1 UNLOAD 750
P2 UNLOAD 750
P1 PRESSURE 250
P2 PRESSURE 11
P1 PUMP 390
and "PROPO-VALVE" (acceleration command P2 PUMP 390
P2 UNLOAD 360
P1 PRESSURE 341
P2 PRESSURE 340
6-30
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
P1 UNLOAD 750
display of current of P1 and P2 unloading P2 UNLOAD 750
P2 PRESSURE 11
520 to 635 mA.
Stop the engine. (The adjusted data is automatically
stored.)
6-31
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
STEP 0
complete although the pump proportional valve ECU OUTPUT 360
P2 PUMP
390
390
P2 UNLOAD 360
33 to 38 MPa (4785 to 5510 psi). P1 PRESSURE 341
STEP 0
Normally the pump pressures of P1 and p2 pumps ECU OUTPUT 360
P2 PUMP
390
390
P2 UNLOAD 360
(It may be affected by the hydraulic oil temperature.) P1 PRESSURE 341
For machines equipped with the lifting magnet, turn the generator OFF.
6-32
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
The hydraulic emergency mode should be used in only case of emergency. Repair the failure part by
troubleshooting as early as possible.
6-33
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
When a certain amount of soot in the exhaust gas is deposited on the filter, DPF automatically burns the trapped
soot according to the operating condition. For details, see "ABOUT AUTOMATIC REGENERATION". In some
operating conditions, the automatic combustion may not be completed. At that time, the indication appears on the
gauge cluster to request the actuation of DPF manual regeneration. Pull up the pilot control shut-off lever and press
the DPF manual regeneration switch. This prevents abnormal deposit of soot and keeps the purification capacity of
DPF in good condition at all times.
LEVEL1~4 (gre e n)
LEVEL7~10 (re d)
6-34
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
on the multi-display.
Immediately after the machine operation and during the regeneration, the temperature around the exhaust pipe and
muffler and of the exhaust gas are very high. Putting any combustible materials close to these hot parts causes a
fire. Touching hot exhaust gas may cause burns.
In some operating conditions, the automatic regeneration may not be completed. When the automatic regeneration
is not performed and soot is deposited, the warning requesting the user to perform the manual regeneration is
displayed on the multi-display. In this case, perform the manual regeneration, referring "ABOUT MANUAL
REGENERATION".
The above indication may be displayed also when the deposited amount of soot is low. 6
To maintain the condition inside the muffler proper, the automatic regeneration may be performed even when the
soot deposition meter on the gauge cluster indicates Level 2 or lower.
6-35
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
When this warning is displayed on the multi-display, perform the manual regeneration of DPF immediately.
• DPF starts the automatic regeneration when a certain amount of soot is deposited, but it may not be completed
in some operating conditions.
When the automatic regeneration is not performed and soot is deposited, the above warning is displayed and the
warning sounds. In that case, perform the manual regeneration in the following procedure.
• When too much soot is deposited, DPF failure occurs and the engine speed is restricted.
• Immediately after the machine operation and during the regeneration, the temperature around the exhaust pipe
and muffler and of the exhaust gas are very high. Putting any combustible materials close to these hot parts
causes a fire. Touching hot exhaust gas may cause burns.
S
12h
2
6-36
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
None 1 to 4 Green
5 to 6 Yellow
8 to 9
Red
10
• If the soot deposition meter shows Level 3 (green) or more, push the switch to perform manual regeneration.
6
• If the soot deposition meter shows Level 5 (yellow) or more, the warning appears with sound.
• If the soot deposition meter shows Level 7 (red) or more, the additional warning, "EXHAUST GAS AFTER
TREATMENT EQUIPMENT WILL BE DAMAGED", is displayed.
• If the soot deposition meter shows Level 8 (red) or more, the engine speed is restricted.
• If the soot deposition meter shows Level 10 (red), and the "EXHAUST GAS AFTER TREATMENT EQUIPMENT
FAILURE" warning is displayed, the engine speed and the engine output are restricted. Manual generation
becomes impossible in this state even if the switch is pressed.
6-37
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Use the low-sulfur light oil (S50: Sulfur component 50 ppm or lower). In cold areas, use appropriate low-sulfur light
oil. If you use other fuel other than the specified fuel, it has an adverse effect on the engine and DPF, causing white
smoke and malfunction.
Use the recommended brand engine oil to keep the DPF function normal for a long time.
Do not remove the exhaust pipe or disassemble the muffler and parts around it. This may affect the performance of
DPF adversely or break it.
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6.12.1 SCR
SCR equipped with this machine reduces NOx in exhaust gas by injecting DEF/AdBlue into the muffler to resolve
NOx in the exhaust gas into water and nitrogen.
6.12.2 DEF/AdBlue
DEF/AdBlue is used for the SCR system on this machine. Use only specified DEF/AdBlue.
Before turning the battery power-off switch to the "O (OFF)" position or removing the battery terminals, turn the
starter switch to the OFF position and wait 5 minute or more.
If the battery power is turned off immediately after stopping the engine, it may cause damage to the exhaust gas
cleaning device.
Even after turning the engine OFF, you may hear running sound of the DEF/AdBlue supply module.
To prevent DEF/AdBlue remaining in the DEF/AdBlue pipe from freezing and drying, DEF/AdBlue is returned to the
tank with the DEF/AdBlue supply module.
6
6.12.4 STORING DEF/ADBLUE
DEF/AdBlue freezes at - 11 degrees C. The container may be damaged from volume expansion due to freezing.
• DEF/AdBlue should be stored in a place without direct sunlight and with well ventilation, with its container
sealed.
• Do not mix DEF/AdBlue with other chemicals, heat it, or dilute it with water.
6-39
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
LEVEL1 (re d)
When the level gauge of the gauge cluster showed Level 2 (yellow), Level 1 (red), or Level 0 (no display), add DEF/
AdBlue promptly until it reaches Level 3 (green) or more.
DEF/AdBlue shortage restricts the engine output.
When the following warnings are displayed in the multi-display, see "CHECKING DEF/ADBLUE LEVEL AND
REFILLING" to supply DEF/AdBlue.
Displayed with the warning sound when the DEF/AdBlue level gauge
2nd Level is Level 1 (red). Gradually, a restriction is applied to the engine
output.
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
When the following warnings are displayed on the multi-display, something other than DEF/AdBlue is in the DEF/
AdBlue tank. See "DRAINING DEF/ADBLUE" in Chapter 4 and "CHECKING DEF/ADBLUE LEVEL AND
REFILING" in Chapter 3 to drain and refill DEF/AdBlue.
When keeping the operation with DEF/AdBlue having a quality problem, the engine output is restricted.
Also, when something else than DEF/AdBlue is put in the tank and the engine is started, the DEF/AdBlue pipes and
the DEF/AdBlue supply module may need to be replaced. In that case, contact our service factory.
Displayed with the warning sound when a certain period of time has
Level 2
passed from Level 1. The engine output is gradually restricted.
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
When the level gauge of gauge cluster indicates Level 2 (Yellow), Level 1 (Red), or Level 0 (No display), refill DEF/
AdBlue immediately to Level 3 (Green) or over.
DEF/AdBlue shortage restricts the engine output and, in the end, the machine becomes inoperable.
1
2. Use the starter key to open tool box cover (2) on the
right front of the machine.
3. Turn inlet port cap (3) to open it.
When dirt is adhered on strainer (4) of the inlet port
take out strainer (4), wash it with water, dry it
completely, and then attach it to the inlet port again.
2
4. Refill DEF/AdBlue from the inlet port. Refill it until
the level reaches the line F, while checking level
gauge (5) on the right side of the tank.
Full capacity of tank: 83 L (22 Gal)
3
5. After refilling, tighten inlet port cap (3) securely and 5
close tool box cover (2).
4
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
When supplying DEF/AdBlue after draining, the quality of DEF/AdBlue is promptly judged if the starter key switch is
"ON"; however, if it is done while the switch is "OFF", it takes a while to judge its quality after turning the switch
"ON" at the next time.
When the work is done in "OFF", wait for approximately 10 minutes after turning the switch "ON", and check the
warning is not displayed on the gauge cluster.
6-43
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
When the exhaust gas cleaning device has a failure and an error repeatedly, the warning level goes up. After the
exhaust gas cleaning device had been repaired, when another failure or error occurred in a short period of time,
Level 3 warning appears.
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
• The emergency evacuation mode can be used for only total 30 minutes or up to 3 times. Use this mode only in a
case of emergency and if the warnings are displayed, take proper measures immediately.
• Keep pressing switch (1) for 5 seconds securely to enter the emergency evacuation mode. If not keeping
pressing switch (1) for 5 seconds securely, the machine will not enter the emergency evacuation mode.
6-45
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
Before replacing the DEF/AdBlue supply module filter, stop the engine and wait about 30 minutes.
1. DEF/AdBlue supply module (6) is mounted to the
upper frame on the right side of the machine. 6
A: Filter side
2. When there is a cover around the pump, remove it.
3. When replacing the filter, DEF/AdBlue may spill.
Prepare a container to catch DEF/AdBlue under
A
pump (6) and cloth to wipe off DEF/AdBlue.
6-46
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6
After the operation, make sure that DEF/AdBlue is not leaking from the area around the DEF/AdBlue supply
module, DEF/AdBlue tank, DEF/AdBlue piping and muffler.
6-47
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[6. MAINTENANCE STANDARD AND TEST PROCEDURE]
6-48
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[7. MECHATRO CONTROLLER]
7. MECHATRO CONTROLLER
7.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................7-3
7.2 FOREWORD ............................................................................................................................7-4
7.3 SUMMARY OF MECHATRO CONTROL SYSTEM......................................................................7-6
7.3.1 MECHATRO CONTROL SYSTEM IN GENERAL .....................................................................7-6
7.3.2 UNLOAD VALVE CONTROL ..................................................................................................7-8
7.3.3 POSITIVE CONTROL AND P-Q CONTROL ..........................................................................7-10
7.3.4 BOOM UP CONFLUX CONTROL .........................................................................................7-12
7.3.5 CONTROL OF ARM-IN RECIRCULATION AND CONFLUX ...................................................7-14
7.3.6 ARM-IN ANTI-CAVITATION CONTROL.................................................................................7-16
7.3.7 ARM-OUT CONFLUX CONTROL .........................................................................................7-17
7.3.8 BOOM DOWN AND ARM-OUT CONTROL............................................................................7-20
7.3.9 BUCKET DIGGING AND ANTI-CAVITATION CONTROL .......................................................7-22
7.3.10 SWING PRIORITY CONTROL ............................................................................................7-24
7.3.11 TRAVEL STRAIGHT CONTROL .........................................................................................7-26
7.3.12 PRESSURE RELEASE CONTROL .....................................................................................7-28
7.3.13 WARNING OF RETURN FILTER CLOGGING ......................................................................7-30
7.4 MECHATRO CONTROLLER ...................................................................................................7-32
7.4.1 SUMMARY OF MULTI-DISPLAY...........................................................................................7-32
7.4.2 SELF DIAGNOSIS DISPLAY FUNCTION ..............................................................................7-39
7.4.3 SERVICE DIAGNOSIS DISPLAY FUNCTION ........................................................................7-42
7.4.4 TROUBLE HISTORY DISPLAY FUNCTION...........................................................................7-52
7.4.5 CHANGE PROCEDURES OF REPLACEMENT INTERVAL....................................................7-53
7.4.6 VARIOUS ADJUSTMENT FUNCTION (USER MENU)............................................................7-55
7.4.7 VARIOUS ADJUSTMENT FUNCTION (SERVICE MENU) ......................................................7-62
7.4.8 MECHATRO CONTROL DEVICES .......................................................................................7-73
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
7-3
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[7. MECHATRO CONTROLLER]
7.2 FOREWORD
This chapter explains the control related to hydraulic to electric power conversion or vice versa as mechatro control
and explains only the summary of the mechatro system and mechatro controller related devices and functions.
Regarding the conditions before and after each conversion, refer to Chapters "HYDRAULIC SYSTEM" and
"ELECTRICAL SYSTEM".
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[7. MECHATRO CONTROLLER]
7-5
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[7. MECHATRO CONTROLLER]
LH RH LH RH
SE-9 NOTE:
SE-10 FOR NOR TH AMERICA:
WITH BHL MULTI SELECT OR VALVE
NOTE FOR EUROPE:
WITHOUT MULTI SELECT OR VALVE
GAUGE CLUSTER
LOW PRESSURE SENSOR
LCD FOR SELECITION SE-4
AND DISPLAY (4)
FUEL LEVEL METER SE-3
COOLANT TEMP.
(3)
GAUGE SE-2 L2
(2) L3
LOWER SW.
SCREEN CHANGE SW. SE-1
(1)
BUZZER STOP SW.
WORK MODE SELECT SE-8
S W. (H, S, AND ECO) (8)
WASHER SW. SE-7
(7)
WIPER SW. L4
OUTPUT VOLTAGE
ENGINE
THROTTLE
SE-16
SE-23
PROP. VOLTAGE
HIGH PRESSURE
SENSOR SE-22
L5
C-1
MECHATRO CONTROLLER A1 A2 A3
ENGINE
INJECT OR SPEED SENSOR
SE-13
PSV-P1
SE-21
P1 PUMP PROPOR TIONAL VALVE
: HIGH PRESSURE SENSOR
(P1, P2, BOOM HEAD, AND BOOM ROD) PSV-P2
P2 PUMP PROPOR TIONAL VALVE
: INJECT OR
CAN COMMUNICATION
: E/G SPEED SENSOR C-8
ENGINE CONTROLLER L6
ENGINE SPEED
: LOW PRESSURE SENSOR COMMAND CURRENT
(ATT: 6 PCS., SWING: 2PCS. AND TRAVEL: 2 PCS.) VOLTAGE OF 24V
PROP . COMMAND CURRENT L7
: ENGINE THROTTLE POTENTIOMETER E-27
ENGINE THROTTLE FOR REDUNDANT MODE
7-6
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[7. MECHATRO CONTROLLER]
P1 UNLOAD
CONFLUX
BOOM 2
BOOM UP
BOOM METER IN CUT
PL1(POWER BOOST)
ARM-IN SPEED 2
ARM-IN SPEED 1
TRAVEL RIGHT
TRAVEL LEFT
BUCKET
P2 UNLOAD
STRAIGHT
BOOM 3
SWING
BOOM
TRAVEL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM-IN
L2
L3
L4
2-SPEED SELECTION OF
TRAVEL MOTOR
TRAVEL 2-SPEED SELECTION
BOOM CYLINDER
BOOM UP CONFLUX
SWING PARKING BRAKE
SE-24
BOOM METER IN CUT
L5
TRAVEL STRAIGHT
ARM-IN SPEED 2
POWER BOOST
LEVER LOCK
P2 UNLOAD
P1 UNLOAD
BOOM 2
BOOM 3
SE-25
ARM CYLINDER
ARM-OUT CONFLUX
ARM-IN CONFLUX RECIRCULATION
7
PSV PSV PSV PSV PSV S V PSV S V SV SV SV
-A -23 -24 -B -C -1 -D -4 -105 -3 -2
(7)
L6 ARM-IN BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
SE-60
CLOGGING SENSOR
SOLENOID OPERA TED DIRECTIONAL
CONTROL VALVE AND PROP. SOLENOID VALVE ) BLOCK
7-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 2 SPEED
ARM 1 SPEED
BUCKET
SWING
BOOM
STRAIGHT
TRAVEL
P2 P1
BOOM CYLINDER
PILOT PILOT
(LEFT) (RIGHT) OPTIONAL VALVE VALVE
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1 | 4 SE-40,41,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
MECHATRO pi :
PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
OF PROPORTIONAL VALVE
1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in each low
pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to each unload proportional valve according to the
input voltage.
3. Each unload proportional valve outputs the pilot secondary pressure according to the command output by the
mechatro controller and switches each unload spool.
4. With this operation, the bleed opening is obtained according to the lever displacement, and the pump pressure
which actuates each actuator is delivered, so that each actuator starts working.
7-8
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[7. MECHATRO CONTROLLER]
7-9
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
BUCKET
BOOM
SWING
STRAIGHT
TRAVEL
BOOM 3
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
BOOM CYLINDER
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1 | 4 SE-40,41,7,8
pi
PILOT SIGNAL
PROCESS COMMAND TO P2 PUMP
P2 PUMP PROP. PROP. VALVE
VALVE PSV-P2
pi
pi
COMMAND TO P1 PUMP
P1 PUMP PROP. PROP. VALVE
PILOT SIGNAL VALVE PSV-P1
PROCESS pi :
MECHATRO SECONDARY PRESSURE
PILOT SECONDARY PRESSURE
CONTROLLER OF PROPORTIONAL VALVE
Positive control
1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in each low
pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs command values to each pump proportional valve according to the input
voltage.
3. Each pump proportional valve outputs the pilot secondary pressure according to the command value output by
the mechatro controller and changes the swash plate angle of each pump to control the delivery rate.
7-10
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[7. MECHATRO CONTROLLER]
4. With this operation, the delivery rate is supplied to the actuator according to the lever displacement, and the
working speed changes according to the lever displacement.
P−Q control
1. The output voltage of the high pressure sensor at each pump line is input to the mechatro controller and the
mechatro controller processes pilot signals and calculates the command value according to the input voltage
(load pressure).
2. A lower value between the command value calculated by positive control and command value (1) calculated by
P-Q control (calculated value in 1.) is selected and is output to each pump proportional valve as the command
value.
3. Each pump proportional valve outputs the pilot secondary pressure according to the command value output by
the mechatro controller and changes the swash plate angle of each pump to control the delivery rate of
pressure oil.
4. With this operation, the actuator load becomes high and even when the pump load becomes high, the machine
can keep working without engine stall.
POSITIVE CONTROL P-Q CONTROL
7-11
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
BUCKET
SWING
BOOM
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
BOOM CYLINDER
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
1. On starting boom up operation, the pilot pressure or boom up operation switches the boom spool and the boom
up conflux spool and is input to the low pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves and the
P1 and P2 unload proportional valves according to the input voltage.
3. Each proportional valve outputs the pilot secondary pressure of the proportional valve according to the
command value output by the mechatro controller and changes the P1 and P2 pump delivery rates and
switches the P1 and P2 unload valves.
7-12
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[7. MECHATRO CONTROLLER]
4. The boom main spool and the boom up conflux spool are switched by the original hydraulic pressure
command, and also the P1 and P2 pumps and the P1 and P2 unload valves are switched by the command of
the mechatro controller, and the delivery oil of the P1 pump joins the delivery oil of the P2 pump during boom
up operation.
7-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
BUCKET
BOOM
SWING
STRAIGHT
BOOM 3
TRAVEL
PILOT
VALVE
P2 P1
BOOM CYLINDER
LOW
PRESSURE LOW PRESSURE
SENSOR SENSOR
SE-1 | 4,40,41 SE-7
CONTROL PROCESS
OF 2-SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
P1 PUMP
PROP. VALVE
PSV-P1
P1 UNLOAD
PROP. VALVE
pi PSV-D
pi
CONTROL PROCESS ARM-IN SPEED 2
OF ARM-IN SPEED 2 INVERSE PROP.
INVERSE PROP. VALVE PSV-A
VALVE
PILOT SECONDARY
PRESSURE OF ARM
7-14
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[7. MECHATRO CONTROLLER]
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves, the P1
and P2 unload proportional valves, and the arm-in speed 2 inverse proportional valve according to the input
voltage.
In case of combined operation, the pilot pressure of other than arm-in operation is input to the low pressure
sensor and the output voltage is input to the mechatro controller. And the mechatro controller processes the
pilot signals according to the combined operation and outputs the command values to the P1 pump
proportional valve, the P1 unload proportional valve, and the arm-in speed 2 inverse proportional valve,
differently from arm-in independent operation.
3. The primary pressure of the arm-in speed 2 inverse proportional valve is the pilot secondary pressure of arm-in
operation and the arm 2 spool is switched by the secondary pressure of the proportional valve according to the
command value. (The arm 2 spool controls recirculation rate and conflux rate.)
The other proportional valves output the secondary pressure of the proportional valve according to the
command value of the mechatro controller, change the delivery rate of the P1 and P2 pumps, and switch the
P1 and P2 unload spools.
4. The arm speed 1 spool is switched by the original hydraulic pressure command, and the P1 and P2 pumps, the
P1 and P2 unload spools, and the arm speed 2 spool are switched by the command of the mechatro controller
to recirculate the return oil from the arm cylinder rod side and mix it with the delivery oil from the P1 and P2
pumps during arm operation.
Recirculation cut
The voltage output value from the high pressure sensor at the P2 side is input to the mechatro controller, and when
load becomes high during arm-in operation, the mechatro controller processes the pilot signals according to the
pressure detected by the high pressure sensor and outputs the command value to the arm-in speed 2 inverse
proportional valve to command recirculation cut on the arm-in speed 2 function.
The arm-in speed 2 inverse proportional valve outputs the pilot secondary pressure according to the command
value of the mechatro controller and switches the arm 2 spool to the recirculation cut position to block the
recirculation passage.
7-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
BUCKET
BOOM
SWING
TRAVEL
PILOT
VALVE
P2 P1
BOOM CYLINDER
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
pi :
ENGINE SPEED (COMMAND VALUE) MECHATRO
SECONDARY PRESSURE
CONTROLLER
OF PROPORTIONAL VALVE
1. On starting arm-in operation, the pilot secondary pressure of arm-in operation switches the arm speed 1 spool
and is input to the low pressure sensor.
2. The engine speed command output by the engine throttle potentiometer is input to the mechatro controller.
3. The output voltage of the low pressure sensor is input to the mechatro controller, and the mechatro controller
processes the pilot signals and outputs the command value to the P2 pump proportional valve and the P2
unload proportional valve according to the input voltage.
4. And also the mechatro controller outputs the command value to the arm-in speed 2 inverse proportional valve
according to the input voltage from the engine throttle potentiometer.
5. Each proportional valve outputs the pilot secondary pressure according to the command value of the mechatro
controller, and spool stroke of the arm-in speed 2 inverse proportional valve is controlled according to the
engine speed. By changing the recirculation rate, cavitation can be prevented even when a pump delivery rate
is low due to a low engine speed.
7-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 2 SPEED
ARM 1 SPEED
BUCKET
BOOM
SWING
STRAIGHT
BOOM 3
TRAVEL
PILOT
P2 P1
VALVE
BOOM CYLINDER
LOW PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
7-17
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[7. MECHATRO CONTROLLER]
4. The arm speed 1 and 2 spools are switched by the original hydraulic pressure command, and also the P1 and
P2 pumps and the P1 and P2 unload valves are switched by the command of the mechatro controller, and the
delivery oil of the P1 pump joins the delivery oil of the P2 pump during arm-out operation.
7-18
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[7. MECHATRO CONTROLLER]
7-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
TRAVEL LEFT
ARM 1 SPEED
BUCKET
BOOM
SWING
TRAVEL
P2 P1
BOOM CYLINDER
LOW
PRESSURE
SENSOR LOW PRESSURE
SE-4
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1
pi
BOOM 2 PSV-23
BOOM DOWN AND
ARM-OUT PROCESS
BOOM 3 PSV-24
7-20
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[7. MECHATRO CONTROLLER]
1. When arm-out operation is performed during boom down operation (or boom down operation is performed
during arm-out operation), the pilot secondary pressure of the boom down operation switches the boom spool
and is input to the low pressure sensor and also that of arm-out operation switches the arm spool and is input
to the low pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves, the P1
and P2 unload proportional valves, the boom 2 and 3 proportional valves, and the boom meter in cut solenoid
valve according to the input voltage.
3. Each proportional valve outputs the pilot secondary pressure according to the command value output by the
mechatro controller and changes the P1 and P2 pump flow rates and switches the P1 and P2 unload spools,
the boom 2 and 3 spools, and the meter in cut valve.
4. The boom spool, and the arm speed 1 and 2 spools are switched by the original hydraulic pressure command,
and also the P1 and P2 unload spools, the boom 2 and 3 spools, and the boom meter in cut valve are switched
by the command of the mechatro controller. With this operation, the return oil from the boom head can be
supplied to the arm-out side.
7-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
BUCKET
SWING
BOOM
BOOM METER IN CUT
STRAIGHT
P2 UNLOAD
BOOM 3
TRAVEL
PILOT
VALVE P2 P1
BOOM CYLINDER
LOW
PRESSURE
SENSOR
SE-1(2) pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
pi :
MECHATRO SECONDARY PRESSURE
P1 PUMP PRESSURE CONTROLLER OF PROPORTIONAL VALVE
1. On starting bucket digging operation, the pilot pressure of bucket digging operation switches the bucket spool
and is input to the low pressure sensor.
7-22
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[7. MECHATRO CONTROLLER]
2. The engine speed command output by the engine throttle potentiometer is input to the mechatro controller.
3. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves, the P1
and P2 unload proportional valves, and the travel straight proportional valve according to the input voltage.
4. Each proportional valve outputs the pilot secondary pressure of the proportional valve according to the
command value output by the mechatro controller and changes the P1 and P2 pump delivery rates and
switches the P1 and P2 unload valves and the travel straight valve in the control valve.
5. The tandem passage at the P1 side communicates with the P2 port due to the switched travel straight valve
and the P1 pump delivery oil and P2 pump delivery oil join together because of the switched P2 unload valve.
6. The power boost solenoid valve turns the solenoid valve on according to the engine speed, outputs the
secondary pressure, actuates the stroke limiter, and limits stroke of the bucket spool.
By limiting the spool stroke, cavitation can be prevented even when a pump delivery rate is low due to a low
engine speed.
7. When the P1 pump pressure is increased due to cylinder stroke end, etc., the solenoid valve turns OFF
according to the pump pressure, and when the pump pressure is high, the power boost solenoid valve does not
limit stroke of the bucket spool.
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
PILOT
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
VALVE
BUCKET
SWING
BOOM
BOOM METER IN CUT
STRAIGHT
P2 UNLOAD
BOOM 3
TRAVEL
P2 P1
LOW
PRESSURE BOOM CYLINDER
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
P1 PUMP
PILOT SECONDARY PRESSURE OF ARM-IN PROP. VALVE
pi PSV-P1
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
P1 UNLOAD
PROP. VALVE
PILOT SECONDARY PRESSURE OF ARM-IN PSV-D
pi
COMMAND TO TRAVEL TRAVEL STRAIGHT
STRAIGHT PROP. PROP. VALVE
VALVE PSV-C
pi :
PILOT SECONDARY PRESSURE OF SWING MECHATRO SECONDARY PRESSURE
CONTROLLER OF PROPORTIONAL VALVE
1. When swing operation is performed during arm-in operation (or arm-in operation is performed during swing
operation), the pilot secondary pressure of arm operation switches the arm spool and is input to the low
pressure sensor and also the pilot secondary pressure of swing operation switches the swing spool and is
input to the low pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves, the P1
and P2 unload proportional valves, the travel straight proportional valve, and the arm-in speed 2 inverse
proportional valve according to the input voltage.
3. Each proportional valve outputs the pilot secondary pressure according to the command value output by the
mechatro controller and changes the P1 and P2 pump delivery rates and switches the P1 and P2 unload
spools, the travel straight spool, and the arm speed 2 spool.
4. The arm speed 1 spool and the swing spool are switched by the original hydraulic pressure command, and the
P1 and P2 unload spools, the travel straight spool, and the arm speed 2 spool are switched by the command of
the mechatro controller to supply the flow rates of two pumps to the arm cylinder head side and recirculate the
return oil from the arm cylinder rod side to the arm cylinder head side.
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[7. MECHATRO CONTROLLER]
5. The return oil from the arm rod side is recirculated and it makes the working pressure increase and the pump
delivery rate be used for swing operation preferentially. The arm is operated by the recirculated oil and
because of this, the operation at a speed decreased by a minimum range becomes possible.
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
BUCKET
SWING
BOOM
OPTIONAL
PILOT VALVE
TRAVEL
(LEFT) (RIGHT)
BOOM
CYLINDER P2 P1
PILOT VALVE
FOR TRAVEL
PILOT PILOT
VALVE VALVE
SE-11 LOW
SE-10 SE-9 PRESSURE
SENSOR
S E-1~4,
7,8,40,41
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROP. VALVE
PSV-C
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
BUCKET
SWING
BOOM
BOOM METER IN CUT
STRAIGHT
P2 UNLOAD
PILOT
BOOM 3
TRAVEL
VALVE
GAUGE CLUSTER
P2 P1
SE-23 SE-22
BOOM
CYLINDER ENGINE
PRESSURE
RELEASE ENGINE SPEED
CONTROL CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROP. VALVE
PSV-D
MECHATRO pi : SECONDARY PRESSURE
CONTROLLER OF PROPORTIONAL VALVE
1. Change the mechatro controller to the pressure release mode by operating switches on the gauge cluster.
For details of mode switching method, refer to "How to switch to 'Pressure release mode'" in Chapter
"HYDRAULIC SYSTEM".
2. Once the mechatro controller judges the operation as pressure release control, regardless of each input signal
(operation pilot and engine throttle potentiometer, etc.), the mechatro controller;
1) Outputs the command value of the minimum swash plate angle to the P1 and P2 pump proportional valves
and fixes the swash plate angle of the P1 and P2 pumps at the minimum.
2) Outputs the command value of pressure release to the ECU and fixes the engine speed to a pressure
release control speed.
3) Outputs the maximum command value to the P1 and P2 unload proportional valves and each pilot
secondary pressure fixes the P1 and P2 unload valves at the maximum opening.
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[7. MECHATRO CONTROLLER]
3. The mechatro controller senses the output voltage from the high pressure sensor of the main pump, judges the
pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on the gauge cluster.
4. By operating each control lever and switching spools with the unload valve opened, each pump delivery oil is
unloaded to the tank passage enabling the remained pressure (trapped pressure) of each actuator to be
released.
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[7. MECHATRO CONTROLLER]
SUCTION
CHAMBER SIDE
M4 NUT
TIGHTENING TORQUE:
0.49 N .m (0.36 lbf .ft) OR LESS
HYD. OIL TEMP.SENSOR(SE-21)
WARNING DISPLAY
(0.64 inch)
16.2
COM NC
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[7. MECHATRO CONTROLLER]
Pressure sensor
• This is a normal close, voltage detection type sensor.
• At 0 MPa (0 psi), it turns OFF (close), and at 0.1 MPa (14.5 psi) or more, it turns ON (open).
Detection mode
During normal operation, even when the pressure sensor turns ON, it does not affect detection.
When the operation under the condition that the oil temperature is 30 degrees C (86 degrees F) or more and the
engine speed is 1600 min–1 or more is performed for total 60 seconds or more, the pump flow rate increases to the
maximum automatically for approximately 3 seconds while each control lever, pedal, and switch are at the neutral
position to detect ON/OFF of the pressure sensor.
Count
When the pressure switch turns ON during the detection mode, if the starter switch is turned off with that condition,
ON is counted as 1 time. If ON is counted for three times continuously, the return filter is judged as being clogged.
But, even if ON of the pressure sensor is detected during the detection mode, if OFF is detected at the next
detection mode during a continuous operation, ON of the previous time can be cancelled. In other words, ON just
before turning off the starter switch is only applied for count.
Warning display
When the return filter is judged as being clogged due to the third count at the time of starter switch OFF, "CHANGE
HYD. OIL FLTR" appears on the gauge cluster at the time of the next starter switch ON.
Furthermore, the warning display for filter replacement appears not only when clogging occurs but also when the
remaining time for maintenance set from the gauge cluster becomes zero.
Canceling warning
When the return filter is clogged or the replacement interval of the return filter has been reached, replace the filter.
At that time, the warning can be cancelled by either of the following method.
1. Reset the maintenance interval of the return filter from the gauge cluster. (Default value: 1,000 hours)
2. Set the machine in the detection mode to make the pressure sensor OFF, and then turn the starter switch off.
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[7. MECHATRO CONTROLLER]
7.4.1.1 CONTROLS
5 12
11
3 2
1
6 13
7 14
8
10
4
9
DETAILA
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[7. MECHATRO CONTROLLER]
(10)Menu switch 10
6
11 30
MIN
25 20 15 10 5 0
0
(12)Nibbler switch
(13)Breaker switch 8 7
5 13
(14)Up arrow switch 4 16
(15)Down arrow switch 10
(16)Right arrow switch
(17)Left arrow switch
17 3 14 15 12
(18)Multi-display (LCD)
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[7. MECHATRO CONTROLLER]
The work mode after engine start always starts from the "H" mode.
S
K
S: S mode The "S mode" is suitable for a standard digging work and loading
(for standard digging operations. It provides good fuel consumption and is well-balanced
work) with a workload.
E
K
E: ECO mode
(for digging work with The "ECO mode" focuses on a low fuel consumption operation.
low fuel consumption)
H
K
H: H mode
The "H mode" is suitable for a heavy duty digging work with high
(for heavy duty digging
speed, which gives priority to a workload.
work)
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[7. MECHATRO CONTROLLER]
"breaker".
Before operation, always check that the attachment
mode is appropriately set.
When digging switch (1) is pressed, the attachment
mode is switched to the digging mode, and the icon of
the selected digging mode is displayed.
When nibbler switch (2) is pressed, the attachment mode 2
is switched to the nibbler mode, and the icon of the
selected nibbler mode is displayed.
When breaker switch (3) is pressed, the attachment
mode is switched to the breaker mode, and the icon of
the selected breaker mode is displayed. 3
(1)Digging switch 1
(2)Nibbler switch
(3)Breaker switch
S
K
S
K
S
K
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[7. MECHATRO CONTROLLER]
After turning the starter switch "ON" or starting the S INTERVAL REMAINDER
EXCHANGE
DAY
engine, press "menu switch" (8) to enter user menu K
USER MENU ENGINE OIL 500Hr 500Hr 14/12/12
K
screen (b). Move the cursor to "MAINTENANCE" and MAINTENANCE FUEL FILTER 500Hr -100Hr 14/12/12
interval of the engine oil, fuel filter, hydraulic oil filter, and
EXCHANGE
hydraulic oil, the remaining time until the next ENGINE OIL
INTERVAL REMAINDER
500Hr 500Hr
DAY
14/12/12
replacement interval, and the date of the previous BACK
HOME
UP
DOWN
NEXT
FUEL FILTER 500Hr -100Hr 14/12/12
EXCHANGE EXCHANGE
INTERVAL REMAINDER INTERVAL REMAINDER
DAY DAY
ENGINE OIL 500Hr 500Hr 14/12/12 ENGINE OIL 500Hr 500Hr 14/12/12
FUEL FILTER 500Hr -100Hr 14/12/12 FUEL FILTER 500Hr -100Hr 14/12/12
HYD. FILTER 1000Hr 500Hr 14/12/12 HYD. FILTER 1000Hr 500Hr 14/12/12
HYD. OIL 3000Hr 3000Hr 14/12/12 HYD. OIL 3000Hr 3000Hr 14/12/12
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
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[7. MECHATRO CONTROLLER]
(1)Clock display
(2)Self diagnosis display 1
4
(3)Warning display S
K
(4)Machine condition display
2,3
DATA
CP U COMMUNICATION CLOGGED AIR FLTR
W008
WARM AUTO WARMING UP
ERROR
SWING BRAKE
ENGINE ST OP CHANGE ENG OIL
DISENGAGED W001
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[7. MECHATRO CONTROLLER]
DEF/ADBLUE INJECTION
EGR VALVE FAILURE
FAILURE
POWER LIMITATION IN POWER LIMITATION IN
PROGRESS PROGRESS
Error codes are stored as trouble history, and displayed on the multi-display by the trouble history display function.
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[7. MECHATRO CONTROLLER]
CONTROL
Pressure sensor, Engine controller CAN COMMUNICATION
INPUT Proportional valve, Battery relay Gauge cluster
Selector valve (SOL) (Buzzer sound)
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[7. MECHATRO CONTROLLER]
S e e following pa rt.
Arm variable Swing flasher
Offset left recirculation right relay
Swing flasher
Offset right Fan drive left relay
Travel rear Travel alarm
right Bypass valve relay
P1 side
option Spare 1 AIS relay 2
P2 side Boom Engine stop
option recirculation relay
Lever lock
Dozer up Boom M/O relay
Dozer down
Travel rear
left
Adjustment CAN
data sector 1 communication Safety relay
Adjustment CAN
data sector 2 communication
Hour meter
sector 1
Hour meter
sector 2
Proportional valve
adjustment data
Cluster
communication
Expansion
controller
communication
Last 1
digit
Larger than Larger than
normal range normal range Abnormal
S e e Cha pte r "ENGINE".
Transistor
S e e following pa rt.
OFF failure
/GND short GND short CAN error
Abnormal Abnormal Transistor Transistor
output output ON failure ON failure Overrun
Transistor
ON failure
Disconnection Disconnection Disconnection Disconnection /disconnection Disconnection Disconnection Time out
Contact point
Power short Power short Power short adhesion due Power short
circuit circuit circuit to melting circuit
Failure value
*H11 Temperature sensor for clogging of hydraulic oil
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
2. After the logo mark appears, the screen enters service diagnosis mode. The service diagnosis screen "Mode
No.1", and "Screen No.1" are displayed first. The service diagnosis is classified into two modes, 1, and 2, and
the present mode is displayed on "Screen No.1".
The screen numbers on the screen differ according to each mode. The screen numbers displayed at each
mode are as follows.
• Mode No.1 : Screen No.1 to No.22
• Mode No.2 : Screen No.1, and screen No.23 to No.34
3. Then, the screen changes each time each switch is pressed.
Up arrow switch
Screen changes to the next number.
(No.2→No.3→No.4→...)
4. Turn the key switch "OFF" and the display of service diagnosis mode is closed.
To switch the service diagnosis mode to No. 3, turn the swing parking brake release switch ON for 1 second or
more with the service diagnosis screen NO.1 displayed and then turn OFF that switch.
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[7. MECHATRO CONTROLLER]
2 NO.2 ENG
7 NO.6 SENSOR PROPO-V
HOUR METER 35.3h HOUR METER 35.3h
G-3 SPEED SET 2205 No load set speed C-1 P1 PUMP
MEAS.1 2201 Actual speed 1 3.5V 2.6M Sensor voltage/pressure converted value
MEAS.2 2201 Actual speed 2 (engine controller) C-2 P2 PUMP
G-5 ENG PRS LIVE Engine oil pressure 3.5V 2.6M Sensor voltage/pressure converted value
W ATER TEMP 100¥¥ OFF Coolant temperature sensor E-1 P1 PUMP
MODE H Work mode COMP . 600mA 4.5M Command value/pressure converted value
ATT MODE BRK Attachment mode MEAS. 600mA 4.5M Measured value/pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage POWER SHIFT 100mA Amount of horse power reduction
POS. 100% Volta ge % dis pla y FLOW RA TE 100L P1 pump flow rate
ECU OUTPUT 0.5V Acceleration output voltage to engine controller E-2 P2 PUMP
FIN. ACCEL POS. 100% Final acceleration openin COMP . 600mA 4.5M Command value/pressure converted valu e
CAN COMMAND ENG SPEED Final target speed MEAS. 600mA 4.5M Measured value/pressure converted value
2500 POWER SHIFT 100mA Amount of horse power reduction
ACCEL SENSOR 1 VOL. 5.0V Acceleration voltage FLOW RA TE 100L P2 pump flow rate
COMP . FUEL CONS. Final injection quantity
500mm /VV W .cyl.
3
COMP . FUEL CONS. Final injection quantity
H-10 HYD. OIL TEMP 100 ¥ Hydraulic oil temperature 500mm 3 /VV W .cyl.
PERCENT TORQUE 100% Percent torque
ENG SPEED 2350 Input speed from ECU
BOOST PRESS. 400 Intake air pressure
ENG RAIL PRESS. 200.0M Common rail pressure
EGR V ALVE P OS . 100.0% EGR valve actual opening
SCV CURRENT 900mA SCV drive current
VNT POS. 100.0% VNT opening
EXHAUST TEMP 100 ¥ Exhaust gas temperature
TURB SPEED 50000 Turbo s pe e d
INTAKE AIR 500k J /h Intake air amount
100 ¥ Intake air temperature
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[7. MECHATRO CONTROLLER]
7-44
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[7. MECHATRO CONTROLLER]
20
NO.19 WIPER SYSTEM
HOUR METER 35.3h
WIPER SW OFF Wiper switch
RISEUP SW OFF Wiper rise-up switch
REVERSE SW OFF Wiper reverse rotation switch
PREVENT ARC OFF Wiper motor ark prevention relay
CW MOT OR RLY OFF Wiper normal rotation relay
CCW MOT OR RLY OFF Wiper reverse rotation relay
WASHER SW OFF Wa s he r s witch
MOTOR RELAY OFF Wa s he r motor re la y
22 NO.21 IT SYSTEM
HOUR METER 35.3h
COMMUNICATION MC-IT OFF Communication status between controller of
machine operation management system
COM ANTENNA ON Communication antenna status
NETWORK CONNECTION --- Network connection status
RADIO WAVE INTENS ITY 0 Communication radio field intensity
GPS ANTENNA ON Connection status of GPS antenna
GPS CONDITION OFF Positioning condition of GPS
SIM CONDITION ON SIM card condition
COM PERMISSION OFF Communication permission status
AUTHENTICATION OFF Initial authentication status
REMOVAL DETECTION OFF Removal condition
LOCK CONDITION 0 Lock condition
INTERNAL ERROR 0 IT controlle r dia gnos is informa tion
IT VERS ION 0 Version number of IT controller software
S ATELLITE CONNECTION OFF Communication satellite connection status
7-45
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[7. MECHATRO CONTROLLER]
26 29
NO.25 BUCKET NO.28 ENG S TART CHECK
HOUR METER 35.3h HOUR METER 35.3h
C-1 P1-PRES 13.9M Pump pressure sensor WATER TEMP 100 ¥ Coolant temperature
C-2 P2-PRES 13.9M Pump pressure sensor OIL TEMP 100 ¥ Hydraulic oil temperature
E-1 P1-PSV 600mA Command value E-1 P1 PUMP P1 pump proportional valve
E-2 P2-PSV 600mA Command value COMP . 700mA 25.0M Command value/pressure converted value
D-1 P1-UL(BPC) 600mA Command value MEAS. 700mA 25.0M Measured value/pressure converted value
D-2 P2-UL(BPC) 600mA Command value E-2 P2 PUMP P2 pump proportional valve
D-3 S-TRA VEL 600mA Command value COMP . 700mA 25.0M Command value/pressure converted value
B-5 BUCKET DIG 1.9M Bucket digging pressure sensor MEAS. 700mA 25.0M Measured value/pressure converted value
B-6 BUCKET DUMP 1.9M Bucket dump pressure sensor ECU OUTPUT 4.8V Acceleration voltage to ECU
G-3 ENG SPEED 2205 Engine speed ENG SPEED 2350 Input speed from ECU
POWER SHIFT 100mA Horse power reduction current COMP. FUEL CONS. Final injection quantity
500mm 3 /st .cyl.
ENG RAIL PRESS 200.0M Actual common rail pressure
FIN. ACCEL POS. 100% Final acceleration opening
BAROMETRIC P . --- Atmospheric pressure
S TARTER S W --- Starter switch of ECU side
KEY SWITCH ECU --- Key switch of ECU side
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
Operation No.5 :
Boom down in full lever operation & in operation
H mode Hi idle
No.23 BOOM
C-1 P1-PRES 12.5 to 16.0 M
C-2 P2-PRES 0.2 to 1.5 M
E-1 P1-PSV 600 to 617 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427 to 477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970 to 2030 mA
POWER SHIFT
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
4. The trouble history data (one or many) and the hour DOWN
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[7. MECHATRO CONTROLLER]
• When the remaining time to engine oil replacement becomes 20 hrs. or less, the display for forecasting
replacement appears on the multi-display and after that, when 500 hrs. has been reached, the warning appears
but the buzzer does not sound.
• When the remaining time to fuel filter replacement becomes 20 hrs. or less, the display for forecasting
replacement appears on the multi-display and after that, when 500 hrs. has been reached, the warning appears
but the buzzer does not sound.
• When the remaining time to hydraulic oil filter replacement becomes 20 hrs. or less, the display for forecasting
replacement appears on the multi-display and after that, when 1000 hrs. has been reached, the warning appears
but the buzzer does not sound.
• When the remaining time to hydraulic oil replacement becomes 20 hrs. or less, the display for forecasting
replacement appears on the multi-display and after that, when 5000 hrs. has been reached, the warning appears
but the buzzer does not sound.
7-53
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[7. MECHATRO CONTROLLER]
EXCHANGE EXCHANGE
S INTERVAL REMAINDER DAY INTERVAL REMAINDER DAY
12h
USER MENU ENGINE OIL 500Hr 500Hr 08/12/12 ENGINE OIL 500Hr 500Hr 08/12/12
MAINTENANCE
FUEL FILTER 500Hr -100Hr 08/12/12 FUEL FILTER 500Hr -100Hr 08/12/12
SWITCH ST ATUS HYD. FILTER 1000Hr 1000Hr 08/12/12 HYD. FILTER 1000Hr 1000Hr 08/12/12
OPTION SETTING HYD. OIL 5000Hr 5000Hr 08/12/12 HYD. OIL 5000Hr 5000Hr 08/12/12
CONSUMPTION
SCREEN SETTING
CLOCK SETTING
EXCHANGE
INTERVAL REMAINDER DAY
EXCHANGE EXCHANGE
INTERVAL REMAINDER DAY INTERVAL REMAINDER DAY
ENGINE OIL 500Hr 500Hr 08/12/12 ENGINE OIL 500Hr 500Hr 08/12/12
FUEL FILTER 500Hr -100Hr 09/01/12 FUEL FILTER 500Hr 500Hr 09/01/12
HYD. FILTER 1000Hr 500Hr 08/12/12 HYD. FILTER 1000Hr 1000Hr 08/12/12
HYD. OIL 5000Hr 3000Hr 08/12/12 HYD. OIL 5000Hr 5000Hr 08/12/12
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the up or down arrow switch, move the cursor to "MAINTENANCE". Press the right arrow switch to enter
the maintenance information setting.
3. Using the up or down arrow switch, move the cursor to one of the items from "ENGINE OIL", "FUEL FILTER",
"HYD.FILTER" or "HYD.OIL".
4. Press the right arrow switch. The background color of "REMAINDER" turns blue.
5. Press "menu switch" (8) to reset the remaining time.
To set "REMAINDER" to a desired value, press the up or down arrow switch to set the desired value between
the recommended replacement time and zero.
At this time, "EXCHANGE DAY" is updated.
6. Press the right arrow switch to store the value.
At this time, "REMAINDER" turns black.
7. Press "screen change switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU CLOCK CLOCK
SETTING SETTING
MAINTENANCE MAINTENANCE YEAR 10 YEAR 10
SWITCH ST ATUS SWITCH ST ATUS MONTH 01 MONTH 01
OPTION SETTING OPTION SETTING DATE 01 DATE 01
CONSUMPTION CONSUMPTION HOUR 13 HOUR 13
SCREEN SETTING SCREEN SETTING MINUTE 25 MINUTE 25
CLOCK SETTING CLOCK SETTING
CLOCK CLOCK
SETTING SETTING
YEAR 11 YEAR 11
MONTH 01 MONTH 01
DATE 01 DATE 01
HOUR 13 HOUR 13
MINUTE 25 MINUTE 25
(g) (f)
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the up or down arrow switch, move the cursor to "CLOCK SETTING". Press the right arrow switch to
enter "CLOCK SETTING".
3. Using the up or down arrow switch, select any of "YEAR/MONTH/DAY/HOUR/MINUTE".
4. Press the right arrow switch to enter screen (e). The background color of the value turns blue. 7
5. Using the up or down arrow switch, select a desired value.
6. Press menu switch (8) to set the desired value.
At this time, the background color of "value" turns black.
7. Press "screen change switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU SCREEN SCREEN
SETTING SETTING
MAINTENANCE MAINTENANCE CONTRAST 5 CONTRAST 5
SWITCH ST ATUS SWITCH ST ATUS Brightness(day) 100 Brightness(day) 100
OPTION SETTING OPTION SETTING Brightness(night) 50 Brightness(night) 50
CONSUMPTION CONSUMPTION
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING
SCREEN SCREEN
SETTING SETTING
CONTRAST 6 CONTRAST 6
Brightness(day) 100 Brightness(day) 100
Brightness(night) 50 Brightness(night) 50
(g) (f)
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the up or down arrow switch, move the cursor to "SCREEN SETTING". Press the right arrow switch to
enter "SCREEN SETTING".
3. Using the up or down arrow switch, move the cursor to "CONTRAST".
4. Press the right arrow switch to enter screen (e). The background color of the value turns blue.
5. Using the up or down arrow switch, select a desired value.
The adjustable range is from 1 (faint) to 10 (clear).
* The default value is 5.
6. Press menu switch (8) to set the desired value.
At this time, the background color of "value" turns black.
7. Press "screen change switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU SCREEN SCREEN
SETTING SETTING
MAINTENANCE MAINTENANCE CONTRAST 5 CONTRAST 5
SWITCH ST ATUS SWITCH ST ATUS Brightness(day) 100 Brightness(day) 100
OPTION SETTING OPTION SETTING Brightness(night) 50 Brightness(night) 50
CONSUMPTION CONSUMPTION
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the up or down arrow switch, move the cursor to "SCREEN SETTING". Press the right arrow switch to
enter "SCREEN SETTING".
3. Using the up or down arrow switch, move the cursor to "Brightness (day)".
4. Press the right arrow switch to enter screen (f). The background color of the "value" turns blue.
5. Using the up or down arrow switch, select a desired value. 7
The adjustable range is from 1 (dark) to 100 (bright).
* The default value is 100.
6. Press menu switch (8) to set the desired value.
At this time, the background color of "value" turns black.
7. Press "screen change switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU SCREEN SCREEN
SETTING SETTING
MAINTENANCE MAINTENANCE CONTRAST 5 CONTRAST 5
SWITCH ST ATUS SWITCH ST ATUS Brightness(day) 100 Brightness(day) 100
OPTION SETTING OPTION SETTING Brightness(night) 50 Brightness(night) 50
CONSUMPTION CONSUMPTION
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the up or down arrow switch, move the cursor to "SCREEN SETTING". Press the right arrow switch to
enter "SCREEN SETTING".
3. Using the up or down arrow switch, move the cursor to "Brightness (night)".
4. Press the right arrow switch to enter screen (f). The background color of the "value" turns blue.
5. Using the up or down arrow switch, select a desired value.
The adjustable range is from 1 (dark) to 100 (bright).
* The default value is 5.
6. Press menu switch (8) to set the desired value.
At this time, the background color of "value" turns black.
7. Press "screen change switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
S
12h
USER MENU USER MENU CONSUMPTION CONSUMPTION
L/h L/h
MAINTENANCE MAINTENANCE 50 50
40 40
SWITCH ST ATUS SWITCH ST ATUS 30 30
20 20
OPTION SETTING OPTION SETTING
10 10
CONSUMPTION CONSUMPTION 0 0
30 25 20 15 10 5 0 30 25 20 15 10 5 0
MIN MIN
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING
WORKTIME 100 HOURS WORKTIME 0 HOURS
CONSUMPTION 100 L CONSUMPTION 0L
AVERAGE 24.4 L/h AVERAGE 0 L/h
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the up or down arrow switch, move the cursor to "CONSUMPTION". Press the right arrow switch to enter
the fuel consumption information.
3. The graph indicates the average fuel consumption by 2 hours for this 12 hours. The values of "Operating
Time", "Fuel Consumption", and "Average Fuel Consumption" are displayed.
4. To reset these values, press the down arrow switch.
5. Press "screen change switch" (1) to return to main screen (a).
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[7. MECHATRO CONTROLLER]
7.4.6.6 PUMP FLOW RATE SETTING (NIBBLER MODE/BREAKER MODE) AND SELECTION OF
OPTION RELIEF PRESSURE
If there is no switch operation for 20 seconds, the display returns to the main screen.
In nibbler mode
S S
12h 12h
USER MENU USER MENU NIBBLER
SETTING
FLOW RATE 780 L/min MAINTENANCE MAINTENANCE SET1 440
MPa
30
SET8 176
MPa
15 SET9 154
MPa
SET10 132
0 MPa
30 25 20 15 10 5 0
MIN BACK UP NEXT BACK UP NEXT BACK UP
AVERAGE 0.0 L/h RESET HOME DOWN HOME DOWN HOME DOWN OK
In breaker mode
S
12h
USER MENU USER MENU BREAKER
SETTING
FLOW RATE 480 L/min MAINTENANCE MAINTENANCE SET1 220
MPa
30
SET8 66
MPa
15 SET9 44
MPa
SET10 30
0 MPa
30 25 20 15 10 5 0
MIN BACK UP NEXT BACK UP NEXT BACK
AVERAGE 0.0 L/h RESET HOME DOWN HOME DOWN HOME OK
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[7. MECHATRO CONTROLLER]
5. When the display is option setting screen (e), move the cursor to a desired flow rate. Press menu switch (8) to
set the desired flow rate value.
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[7. MECHATRO CONTROLLER]
Item Contents
Language Language selection
Idle stop Adjustment of time (sec) until auto idle stop function starts.
P1 side option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 side option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Selection of using left pedal for rotation or not. (Unload valve does not actuate because
Left pedal for rotation
P4 pump is equipped. Europe specification.)
Optional flow rate limitation, relief pressure limitation, adjustment for combination of
Option adjustment setting
return selector.
Engine speed display ON/OFF of engine speed display
Rise-up wiper Switching wiper control(Changed when cab is changed to new demolition cab )
Flow rate setting of breaker Pump flow rate setting for using breaker
Fuel consumption gauge display ON/OFF of fuel consumption gauge (eco mark) display
Pump difference study Clearance and restudy of ECU difference study contents
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[7. MECHATRO CONTROLLER]
1 7
2
8 5 6
According to the attachment to be installed, the flow rate of the service circuit needs to be reduced.
Regarding the flow rate of the nibbler service circuit, there are 10 patterns of setting.
SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9 SET 10
Nibbler Flow
L/min 440 396 352 308 264 220 176 132 98 30
(crusher) rate
Flow
Breaker L/min 220 198 176 154 132 110 88 66 49 15
rate
The flow rate of the nibbler service circuit is set at "SET6" of the above table as a factory-set value when the
machine is shipped from a factory.
The flow rate of the breaker service circuit is set at "SET1" of the above table as a factory-set value when the
machine is shipped from a factory.
Refer to the following procedure when setting the flow rate. Set values of above-mentioned adjustment can be
selected from the user menu of "the pump flow rate at the nibbler or breaker mode".
2-VRE 00.00 TROUBLE HIST ORY START MODE X SET2 443 SET2 443
L/min L/min
SER VICE DIAG 1 LANGUAGE & LOGO SETTING CANCEL LOW TEMP ON SET3 394L/min
SET3 394
L/min
FACTORY PRESET
CANCEL MODE
CHECK INJECT OR
L/min
SET4
SET5
SET6
344
L/min
295
L/min
246
7
L/min L/min
ENGINE CONT . P/N
MIS FF FAULT DIAG MODE NIBBLER SETTING SET7 221L/min
SET7 221
L/min
ENGINE SERIAL NUMBER
MIS FF
BREAKER SETTING SET8 197L/min
SET8 197
L/min
1. Turn the starter switch "ON". Press nibbler switch (3) to select the nibbler mode, then turn the starter switch
"OFF".
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[7. MECHATRO CONTROLLER]
2. With holding down buzzer stop switch (1), turn the starter switch "ON". Service diagnosis screen (a) is
displayed.
3. Start the engine.
4. With holding down buzzer stop switch (1), press menu switch (2) 3 times. "SERVICE MENU" screen (b) is
displayed.
5. Using up arrow switch (5) or down arrow switch (6), point the cursor to "SERVICE ADJUST 1" of screen (b).
Press right arrow switch (7), and the "SERVICE ADJUST 1-1" screen is displayed. Then press down arrow
switch (6) several times and "SERVICE ADJUST 1-2" screen (c) is displayed.
6. Using up arrow switch (5) or down arrow switch (6), point the cursor to "NIBBLER SETTING" of screen (d).
Press right arrow switch (7), and "NIBBLER SETTING" screen (e) is displayed.
7. There are 10 step settings from "SET 1" to "SET 10". Using up arrow switch (5) or down arrow switch (6),
select a desired set number. To set the desired set number, press right arrow switch (7).
8. Using up arrow switch (5) or down arrow switch (6), select a desired flow rate and press menu switch (2) and
confirm it.
9. After that, press left arrow switch (8) to return to "SERVICE ADJUST 1-2" screen (c).
2-VRE 00.00 TROUBLE HIST ORY START MODE X SET2 221 SET2 221
L/min L/min
SER VICE DIAG 1 LANGUAGE & LOGO SETTING CANCEL LOW TEMP ON SET3 197
L/min
SET3 197
L/min
CLUSTER GAUGE P/N SER VICE ADJUST 1 CANCEL MODE SET4 172
L/min
SET4 172
L/min
YN59S00033F1 SER VICE ADJUST 2 CHECK INJECT OR SET5 148 SET5 148
PROGRAM VERSION L/min L/min
1. Turn the starter switch "ON". After pressing breaker switch (4) to select the breaker mode, turn the starter
switch "OFF".
2. With holding down buzzer stop switch (1), turn the starter switch "ON". Service diagnosis screen (a) is
displayed.
3. Start the engine.
4. With holding down buzzer stop switch (1), press menu switch (2) 3 times. "SERVICE MENU" screen (b) is
displayed.
5. Using up arrow switch (5) or down arrow switch (6), point the cursor to "SERVICE ADJUST 1" of screen (b).
Press right arrow switch (7), and the "SERVICE ADJUST 1-1" screen is displayed. Then press down arrow
switch (6) several times and "SERVICE ADJUST 1-2" screen (c) is displayed.
6. Using up arrow switch (5) or down arrow switch (6), point the cursor to "BREAKER SETTING" of screen (d).
Press right arrow switch (7), and "BREAKER SETTING" screen (e) is displayed.
7. There are 10 step settings from "SET 1" to "SET 10". Using up arrow switch (5) or down arrow switch (6),
select a desired set number. To set the desired set number, press right arrow switch (7).
8. Using up arrow switch (5) or down arrow switch (6), select a desired flow rate and press menu switch (2) and
confirm it.
9. After that, press left arrow switch (8) to return to "SERVICE ADJUST 1-2" screen (c).
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[7. MECHATRO CONTROLLER]
(f)
CYLINDER BALANCING(FCCB)
HOUR METER 99999.4h
OK
1. With holding down buzzer stop switch (2), turn the starter switch "ON". Service diagnosis screen (a) appears.
2. With holding down buzzer stop switch (2), press menu switch (8) 3 times. "SERVICE MENU" screen (b)
appears.
3. Using the up or down arrow switch, point the cursor to "SERVICE ADJUST 1" of screen (c). Press the right
arrow switch, and the "SERVICE ADJUST 1-1" screen is displayed. 7
4. Start the engine and using the up or down arrow switch, point the cursor to "CHECK INJECTOR" of screen (e).
Press the right arrow switch, and the "CYLINDER BALANCING (FCCB)" screen is displayed and inter-cylinder
calibration starts.
5. The engine speed is fixed at approximately 800 rpm.
6. When the value of [mm3/st.cyl] for each cylinder becomes stabled, the inter-cylinder calibration is completed.
Press menu switch (8) to return to the service adjust screen.
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[7. MECHATRO CONTROLLER]
RISE-UP WIPER ON
BACK UP NEXT BACK UP NEXT BACK UP NEXT BACK UP NEXT
DOWN DOWN DOWN DOWN
STOP ENG CYLINDER STOP ENG CYLINDER STOP ENG CYLINDER STOP ENG CYLINDER STOP ENG CYLINDER
HOUR METER 3.0h HOUR METER 3.0h HOUR METER 3.0h HOUR METER 3.0h HOUR METER 3.0h
STOP CYLINDER No. 4 STOP CYLINDER No. 3 STOP CYLINDER No. 2 STOP CYLINDER No. 1 1 STOP CYLINDER No. +
ENG SPEED 1134 ENG SPEED 1127 ENG SPEED 1134 ENG SPEED 1129 ENG SPEED 1149
COMP. FUEL CONS. 24mm3/s t .cyl. COMP. FUEL CONS. 20mm3/s t .cyl. COMP. FUEL CONS. 24mm3/s t .cyl. COMP. FUEL CONS. 20mm3/s t .cyl. COMP. FUEL CONS. 16mm3/s t .cyl.
ENG RAIL PRESS 57.0M ENG RAIL PRESS 57.0M ENG RAIL PRESS 57.0M ENG RAIL PRESS 56.0M ENG RAIL PRESS 53.0M
BOOST PRESS 104 BOOST PRESS 104 BOOST PRESS 104 BOOST PRESS 104 1 BOOST PRESS 102
EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0%
EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0%
SCV CURRENT 1020mA SCV CURRENT 1040mA SCV CURRENT 1120mA SCV CURRENT 1920mA SCV CURRENT 1020mA
INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h
INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥
PERCENT TORQUE 0.2% PERCENT TORQUE 0.2% PERCENT TORQUE 0.2% PERCENT TORQUE 0.2% PERCENT TORQUE 0.1%
P1-PRES 0.0M P1-PRES 0.0M P1-PRES 0.0M P1-PRES 0.0M P1-PRES 0.0M
P2-PRES 0.2M P2-PRES 0.2M P2-PRES 0.2M P2-PRES 0.2M P2-PRES 0.2M
P1-PSV 338mA P1-PSV 339mA P1-PSV 339mA P1-PSV 338mA P1-PSV 339mA
P2-PSV 341mA P2-PSV 341mA P2-PSV 341mA P2-PSV 340mA P2-PSV 340mA
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
4 OK 4 OK 4 OK 4 OK 4 OK
1. With holding down buzzer stop switch (2), turn the starter switch "ON". Service diagnosis screen (a) appears.
2. During pressing buzzer stop switch (2), press menu switch (8) three times. "SERVICE MENU" screen (b)
appears.
3. Using the up or down arrow switch, point the cursor to "SERVICE ADJUST 1" of screen (c). Press the right
arrow switch, and the "SERVICE ADJUST 1-1" screen is displayed.
4. Using the up or down arrow switch, point the cursor to "STOP CYLINDER" of screen (e).
Start the engine and press the right arrow switch to display the "STOP ENG CYLINDER" screen.
5. Referring to the display, select the number of a desired cylinder (1 to 4) to be stopped. The selected cylinder is
stopped.
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[7. MECHATRO CONTROLLER]
6. At the time of the cylinder stop, check the value of COMP.FUEL CONS. (If the command injection quantity has
been changed significantly or has not been changed from the command injection quantity of when stopping the
cylinder under a normal machine condition, the stopped injector can be failed.)
7. Press the switch of the same number of the stopped engine cylinder and then the stopped cylinder works
again.
8. Press menu switch (8) to finish the "STOP ENG CYLINDER" screen and return to the "SERVICE ADJUST
SCREEN 1-3" screen.
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[7. MECHATRO CONTROLLER]
• Even if "READ INJECTOR CODE" is not performed, the injector codes can be input but in this case, "F" is input
to all of the boxes of each "injector no." first and it takes a lot of times to rewrite them.
• If a wrong value of the injector code is input, "WRITING FAILED" is displayed.
In this case, the input injector code is not stored. Input the injector code again.
• When replacing the ECU, display the injector code by following the procedure 10. and write the injector code
down, and then input that code. Otherwise, input the code displayed on the tag attached to the injector body.
• When replacing the injector, perform the procedures of 1. to 5. to allow the injector to read the code.
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[7. MECHATRO CONTROLLER]
RISE-UP WIPER ON
BACK NEXT BACK NEXT BACK NEXT BACK NEXT
Example:
When is input (h) (g) (f)
INPUT CODE INJECT OR No.1 INPUT CODE INJECT OR No.1 INPUT CODE INJECT OR No. SELECT INJECT OR SELECT INJECT OR
5.7h 5.6h 5.6h 5.6h 5.7h
A 1 0 0 0 0 E 4 2 1 0 0 0 0 E 4 2 1 0 0 0 0 E 4
INJECT OR No.1 INJECT OR No.1
1 2 3 4
5 6 7 8
9 A B C
BACK NEXT D E F 0 BACK NEXT BACK BACK
OK OK OK OK
or
1. With holding down buzzer stop switch (2), turn the starter switch "ON". Service diagnosis screen (a) appears.
2. With holding down buzzer stop switch (2), press menu switch (8) 3 times. "SERVICE MENU" screen (b)
appears.
3. Using the up or down arrow switch, point the cursor to "SERVICE ADJUST 1" of screen (c). Press the right
arrow switch, and the "SERVICE ADJUST 1-1" screen is displayed.
4. Using the up or down arrow switch, point the cursor to "INPUT INJECTOR CODE" of screen (e). Press the right
arrow switch, and the "SELECT INJECTOR" screen is displayed.
5. Using the up or down arrow switch, point the cursor to "READ INJECTOR CODE" of screen (f) and press menu 7
switch (8). The injector code is read from the ECU and the value is read by each "injector no. n" (n is an
arbitrary number).
6. Using the up or down arrow switch, point the cursor to a desired "injector no. n" of screen (g). Press menu
switch (8) to display "INPUT CODE INJECTOR No. n" (h).
7. Using the up or down arrow switch, point the cursor to a desired box of screen (h). Press the right arrow switch,
and input a desired code referring to the screen of the gauge cluster.
8. After inputting the code, the cursor is moved to the next right box. Input a code again following the same
procedure of 7.
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[7. MECHATRO CONTROLLER]
9. After inputting the codes to the all boxes, press menu switch (8) to register the input codes. At this time, the
screen returns to "SELECT INJECTOR".
10. Finally, perform "READ INJECTOR CODE" once again and display "INPUT CODE INJECTOR No. n" to check
that the injector codes are input correctly.
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[7. MECHATRO CONTROLLER]
By pressing menu switch (8) under any condition of "CLEARED" or "DONE" in the procedure of 7., the screen shifts
to screen (k) and each condition information is stored.
RISE-UP WIPER ON
BACK UP NEXT BACK UP NEXT BACK UP NEXT BACK UP NEXT
DOWN DOWN DOWN DOWN
BACK
OK OK OK OK OK
7
(k)
STUDY PUMP DIFFERENCE
3.1h
CONDITION DONE
BACK
OK
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[7. MECHATRO CONTROLLER]
1. With holding down buzzer stop switch (2), turn the starter switch "ON". Service diagnosis screen (a) appears.
2. With holding down buzzer stop switch (2), press menu switch (8) 3 times. "SERVICE MENU" screen (b)
appears.
3. Using the up or down arrow switch, point the cursor to "SERVICE ADJUST 1" of screen (c). Press the right
arrow switch, and the "SERVICE ADJUST 1-1" screen is displayed.
4. Using the up or down arrow switch, point the cursor to "STUDY PUMP DIFFERENCE" of screen (e). Press the
right arrow switch, and the "STUDY PUMP DIFFERENCE" screen is displayed.
5. Confirm that "STUDY PUMP DIFFERENCE CONDITION" is "CLEARED" by screen (f). If it is "DONE", press
menu switch (8) to change it to "CLEARED".
6. Start the engine and press menu switch (8) to start pump difference study.
7. The contents of "CONDITION FLAG" shifts through "CLEARED", "LEARNING 2", "LEARNING 1", and
"DONE". When it becomes "DONE", the pump difference study is completed.
8. By pressing menu switch (8), the study result is stored and shifts to screen (k).
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[7. MECHATRO CONTROLLER]
CIRCUIT NUMBER
List of connectors
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
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[7. MECHATRO CONTROLLER]
BREAKER
SWITCH
CN-600
MULTI
DISPLAY(LCD) 1 2 3 4
5 6 7 8
HARNESS SIDE
DIGGING SWIHCH AMP 040 (8P)
HOUSING : 174044-2
TERMINAL : 173681-2
WORK MODE
SELECT SWIHCH
BUZZER STOP
SWITCH
LEFT ARROW
SWITCH RIGHT ARROW SWITCH
MENU SWITCH CN-601
SCREEN CHANGE HARNESS SIDE
DOWN ARROW SWITCH 1 2 3 4 5 6 AMP 040 (12P)
SWITCH
UP ARROW SWITCH 7 8 9 10 1112 HOUSING : 174045-2
TERMINAL : 173681-2
Function
• Signals from communication between the gauge cluster and the mechatro controller are processed and they are
displayed by the lamps, LCD and sound the buzzer.
• Coolant temperature signals, fuel level signals and panel switch signals are output to the mechatro controller
through the communication ports.
7-78
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[7. MECHATRO CONTROLLER]
9 Nibbler switch
10 Breaker switch
11 Up arrow switch
7-79
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[7. MECHATRO CONTROLLER]
Detail of label
7-80
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[7. MECHATRO CONTROLLER]
Circuit schematic
Item Name Device name
diagram No.
7-81
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[7. MECHATRO CONTROLLER]
Circuit schematic
Item Name Device name
diagram No.
7-82
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[7. MECHATRO CONTROLLER]
7-83
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[7. MECHATRO CONTROLLER]
7-84
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[7. MECHATRO CONTROLLER]
7-85
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[7. MECHATRO CONTROLLER]
7-86
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[7. MECHATRO CONTROLLER]
7-87
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[7. MECHATRO CONTROLLER]
O-RING P14
JIS B2401 CLASS1B
PF 3/8
Tighte ning torgue
73.5N .m (54.2lbf .ft)
VIEW A
7-88
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[8. HYDRAULIC SYSTEM]
8. HYDRAULIC SYSTEM
8.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................8-3
8.2 Summary .................................................................................................................................8-4
8.3 HYDRAULIC CIRCUITS AND COMPONENTS ...........................................................................8-6
8.3.1 PART NUMBER OF HYDRAULIC COMPONENT.....................................................................8-6
8.3.2 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS ...................................................8-6
8.3.3 STANDARD.......................................................................................................................... 8–7
8.3.4 N&B (HCP) SPECIFICATION................................................................................................. 8–8
8.3.5 N&B (FOOT) SPECIFICATION .............................................................................................. 8–9
8.3.6 BOOM & ARM SAFETY SPECIFICATION ............................................................................ 8–10
8.3.7 ROTARY (HCP) SPECIFICATION ........................................................................................ 8–11
8.4 NEUTRAL CIRCUIT................................................................................................................8-12
8.4.1 OPERATION OF UNLOADING VALVE AND BY-PASS CUT VALVE HOUSED IN CONTROL
VALVE ...........................................................................................................8-12
8.4.2 SAFETY LOCK LEVER AND PILOT CIRCUIT .......................................................................8-12
8.4.3 PUMP POSITIVE FLOW CONTROL .....................................................................................8-12
8.4.4 PUMP P-Q CURVE CONTROL OPERATION.........................................................................8-12
8.5 TRAVEL CIRCUIT...................................................................................................................8-14
8.5.1 TRAVEL FORWARD PILOT SIMULTANEOUS OPERATION CIRCUIT....................................8-14
8.5.2 2-SPEED TRAVEL SOLENOID COMMAND CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION.....................................................................................................8-14
8.5.3 TRAVEL MAIN CIRCUIT ......................................................................................................8-14
8.5.4 TRAVEL MOTOR FUNCTION ...............................................................................................8-14
8.6 BUCKET CIRCUIT..................................................................................................................8-16
8.6.1 PILOT CIRCUIT FOR BUCKET DIGGING .............................................................................8-16
8.6.2 AUTO ACCELERATION OPERATION ..................................................................................8-16
8.6.3 STAND-BY CURRENT CONSTANT CONTROL.....................................................................8-16
8.6.4 BUCKET DIGGING AND TRAVEL STRAIGHT CONFLUENCE (CONFLUX) MAIN
CIRCUIT ........................................................................................................8-16
8.6.5 BUCKET SPOOL STROKE LIMITER ....................................................................................8-16
8.7 BOOM CIRCUIT .....................................................................................................................8-18
8.7.1 BOOM UP PILOT CIRCUIT ..................................................................................................8-18
8.7.2 BOOM UP 2 PUMPS CONFLUX MAIN CIRCUIT IN C/V .........................................................8-18
8.7.3 BOOM DOWN PILOT CIRCUIT.............................................................................................8-20
8.7.4 PREVENTION OF NATURAL FALL BY LOCK VALVE AND ACTUATION AT
LOWERING....................................................................................................8-20
8.7.5 BOOM DOWN MAIN CIRCUIT..............................................................................................8-20
8.8 SWING CIRCUIT ....................................................................................................................8-22 8
8.8.1 PILOT CIRCUIT FOR LEFT SWING ......................................................................................8-22
8.8.2 SWING AUTO PARKING BRAKE .........................................................................................8-22
8.8.3 SWING MAIN CIRCUIT ........................................................................................................8-22
8-1
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[8. HYDRAULIC SYSTEM]
8-2
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[8. HYDRAULIC SYSTEM]
8-3
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[8. HYDRAULIC SYSTEM]
8.2 Summary
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability,
safety, mass volume handling and low fuel consumption.
Per-
for- Device Function Features
mance
• Pressurized hydraulic oil tank • To prevent hydraulic oil from entering dust and
to promote self suction ability of pump
• Suction strainer
• Remove dust on suction side.
• Line filter ; pilot circuit
• To prevent pilot operating circuit from
• Return circuit
Others malfunctioning
• Cooling hydraulic oil by oil cooler
• To prevent hydraulic oil from contamination
• Pressure draining circuit
• To prevent hydraulic oil from being deteriorated.
• Switching of return line for N&B machine in the
• To release the main circuit pressure for piping
cab (Option)
repair work.
• Switching of return line for N&B machine is able
to change with a switch in the cab
8-4
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[8. HYDRAULIC SYSTEM]
• Electric flow controlled variable pump • Pump flow rate control with command current to
Pump variable pump electromagnetic proportional
• Positive flow rate control
Mass valve
• Flow rate control with pilot pressure
han-
dling • Boom up conflux circuit • Speed up of boom up operation
Attach-
ment • Arm conflux circuit • Speed up of arm operation
capaci-
ty • Bucket conflux circuit • For speed-up of bucket operation (digging &
dump)
• Optimum operation by work mode select (H,S,
E) • Efficient operation in all work modes
8-5
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[8. HYDRAULIC SYSTEM]
6 Arm cylinder mm (ft-in) YN01V00175F4 95 (3.74") dia. x 135 (5.32") dia. x 1558 (5'1")
7 Bucket cylinder mm (ft-in) YN01V00153F2 80 (3.15") dia. x 120 (4.72") dia x 1080 (3'7")
The part numbers may be changed due to modification, so use the table above only as references.
8-6
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[8. HYDRAULIC SYSTEM]
8.3.3 STANDARD
YN01Z00268P1 02
8–7
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[8. HYDRAULIC SYSTEM]
53 52
51
50
YN01Z00263P1 01
8–8
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[8. HYDRAULIC SYSTEM]
61
62
60
LQ01Z00094P1 01
8–9
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[8. HYDRAULIC SYSTEM]
71
70
70 YN01Z00270P1 01
8–10
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[8. HYDRAULIC SYSTEM]
80
82
83
81
YN01Z00269P1 01
8–11
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[8. HYDRAULIC SYSTEM]
8.4 NEUTRAL CIRCUIT 8.4.3 PUMP POSITIVE FLOW 8.4.4 PUMP P-Q CURVE CONTROL
CONTROL OPERATION
This section describes the following.
• Bypass cut valve and unload valve control Type: Type:
• Safety lock lever and pilot circuit Electric flow controlled variable displacement pump. Electrical flow control type variable pump
• Pump positive flow control
Principle: Principle:
• Pump P-Q (Pressure-Quantity) curve control
The current command I to the pump's solenoid proportional Perform an operation of the value from pump high pressure
valve controls the delivery rate of the pump. sensor to P-Q curve control value, and send a command to
8.4.1 OPERATION OF UNLOADING the pump solenoid proportional valve.
VALVE AND BY-PASS CUT Operation:
VALVE HOUSED IN CONTROL • Flow rate rise operation (Eg. P1 pump)
Operation:
VALVE By operating any of control levers, the operating The pump high pressure sensor converts the pressure to
secondary pressure of pilot valve rises, and the rising the output voltage corresponding to the pump delivery
• Unloading valve
pressure is transformed to the rise of output voltage pressure.
On starting engine, like by-pass cut valve, the secondary
corresponding to the pressure input by the low pressure The mechatro controller converts the voltage output by the
pressures output by P1 and P2 unloading proportional
sensor. Mechatro controller signal-processes this high pressure sensor to the P-Q curve control value. On the
valves (PSV-D, PSV-B) exert on PCb and PCa ports,
change of voltage, resulting in rise of command current other hand, select the pump positive control command
consequently the P1 and P2 unloading valves are
value I to the pump proportional solenoid valve and current value from the low pressure sensor in lower order,
switched to OPEN side.
consequently the pump flow rate rises. This is called and the values are output to respective pump proportional
• By-pass cut valve "Positive Control System". valve as a command current.
When machine is under normal conditions, by-pass cut As the pump command current value rises, the With this operation, the pump power is controlled so as not
valve is closed normally. If pilot pressure sensor or secondary pressure of proportional solenoid valve also to be exceed the engine power, therefore engine dose not
unloading proportional valve is disconnected or rises. On the regulator attached on the pump, the spool stall.
malfunctioned, the unloading valve closes completely. (652) through piston (643) is pushed rightward, and
Even if control valve is in neutral position, hydraulic oil is stops at the position where being in proportion to the
trapped. As a result, the pump relieves due to pressure force of pilot spring (646).
increase. The tank port connected to the large bore of servo
In such the case, before the machine is repaired, open piston (532) opens, and the piston moves leftward by
the by-pass cut valve manually. And the machine is delivery pressure P1 of the small bore resulting in the
operable by draining excess oil to hydraulic tank. increase of tilt angle (α).
The servo piston and spool (652) are connected to
8.4.2 SAFETY LOCK LEVER AND feedback lever (611). Therefore when servo piston
PILOT CIRCUIT moves leftward, the spool (652) also moves rightward by
means of feedback lever. With this movement, the
Purpose: opening of spool sleeve closes gradually, and the servo
To protect attachment from unexpected movement for piston stops at the position the opening closed
safety. completely.
• Flow rate reduction operation
Principle: As the current value I of mechtro controller reduces, the
Cut pressure source of pilot valve for operation. secondary pressure of solenoid proportional valve
reduces, and spool (652) is moved leftward by the force
Operation: of pilot spring (646). With the movement of spool, the
delivery pressure P1 usually flows into the large bore of
If the safety lock lever (red) is pushed forward after the
piston through the spool.
engine starts, the limit switch (SW-11) is turned on. The
The delivery pressure P1 flows in the small bore of servo
timer relay is actuated one second later which causes the
piston, but the servo piston moves rightward due to the
solenoid (SV-4) of the solenoid valve block (14) to be
difference of area, resulting in the reduction of tilt angle.
energized and makes the pilot operating circuit to stand by.
Similarly, when the servo piston moves rightward, the
spool (652) is moved leftward by the feedback lever.
The operation is maintained until the opening of spool
sleeve is closed.
8-12
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[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
8-13
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[8. HYDRAULIC SYSTEM]
8.5.1 TRAVEL FORWARD PILOT If the switch is turned, an electric signal is issued. It excites
the 2-speed travel solenoid which in turn converts the
SIMULTANEOUS OPERATION
primary pilot pressure and the self pressure to a tilting angle
CIRCUIT of the variable displacement motor.
Purpose:
Operation:
Light operating force and shockless operation
If the rabbit marked switch on the gauge cluster is pressed,
Operation: the solenoid (SV-3) of the proportional valve block (14) is
excited and changes the proportional valve. Then the
1. If the travel lever with damping mechanism is operated solenoid command pressure is issued from port A3, enters
for travel right, left and forward motions, the secondary the P port of the travel motor (4), opens the oil passage to
pilot proportional pressure comes out of the 3, 1 ports the 2nd speed select piston, and causes the motor to run in
of P/V (10). The higher of the pressures is selected, the 2nd speed tilting mode by its self pressure. However,
comes out of the 6, 5 ports and acts upon the low when the main circuit pressure rises above 28 MPa (4060
pressure sensors (SE9) (SE-10). psi), the motor's self pressure pushes the 2nd speed select
2. The pilot secondary pressure flows to PAr and PAL piston back to the 1st speed.
ports of the control valve (2), moves the travel spool,
and switches the main circuit. 8.5.3 TRAVEL MAIN CIRCUIT
3. The low pressure sensor output voltage is input into
mechatro controller. The mechatro controller performs Operation:
signal processing and outputs current corresponding to The delivery oil from Pump A1 and A2 ports by changing
the increase of flow rate to P1 pump proportional valve the travel spool with the operation of travel pilot flows in
(PSV-P1) and P2 pump proportional valve (PSV-P2), each P1 port on the left side of travel motor (4) and P2 port
and at the same time the command current is output to on the right side of travel motor (4) through C,D ports of
P1 unloading valve (PSV-D) and P2 unloading valve swivel joint (8) from AL, AR ports of C/V, and rotates the
(PSV-B). travel motor.
4. The secondary pressures output by P1 pump
proportional valve (PSV-P1) and P2 pump proportional 8.5.4 TRAVEL MOTOR FUNCTION
valve (PSV-P2) exert on pump regulator, actuating the
pump on the delivery flow rate increase side. Function:
5. The secondary pressure delivered in P1 unloading • Prevents the motor from over running on a slope.
valve (PSV-D) and P2 unloading valve (PSV-B) is fed • Check valve that prevents cavitation of the hydraulic
to Pcb and PCa ports provided in control valve (2). motor.
The secondary pressure from proportional valve which
• Shockless relief valve and anti cavitation valve when
has exerted on PCb and PCa ports switches the
inertia force stops.
unloading spool in CLOSE side.
• High/Low 2 step speed change mechanism and auto 1st
speed return at high load.
• Travel parking brake.
8-14
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[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
8-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[8. HYDRAULIC SYSTEM]
8.6 BUCKET CIRCUIT 8.6.2 AUTO ACCELERATION 8.6.4 BUCKET DIGGING AND
OPERATION TRAVEL STRAIGHT
This section describes the following.
CONFLUENCE (CONFLUX)
• Bucket digging pilot circuit Principle:
MAIN CIRCUIT
• Auto accel operation Auto acceleration actuates according to signals from low
• Flow control in the work mode pressure sensor. Operation:
• Bucket digging travel straight main circuit 1. The oil delivered through A1 port of P1 pump goes into
Operation:
• Bucket spool stroke limiter P1 port of C/V (2), opens load check valve LCc through
• When lever is set to neutral position parallel circuit and enters in bucket spool.
In the event where the sensor does not receive signal for
2. On the other hand, the oil delivered through P2 port of
8.6.1 PILOT CIRCUIT FOR BUCKET 4 seconds or more even though the acceleration dial is
P2 pump goes into P2 port of C/V (2), confluences with
DIGGING set to MAX position, the engine speed should be raised
oil from P1 pump through travel straight valve, and
to 1000 rpm.
Operaion: goes into bucket spool. (Confluence of oil from 2
• When lever is operated pumps)
1. When the operation for bucket digging is performed, When the pressure 0.6 MPa (87 psi) is input to low
3. With the function of pilot circuit, the oil flow is switched
the pilot proportional secondary pressure is delivered pressure sensor in STD specification (travel, bucket,
from bucket spool, and is fed into bucket cylinder head
through port 1 of the right pilot V (9), flows to PAc port, swing, arm), proportional voltage from low pressure
side through AC port of C/V (2). On the other hand, the
and acts on the low pressure sensor (SE-1), and at the sensor inputs in mechatro controller, and then the engine
return oil from cylinder rod (R) side is throttled by
same time the bucket spool is switched. speed returns to the dial set position corresponding to
bucket spool and returns to tank circuit from BC port of
2. The voltage output by low pressure sensor inputs in the lever operation.
C/V (2).
mechatro controller. The mechatro controller performs
signal processing and outputs current corresponding to 8.6.3 STAND-BY CURRENT References:
the increase of pump flow rate to pump proportional CONSTANT CONTROL • In bucket dumping operation, the travel straight valve
valves (PSV-P1) and (PSV-P2) on the P1 and P2 pump
also switches like digging operation, resulting in
sides, and at the same time the command current is Principle:
confluence with travel straight.
output to P1 unloading valve (PSV-D), P2 unloading
When the engine speed is intermediate speed or lower, • When the bucket operation and other operation are
valve (PSV-B) and travel straight proportional valve
command current value to have the pump delivery rate simultaneously performed, the travel straight valve does
(PSV-C).
constant is output. not actuate, resulting in single flow of bucket circuit.
In the following pages, the relation of operation of low
pressure sensor to both the increase of pump flow rate Operation:
and unloading proportional valve is the same. 8.6.5 BUCKET SPOOL STROKE
Even if the engine speed specified by acceleration
Therefore the explanation is omitted.
potentiometer is low speed, as the delivery rate
LIMITER
3. The secondary pressure output by P1 pump corresponds to the intermediate speed, the actuator moves
proportional valve (PSV-P1) and P2 pump proportional Purpose:
earlier than the movement equivalent to the control lever
valve (PSV-P2) exerts on pump regulator, actuating the angle rate in light load operation. To secure simultaneous operability of boom and arm and to
pump onto the delivery flow increase side. prevent cavitations at low engine speed.
4. The secondary pressure delivered in P1 unloading
Operation:
valve (PSV-D) and P2 unloading valve (PSV-B) is led
to PCb and PCa ports provided in control valve (2). On boosting up attachment pressure, pilot primary pressure
The secondary pressure from proportional valve which exerts on PCc port of C/V(2) through attachment booster
has exerted on PCb and PCa ports switches the solenoid valve, operates stroke limiter of bucket spool, and
unloading spool in CLOSE side. throttle oil path of spool. As a result, P1 pump pressure
5. The secondary pressure delivered in travel straight increases, making the simultaneous operation of boom up
proportional valve (PSV-C) is led to PTb port provided and bucket digging possible.
in control valve (2) and shifts the travel straight valve. Even though the engine speed is low, similarly the
cavitations can be prevented by actuating the stroke limiter.
8-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
BUCKET CIRCUIT : Bucket digging (travel straight conflux), auto-accelation and standby flow rate constant control function
8-17
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[8. HYDRAULIC SYSTEM]
Principle:
Confluxing oil from 2 pumps
Operation:
1. The oil delivered through A1 port of P1 pump flows into
C/V (2) P1 port, and branches into bypass circuit and
parallel circuit. Since P1 unloading valve is closed, the
boom spool is moved and bypass circuit is closed, the
oil opens load check valve LCb1 through parallel circuit
and flows into boom spool.
2. Then the oil passes through boom spool, opens lock
valve of boom lock valve CRb1, and is led into H side
of boom cylinder through C/V (2) Ab port.
3. Meanwhile, the oil delivered from the A2 port of the P2
pump enters the P2 port of C/V (2) and due to shut off
the P2 unloading valve, the oil then passes through the
parallel circuit and via the restrictor on the
circumference of the boom conflux spool, pushes the
load check valve CRb2 open from the boom conflux
circuit, and combines the oil delivered by the P1 pump
internally.
4. The return oil from boom cylinder R side flows into tank
circuit through boom spool from C/V (2) Bb port.
8-18
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[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
8-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[8. HYDRAULIC SYSTEM]
This section describes boom lower operation. 8.7.5 BOOM DOWN MAIN CIRCUIT
• Boom down pilot circuit
Operation:
• Prevention of natural fall by lock valve and actuation at
lowering During boom down operation, the hydraulic oil delivered
from hydraulic pump P1 is supplied to the boom cylinder
• Constant recirculation function of boom down main
rod (R) side through port (Bb).
circuit
On the other hand, the oil returned from the boom cylinder
head (H) side enters the C/V through port (Ab). The lock
8.7.3 BOOM DOWN PILOT CIRCUIT valve poppet is pushed and opened because holding of the
lock valve poppet is released.
Operation:
Then the return oil flows the boost check valve and returns
1. If the boom down operation is performed, the to the hydraulic oil tank through tank port T1.
secondary pilot proportional pressure comes out of
portaC of the right pilot valve (9) and acts upon the low
pressure sensor (SE-4).
At the same time, the pressure acts upon the PBb port
of C/V (2).
2. The voltage output of the low pressure sensor (SE-4)
enters the mechatro controller and processed in it.
3. Then, the proportionl secondary pressure fed into C/V
(2) PBb port and branches off in two lines and switches
boom spool and releases boom lock valve.
Principle:
The oil is prevented from returning to the boom spool by the
poppet seat of the boom lock valve.
Operation:
In the boom down action, the selector valve is changed
over by the secondary proportional pressure of PBb port.
Then the poppet spring chamber of the lock valve CRb1
gets through the drain line (Dr) and makes the lock valve
poppet open.
When the boom lever is at neutral, the drain line on the lock
valve CRb1 poppet spring chamber is closed which causes
the poppet closed.
The result is that the oil returning from the boom cylinder
head (H) to the boom spool is held and makes the leak from
the boom spool zero.
Thus the boom cylinder is prevented from making a natural
fall.
8-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
BOOM CIRCUIT : Boom down operation & prevention of natural boom falling by boom lock valve
8-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[8. HYDRAULIC SYSTEM]
Principle:
Release mechanical brake only when required to operate
swing and arm in.
Operation:
1. The swing parking system excites the swing parking
SOL (SV-1) usually if the key switch is turned on and
works by the action of the mechanical brake.
2. The mechanical brake is released if the swing parking
solenoid is de-excited only when the secondary
operating pressure in the swing and arm in actions acts
upon any of the low pressure sensors (SE-7, 41).
3. The swing parking solenoid (SV-1) is excited five
seconds after the pressure of the swing low pressure
sensors (SE-41) is reduced to zero. In the case of arm
in operation, the swing parking solenoid (SV-1) is
excited the moment the pressure of the arm in low
pressure sensor (SE-7) is reduced to zero. This causes
the mechanical brake to operate.
8-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
8-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[8. HYDRAULIC SYSTEM]
8.9 ARM CIRCUIT 8.9.2 ARM-IN, LIGHT-LOAD applied is operated, the meter-in path of arm 2 spool is
VARIABLE NORMAL closed, resulting in single flow operation.
This section describes the following operations.
RECIRCULATION, INTERNAL Spool position at arm in,
• Arm in, light-load operating pilot circuit
CONFLUX MAIN CIRCUIT light load and combined operation
• Arm in, light-load variable normal recirculation main (This position is not shown in hydraulic diagram)
circuit / internal conflux main circuit Operation: Neutral position Meter-in passage
(Close)
1. The P2 pump delivery oil flows in travel left section
8.9.1 ARM IN, LIGHT-LOAD through P2 port of C/V (2) and is branched off in by-
OPERATING PILOT CIRCUIT pass circuit and parallel circuit, but because arm 1
spool is switched, the delivery oil which goes through
Normal recirculation opsition
Purpose: parallel circuit opens load check valve LCa and is Arm 2 spool
Speed-up and Anticavitation when the arm is at light flowed into arm 1 spool.
loaded. 2. On the other hand, P1 pump delivery oil flows in P1
port of C/V (2), and the flows in travel straight section
Principle: and travel right tandem path. Then because arm 2
The oil returning from the arm cylinder rod (R) is spool was switched, the delivery oil opens load check
recirculated variably to the head (H) at arm 2 spool in C/V. valve LCAT2, goes through arm 2 spool, and
confluences with P2 pump delivery oil in the valve
Operation: section, and then is flowed into arm cylinder head (H)
1. When the arm in operation is performed, the secondary side through Aa port of C/V (2).
pilot proportional pressure gets out of port 7 of the left 3. The return oil from arm cylinder (R) side flows in Ba
pilot valve (9) and acts upon the low pressure sensor port of C/V (2) and passes through the Ba port
(SE-7). because the arm lock valve CRa is open, and is flowed
At the same time, the pressure is branched off in two into arm 2 spool through arm 1 spool.
flows, acts upon the Paa1 port and the PLc2 port, 4. Because arm 2 spool is switched to normal
changes over the arm spool and the arm lock valve recirculation position, causing restriction of passage to
CRa. releases. tank, the return oil from arm cylinder (R) side flows into
2. The output voltage by the low pressure sensor is input arm cylinder (H) side.
into mechatro controller, and is pilot signal-processed, • Because, at light load, the pressure in cylinder rod (R)
and is output to P1, P2 pump proportional valve (PSV- side is higher than that in the head (H) side, it opens the
P1), (PSV-P2) and arm 2 inverse proportional valve check valve housed-in arm 2 spool and is recirculated in
(PSV-A). the head (H) side, resulting in the speed up of arm-in
3. The secondary pressure from pilot proportional valve, operation at light load.
which is reduced by arm 2 inverse proportional valve 5. Cavitations prevention control in arm-in operation
(PSV-A) switches arm 2 spool. Command current is output to arm 2 solenoid
proportional valve by signal processing of E/G speed
and arm-in pilot pressure, accordingly the arm 2 spool
is switched to neutral (cavitations prevention) position,
resulting in cavitations prevention.
Neutral position
(Anticavitation position)
Normal recirculation position
Recirculation cut position
Reference:
In light-load arm-in operation (normal recirculation, conflux),
when the attachment to which the circuit in P1 pump side is
8-24
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[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
ARM CIRCUIT : Arm in (light load) operation, arm recirculation, conflux & anti cavitation function
8-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[8. HYDRAULIC SYSTEM]
This section describes the following operations. 8.9.4 ARM IN, HEAVY LOAD
• Arm in, heavy load operating pilot circuit (recirculation OPERATING RECIRCULATION
cut) CUT MAIN CIRCUIT
• Arm in, heavy load operating sequence confluxed main
circuit Purpose:
Power up for arm in operation
8.9.3 ARM IN, HEAVY LOAD
Principle:
OPERATING PILOT CIRCUIT
Cut the recirculation and reduce rod pressure.
Operation:
Operation:
1. Left pilot valve actuation due to arm-in operation is
equivalent to that at light load operation. 1. P2 pump delivery oil flows in the travel left section
through P2 port of C/V (2) and branched off in by-pass
2. In arm-in operation, when the heavy loading is applied
circuit and parallel circuit. Consequently the arm spool
to arm and the P2 pump pressure increases to the set
is switched and pushes and opens load check valve
pressure, the voltage output by P2 pump pressure
LCa through parallel circuit, and flows in the arm spool.
sensor (SE-23) is converted to signal (signal
processing) by mechatro controller, consequently the 2. On the other hand, P1 pump delivery oil flows in P1
current of arm 2 solenoid proportional valve is port of C/V (2), and flow in travel right tandem passage
controlled according to the load pressure and the arm through travel straight section. Then because arm 2
variable recirculation is cut. spool was switched, the delivery oil opens load check
When the recirculation is cut, internal confluence is valve LCAT2, and confluences with P2 pump delivery
held similarly to that in light load operation. oil in the valve section, and is flowed into arm cylinder
head (H) side through Aa port of C/V(2).
3. The return oil from arm cylinder (R) side flows in Ba
port of C/V(2) and is flowed to arm lock valve CRa, but
because the arm lock valve CRa is open, the return oil
goes through arm lock valve CRa and flows in arm 2
spool.
4. The return oil returns directly into tank circuit because
arm 2 spool is switched to recirculation cut position.
8-26
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[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
ARM CIRCUIT : Arm in (heavy load) operation, arm conflux & recirculation cut function
8-27
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[8. HYDRAULIC SYSTEM]
This section describes the following operations. 8.9.7 NATURAL FALL PROTECTION
• Arm out pilot circuit WITH ARM LOCK VALVE
• Arm out 2 pumps conflux main circuit
Purpose:
• Natural fall protection with arm lock valve
To prevent the arm from falling naturally by the weight of the
arm and bucket.
8.9.5 ARM OUT PILOT CIRCUIT
Principle:
Operation:
Complete seat of the return circuit against the arm spool of
1. When the arm out operation is performed, the
the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out of port 8
of the left pilot valve (9), and acts upon the low Operation:
pressure sensor (SE-8). At the same time, the oil is
1. When the secondary pressure for arm operation
branched off in two flows and act upon the PBa1 and
disappears and the arm cylinder stops, the pressure on
Pba2 ports of C/V (2).
the rod (R) side passes through the selector of the lock
2. The operating proportional secondary pressure flowed valve from the Ba port of C/V, acts the back pressure
in Pba1 port of C/V (2) switches the arm 1 spool. on the lock valve CRa and seats the lock valve.
3. Then, the operating secondary pressure flowed in 2. Since the oil flow into the arm spool from the lock valve
PBa2 port of C/V (2) switches the arm 2 spool valve. is shut off completely, natural fall of the arm due to oil
leaks through the arm spool is prevented.
8.9.6 ARM OUT 2 PUMPS CONFLUX
MAIN CIRCUIT
Purpose:
Arm out operation speed up.
Principle:
The oil delivered by the P1 pump is confluxed with that
delivered by the P2 pump in C/V (2).
Operation:
1. P1 pump delivery oil opens load check valve (LCAT2)
by switching arm 2 spool and confluxes with P2 pump
delivery oil just short of the arm lock valve.
2. And, P2 pump delivery oil flows through arm 1 spool
and confluences with P1 delivery oil, opens lock valve
of arm lock valve CRa with free flow and is flowed into
arm cylinder rod (R) side through Ba port of C/V(2).
3. On the other hand, the return oil from arm cylinder (H)
side flows in Aa port, and returns into tank circuit
through arm 1 spool and arm 2 spool.
The return line which does not pass through boost
check valve is used for this return circuit to reduce the
pressure loss.
8-28
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[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
8-29
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[8. HYDRAULIC SYSTEM]
Principle:
8.10.1 BOOM UP / TRAVEL, PILOT
CIRCUIT The travel action and the attachment action are actuated by
separate pumps.
Operation:
Operation:
• Operation: Different point of pilot circuit from
independent operation 1. P1 pump delivery oil flows through P1 port of C/V(2)
and branches off in P1 parallel circuit and travel
1. The mechatro controller outputs command current to straight spool.
travel straight solenoid proportional valve after signal P2 pump delivery oil flows through P2 port of C/V(2)
processing, and the solenoid valve outputs secondary and branches off in P2 tandem circuit and travel
pressure and acts on PTb port of C/V (2). straight spool.
2. Then the pressure of PTb port switches the travel 2. The delivery oil flowed into P1 parallel circuit of P1
straight valve. pump opens check valve LCb1 and flows in boom
spool, which exerts on boom up operation.
The delivery oil flowed into travel straight spool of P1
pump opens check valve LCb2 because the travel
straight spool is shifted, and flows in boom conflux
spool and exerts on boom up operation with the
internal oil conflux.
(In travel straight operation, P1 pump delivery oil exerts
on swing operation of attachment.)
3. The delivery oil flowed into P2 tandem circuit of P2
pump flows in left travel spool to travel leftward.
The delivery oil flowed into travel straight spool of P2
pump flows in right travel spool because the travel
straight spool is shifted and exerts on the right travel
operation.
(In travel straight operation, P2 pump delivery oil exerts
on travel operation.)
4. However, a portion of the flow is led to the travel
straight spool notch restriction. The speed of
attachments like travel, boom, etc. is adjusted by the
circuit of restriction.
8-30
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[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
COMBINED CIRCUIT : Boom up & travel forward (RH & LH) 1st speed operation, travel straight function.
8-31
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[8. HYDRAULIC SYSTEM]
In this section, the independent operation is omitted and 8.10.4 SWING / ARM IN, SWING
describes difference in combined operation. PRIORITY MAIN CIRCUIT
• Swing / Arm in light load, pilot circuit
Purpose:
• Swing / Arm in, swing priority main circuit
Stable swing speed.
8.10.3 SWING / ARM IN LIGHT LOAD, Principle:
PILOT CIRCUIT
Raise the oil pressure flowing to arm cylinder, and give a
Operation: priority of the delivery of P2 pump to swing operation.
8-32
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[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
COMBINED CIRCUIT : Swing left / arm in (light load) operation, swing priority function
8-33
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[8. HYDRAULIC SYSTEM]
Operation
1. Pump proportional valve reduces the pump flow rate to
the minimum.
2. Unloading proportional valves (PSV-D, PSV-B) output
secondary pressure and the secondary pressure flows
in PCb, PCa ports of C/V(2) and switches the P1, P2
unloading valves to OPEN position.
8-34
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[8. HYDRAULIC SYSTEM]
YN01Z00268P1 02
8-35
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[8. HYDRAULIC SYSTEM]
8-36
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[9. ELECTRICAL SYSTEM]
9. ELECTRICAL SYSTEM
9.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................9-3
9.2 ELECTRICAL EQUIPMENT LIST ..............................................................................................9-4
9.3 ELECTRICAL DIAGRAM ....................................................................................................... 9–11
9.4 HARNESS............................................................................................................................. 9–22
9.4.1 HARNESS LIST .................................................................................................................. 9–22
9.4.2 INSTRUMENT PANEL ASSY............................................................................................... 9–24
9.4.3 CONTROLLER&RELAY BOX ASSY INSTAL ....................................................................... 9–26
9.4.4 OPERATORS CONTROLS .................................................................................................. 9–28
9.4.5 SWITCH ASSY ................................................................................................................... 9–31
9.4.6 CONTROLLER INSTAL ...................................................................................................... 9–32
9.4.7 UPPER ELEC ASSY ........................................................................................................... 9–33
9.4.8 UPPER HARNESS ASSY.................................................................................................... 9–36
9.4.9 UPPER HARNESS (FLOOR PLATE) ................................................................................... 9–54
9.4.10 HARNESS ASSY (N&B HCP) ............................................................................................ 9–59
9.4.11 HARNESS ASSY (HCP GRIP+DC-DC)............................................................................... 9–61
9.4.12 HARNESS ASSY (EXTRA PRESSURE SOURCE+N&B SELECTOR) ................................. 9–65
9.4.13 HARNESS ASSY (EXTENSION CONTROLLER) ................................................................ 9–67
9.4.14 HARNESS ASSY (OPT RELIEF)........................................................................................ 9–69
9.4.15 ENGINE HARNESS ASSY................................................................................................. 9–71
9.4.16 WASHER TANK ASSY ...................................................................................................... 9–73
9.4.17 CAB HARNESS ASSY ...................................................................................................... 9–74
9.4.18 RELAY ASSY.................................................................................................................... 9–88
9.4.19 IT KIT HARNESS ASSY (SATELLITE COMMUNICATION).................................................. 9–89
9.4.20 BOOM HARNESS ASSY ................................................................................................... 9–92
9.4.21 BOOM LIGHT INSTAL....................................................................................................... 9–93
9.4.22 UPPER LIGHT INSTAL ..................................................................................................... 9–94
9.4.23 SWING FLASHER INSTAL (LEFT RIGHT) ......................................................................... 9–95
9.4.24 ALARM ASSY .................................................................................................................. 9–97
9.4.25 CAMERA INSTAL ............................................................................................................. 9–98
9.4.26 HARNESS ASSY (REAR CAMERA) .................................................................................. 9–99
9-1
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[9. ELECTRICAL SYSTEM]
9-2
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[9. ELECTRICAL SYSTEM]
9-3
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[9. ELECTRICAL SYSTEM]
(D) DIODE
ACCESSORY OF
D-9 DIODE
FUSE RELAY BOX
D-12 DIODE ↑
D-13 DIODE ↑
D-14 DIODE ↑
D-15 DIODE ↑
ACCESSORY OF
D-20 DIODE
FUSE RELAY BOX
D-21 DIODE ↑
D-22 DIODE ↑
ACCESSORY OF
D-102 DIODE
FUSE RELAY BOX
D-103 DIODE ↑
D-104 DIODE ↑
9-4
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[9. ELECTRICAL SYSTEM]
9-5
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[9. ELECTRICAL SYSTEM]
(L) LIGHT
(M) MOTOR
9-6
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[9. ELECTRICAL SYSTEM]
(R) RELAY
(SE) SENSOR
9-7
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[9. ELECTRICAL SYSTEM]
(SV) SOLENOID
(SW) SWITCH
9-8
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[9. ELECTRICAL SYSTEM]
9-9
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[9. ELECTRICAL SYSTEM]
9-10
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[9. ELECTRICAL SYSTEM]
(1/11)
YN03Z001 10P1 03
9–11
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[9. ELECTRICAL SYSTEM]
(2/11)
YN03Z001 10P1 03
9–12
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[9. ELECTRICAL SYSTEM]
(3/11)
YN03Z001 10P1 03
9–13
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[9. ELECTRICAL SYSTEM]
(4/11)
YN03Z001 10P1 03
9–14
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[9. ELECTRICAL SYSTEM]
(5/11)
YN03Z001 10P1 03
9–15
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[9. ELECTRICAL SYSTEM]
(6/11)
YN03Z001 10P1 03
9–16
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[9. ELECTRICAL SYSTEM]
(7/11)
YN03Z001 10P1 03
9–17
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[9. ELECTRICAL SYSTEM]
(8/11)
YN03Z001 10P1 03
9–18
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[9. ELECTRICAL SYSTEM]
(9/11)
YN03Z001 10P1 03
9–19
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[9. ELECTRICAL SYSTEM]
(10/11)
YN03Z001 10P1 03
9–20
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[9. ELECTRICAL SYSTEM]
(11/11)
YN03Z001 10P1 03
9–21
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[9. ELECTRICAL SYSTEM]
9.4 HARNESS
9.4.1 HARNESS LIST
9–22
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[9. ELECTRICAL SYSTEM]
9–23
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[9. ELECTRICAL SYSTEM]
9–24
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[9. ELECTRICAL SYSTEM]
9–25
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[9. ELECTRICAL SYSTEM]
9–26
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[9. ELECTRICAL SYSTEM]
9–27
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[9. ELECTRICAL SYSTEM]
9–28
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[9. ELECTRICAL SYSTEM]
9–29
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[9. ELECTRICAL SYSTEM]
9–30
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[9. ELECTRICAL SYSTEM]
9–31
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[9. ELECTRICAL SYSTEM]
9–32
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[9. ELECTRICAL SYSTEM]
9–33
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[9. ELECTRICAL SYSTEM]
9–34
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[9. ELECTRICAL SYSTEM]
9–35
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[9. ELECTRICAL SYSTEM]
9–36
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[9. ELECTRICAL SYSTEM]
9–37
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[9. ELECTRICAL SYSTEM]
9–38
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[9. ELECTRICAL SYSTEM]
9–39
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[9. ELECTRICAL SYSTEM]
9–40
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[9. ELECTRICAL SYSTEM]
9–41
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[9. ELECTRICAL SYSTEM]
9–42
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[9. ELECTRICAL SYSTEM]
9–44
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[9. ELECTRICAL SYSTEM]
9–45
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[9. ELECTRICAL SYSTEM]
9–46
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[9. ELECTRICAL SYSTEM]
9–47
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[9. ELECTRICAL SYSTEM]
9–48
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[9. ELECTRICAL SYSTEM]
9–49
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[9. ELECTRICAL SYSTEM]
9–50
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[9. ELECTRICAL SYSTEM]
9–51
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[9. ELECTRICAL SYSTEM]
9–52
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[9. ELECTRICAL SYSTEM]
100
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010
9–53
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[9. ELECTRICAL SYSTEM]
9–54
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[9. ELECTRICAL SYSTEM]
9–55
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[9. ELECTRICAL SYSTEM]
9–56
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[9. ELECTRICAL SYSTEM]
9–57
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[9. ELECTRICAL SYSTEM]
100
1PAF
9–58
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[9. ELECTRICAL SYSTEM]
9–59
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[9. ELECTRICAL SYSTEM]
9–60
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[9. ELECTRICAL SYSTEM]
9–61
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[9. ELECTRICAL SYSTEM]
9–62
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[9. ELECTRICAL SYSTEM]
9–63
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[9. ELECTRICAL SYSTEM]
9–64
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[9. ELECTRICAL SYSTEM]
9–65
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[9. ELECTRICAL SYSTEM]
9–66
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[9. ELECTRICAL SYSTEM]
9–67
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[9. ELECTRICAL SYSTEM]
9–68
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[9. ELECTRICAL SYSTEM]
9–69
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[9. ELECTRICAL SYSTEM]
9–70
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[9. ELECTRICAL SYSTEM]
9–71
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[9. ELECTRICAL SYSTEM]
9–72
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[9. ELECTRICAL SYSTEM]
(0.43")
(11)
GROMMET CUT THE S URP LUS LENGTH
THAT ADJ US TMENT.
CONNECT OR
610
(24 ")
FOR WARD
(5.9")
(5.1")
150
130
TIGHTENING TORQUE
23N .m (17.0 lbf .ft)
(2")
52
SEMS-BOL T
1
VIEW I
BRACKET
SEMS-BOL T
TIGHTENING TORQUE
9.7N .m (7.15 lbf .ft)
III
FOR WARD
TUBE
RUBBER
1 3 0 ") A
(5 . 1
205 )
7”)
50
"
(8 . 1
(1.9
4 4 3 ")
(1 7
0
.
)
.7 9 ”
20)
(1 0 ~
9 ~0
(0 . 3
II
S TARTING S TICK P OS ITION OF A
RUBBER (END OF R)
9–73
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[9. ELECTRICAL SYSTEM]
9–74
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[9. ELECTRICAL SYSTEM]
9–75
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[9. ELECTRICAL SYSTEM]
9–76
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[9. ELECTRICAL SYSTEM]
9–77
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[9. ELECTRICAL SYSTEM]
9–79
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[9. ELECTRICAL SYSTEM]
9–80
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[9. ELECTRICAL SYSTEM]
9–81
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[9. ELECTRICAL SYSTEM]
9–82
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[9. ELECTRICAL SYSTEM]
9–83
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[9. ELECTRICAL SYSTEM]
9–84
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[9. ELECTRICAL SYSTEM]
9–85
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[9. ELECTRICAL SYSTEM]
9–86
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[9. ELECTRICAL SYSTEM]
9–87
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[9. ELECTRICAL SYSTEM]
9–88
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[9. ELECTRICAL SYSTEM]
9–90
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[9. ELECTRICAL SYSTEM]
9–91
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[9. ELECTRICAL SYSTEM]
9–92
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[9. ELECTRICAL SYSTEM]
9–93
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[9. ELECTRICAL SYSTEM]
A
1
NUT
(SUPPLIED WITH LIGHT )
GROMMET
BRACKET
VIEW I
SEMS-BOLT
LIGHT HARNESS TIGHTENING TORQUE
46.1N .m(34.0lbf .ft)
SECTION AA
NOTE
1. TIGHTENING TORQUE OF ITEM 1 TO BE 18.6 N.m (13.7lbf .ft)
9–94
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[9. ELECTRICAL SYSTEM]
9–95
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[9. ELECTRICAL SYSTEM]
9–96
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[9. ELECTRICAL SYSTEM]
9–97
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[9. ELECTRICAL SYSTEM]
9–98
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[9. ELECTRICAL SYSTEM]
9–99
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[9. ELECTRICAL SYSTEM]
9–100
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[9. ELECTRICAL SYSTEM]
9–101
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[9. ELECTRICAL SYSTEM]
9–102
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[10. COMPONENTS SYSTEM]
10-1
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[10. COMPONENTS SYSTEM]
10-2
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[10. COMPONENTS SYSTEM]
10-3
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
a4
a5 A1 A2
(Dr) Psv
VIEW
MAX. FLOW RATE MIN. FLOW RATE
ADJUSTING SCREW ADJUSTING SCREW
2 2-1 EYE BOLT (M10) 2-1
2
a4 a5
Psv
3 Psv
(Dr)
B3 B3
B1
A3
a1 a2
(Dr) a3 a3
P H1 P H2 P H2
A1 A2
Hydraulic ports
No. Parts Q'TY No. Ports name Size
1 Main pump assy 1 A1,A2 Delivery port SAE 6000psi 1"
2 Regulator assy 2 B1 Suction port SAE 2500psi 2 1/2 "
2-1 Solenoid proportional reducing valve 2 Dr Drain port PF3/4-20
3 Gear pump assy (for pilot) 1 Psv Servo assist port PF3/8-17
PH1,2 pressure sensor port PF3/8-17
a1,a2 gauge port PF1/4-15
a3 gauge port PF1/4-14
a4,a5 gauge port PF1/4-15
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
10-4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(FRONT) (REAR)
(KDRDE5K) (KR7G-0E1K-V) a 1 A1 P H1 P s v P H2 A2 a 2 (KR7G-0E1K-V) (KDRDE5K) Solenoid
Solenoid
proportional proportional
reducing reducing
valve (PSV -P1) valve (PSV -P2)
a4 a5
Regulator
10
Regulator
Main pump
Dr A3
B1 B3 a3
Specifications
Item Main pump Gear pump
Revolu- min-1
Rated 2000 ←
tion (Clockwaise seen from shaft end)
10-5
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[10. COMPONENTS SYSTEM]
Main pump
953 806 537 789 732 532 532 548 531 214 808 901 954 792 702 534 717 981 983 151 152
211
490
251
C C
886
B B 04
127
111
A A
774
261 113
710 272
123 824 271 212 153 466 156 157 468 313 124 711 116 312 724 885 314 401 141
406 723 726
414
326
Tighte ning torque
Item Tighte ning torque
number Thread size
N.m (lbf.ft)
401 M20 430 (317)
406 M8 29 (21) (537) 953 806 419
414 M10 57 (42)
419 M16 240 (177) 544 724
466 PF 1/4 36 (27)
468 PF 3/4 170 (125) 723
545
490 M7X0.75 18 (13)
806 M16 130 (96)
808 M20 240 (177) 541
VIEW C SECTION B-B SECTION A-A
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 314 Va lve pla te & L) 1 717 O-ring 2
113 Drive shaft (R) 1 326 Cover 1 723 O-ring 14
116 Gear #1 1 401 Socket bolt;M20X210 4 724 O-ring 10
123 Roller bearing 2 406 Socket bolt;M8X16 4 726 O-ring 4
124 Needle bearing 2 414 Socket bolt;M10X20 4 732 O-ring 2
127 Bearing spacer 4 419 Socket bolt;M16X35 4 774 Oil seal 1
141 Cylinder block 2 466 ROH plug PF1/4 2 789 Back-up ring P18 2
151 Piston 18 468 ROH plug PF3/4 4 792 Back-up ring G35 2
152 Shoe 18 490 Plug;M7X0.75 18 806 Nut ; M16 2
153 Set plate 2 531 Tilting pin 2 808 Nut ; M20 2
156 Spherlcal bush 2 532 Servo piston 2 824 Stop ring 2
157 Cylinder spring 18 534 Stopper (L) 2 885 Pin 4
211 Shoe plate 2 535 Stopper (S) 2 886 Pin 2
212 Swash plate 2 537 Servo cover 2 901 Eye bolt ; M10 2
214 Tilting bus h 2 541 Seat 4 953 Socket screw 2
251 Swash plate support 2 544 Stopper 1 4 954 Set screw ; M20 2
261 Seal cover (F) 1 545 Steel ball 4 981 Name plate 1
271 Pump casing (F) 1 548 Feed back pin 2 983 Pin 2
272 Pump casing (R) 1 702 O-ring 2 04 Gear pump 1
312 Va lve block B 1 710 O-ring 1
313 Va lve pla te & R) 1 711 O-ring 1
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
10-6
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[10. COMPONENTS SYSTEM]
Z
X
10
B3
434
X
311 A3
X
312
a3 850
732 355
Z
435 361 353 307 310 308 309 434 466
SECTION ZZ 725
Delivery port : PF1/2
Tightening torque : 53N .m (39.1 lbf .ft)
10-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10.2.1.3 OPERATION
The pump assy is equipped with two pumps arranged on
the same axis that are connected with gear (116) and
distribute the rotating power to the gear trains on a
REGULATOR
different axis. Thus the engine rotation is transmitted to
front shaft (111) that drives the two pumps and, at the
same time, drives the auxiliary pump (OPT) arranged on
another shaft.
116
The pump assy consists largely of the rotary group, the
main part of the pump that makes rotary on; the swash
plate group that changes the delivery rate; the valve 111
block group that selects between oil suction and delivery
and the PTO group (OPT) that transmits the drive power
to the auxiliary pump.
Rotary group
The rotary group consists of shaft(111), cylinder block PTO GEAR CASE
(OPT)
(141), piston (151), shoe (152), plate (153), spherical
AUXILIARY PUMP
bushing (156), and cylinder spring (157). The shaft is (OPT)
supported by bearings (123) and (124) at its both ends.
The shoe, which is caulked to the piston, forms a
Construction of hydraulic pump
spherical joint and relieves it of thrust force that is
generated by load pressure. Further, the piston is
provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic balance.
The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and
the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder block (141) is also pressed
against valve plate (313) by the action of cylinder spring (157).
3 1 3
1 2 4
3 1 2
1 1 1
1 1 6
1 2 4
3 1 4
1 4 1
1 5 7
1 5 6
1 5. 1 1 5 3
1 5 2
2 1 1
Rotary group
10-8
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[10. COMPONENTS SYSTEM]
10-9
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[10. COMPONENTS SYSTEM]
728
a
641
924
755 801
758 656
708 402
A
887
468 658
726 755
VIEW B
614 466
Tighte ning torque
10-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
The item having the number marked with * is an adjusting screw. Do not touch the adjusting screw as much as
possible.
10-11
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[10. COMPONENTS SYSTEM]
Control function
Control function :
• Positive flow control
Summary
Regulator KR7G-0E2K-V for the swash plate type axial piston pump K7V series consists of the following control
mechanisms.
• Control of current flow rate, Positive flow control
The pump swash plate angle (delivery flow rate) is controlled in accordance with a controlled command current
value of the proportional pressure reducing solenoid valve equipped with this regulator. This regulator is
operated by a positive control, which increases a delivery flow rate as command current value I increases. With
this mechanism, when a current is input in accordance with the working status, the pump delivers only a required
flow rate and do not use an extra power.
Operation
• Control of current flow rate
The delivery flow rate of the pump is controlled in
accordance with command current value I as shown
De live ry flow ra te Q
in the right figure.
• Operation to increase current flow rate
When command current value I increases, the second
pressure of the proportional pressure reducing
solenoid valve increases and spool (642) moves
through pilot piston (898) and stops at the position
where the hydraulic pressure to the right direction and
the power of pilot spring (646) balance each other. Command current I
If spool (642) moves, pilot sleeve/spool pressure
adjusting part (C1) opens and the pressure at the large-diameter part of servo piston (532) is released. Then,
servo piston (532) moves right due to delivery pressure P1 of the small-diameter part to increase the swash
plate angle.
Feedback lever (611) is linked with the servo piston and sleeve (643) and if the servo piston moves right, the
feedback lever rotates around the supporting point and the sleeve moves right. Opening part (C1) of the spool
and the sleeve starts to close gradually and at its fully-closed position, the servo piston stops and stabilizes.
• Operation to decrease current flow rate
If command current value I decreases, the secondary pressure of the proportional pressure reducing solenoid
valve decreases and spool (642) moves left.
After the spool moves, pilot sleeve/spool pressure adjusting part (C2) opens and delivery pressure P1 is led to
the large-diameter chamber of the servo piston. Delivery pressure P1 is always led to the small-diameter
chamber of the servo piston and the servo piston moves left due to the difference of the areas to decrease the
swash plate angle. If the servo piston moves left, the feedback lever rotates around the supporting point and the
sleeve moves left. It moves until the opening part of the spool and the sleeve closes and it stops at the closed
position.
10-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
898 Pd1
P2
532
C1 C2 10
924
Pd1 Pcl
030
801
Pcl
656
954
953
Left Right 808
806 (Flew reducing) (Flew reducing)
10-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10-14
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[10. COMPONENTS SYSTEM]
10-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
300
(79)
250
(66)
Q d (Up side)
699mA 220 L/min (58 ga l/min)
737mA
200 3.92
Flow ra te Q d [L/min (ga l/min)]
(53) (568)
3.43
(497)
150 2.94
100 1.96
(26) (284)
1.47
(213)
0.92 MPa (133 ps i)
400mA
50 0.98
(13) (142)
0 0
200 300 400 500 600 700 800
Input electric current (mA)
10-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
OUTSIDE VIEW
P Tb
PBL
P2
CT2
10
CP 2
Pc
(P6 ) (P5 )
Dr2
P1
P Cb PAL
P Tb CT1 T2 T1
CT2
Travel Dr1 P1 P Cb PAL
P AL
Travel left
PCb P BL
straight CMR1 CMR2
PL unload CP 2 BL
MR AL
Ar
P Ca
Travel PAr PB1 Boom
PBr right PAr PB1
Br
CP L Ab
AbR conflux LCb2 P2 unload
PAb XAb Prb
Bb PBb Pra Boom 2 CAb
Pc PBb Pra
Dr2 CRbL
Boom CRb2 CRa CBb Boom 3
P Lc1
PAc Bucket PBs
Ac Bc BcR PBs Swing As Bs P Aa
LCc LCs
PBc P Cc P Cc P Aa 1
Arm 2 CBa PBa 1 P Lc2 CRa
PBa 2 Arm 1 Aa
PAa 2 PBa 2 PBa 1
Ta LCAP 2 LCAT2 MU Ba LCa
MU Ba R
PBa 2 PBa 1
Dr2 BbR
Boom PAb
Boom 3
Pc Prb
VIEW A
A
Outside view
10-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
PORTS
Tightening
Port size Ports Description
torque
10-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
SPECIFICATIONS
Item Specifications
Model KMX15YF/B44002A
Maximum flow rate [L/min (gal/min)] 220 (58) X 2
Maximum set pressure [MPa (psi)] 37.8 (5480) (P port)/39.7 (5760) (A,B port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 70 X 2 L/min (18.5 X 2 gal/min)]
When power boost pressure High 37.8 (5480) [at 60 X 2 L/min (15.9 X 2 gal/min)]
10-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Control valve
J
J
154 164 101
P2
T2
PAL P BL
J
P B1 P Ca
Pra Prb
P Bs PAs
PBa 1 PAa 1
154 164
P1 102
974
973
P Tb P Cb
974
973
P Br PAr
973
PAb P Bb
973 973
PAc
973 P Cc
P Bc
PAa 2 PBa 2
973 973
SECTION B-B
Section (1/6)
10-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
T2
H 273x1 0 H
P1 unload P Cb PAL Travel left
C 273x10 C
PAr P B1 977 10
Travel right Boom conflux
D D
978x2
Boom P Bb Pra
Boom 2
E
E
P Bs
Bucket Swing
F F
P Cc
PBa 2 PBa 1
Arm 2
Arm 1
G G
MU
K K
B A
PBa 2 PBa1
274x 4 274x4
Dr2
Pc
213 213
PAa 1
PAa 2
Section (2/6)
10-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
331 331
261 MR 261
309
601
PL 306
AL 163
511
512
521
522 CP2
CMR2 551
552 164
562
CMR1 162
BL
552
522 163
Dr1
512
307
261
331 PBL 264
327 205
329
336
331 SECTION C-C
333
202 PTb
Travel straight
331 331
261 261
306
305
161
Ar
511 511
521 521
CP1 LCb2
551
551
164 164
163 Br
310
161
(T3)
164
264 154
PBr
261
205 331
327
SECTION D-D
329
336
PCa 331
P 2 unload 333
202
Section (3/6)
10-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
203 202
333 Boom Boom 2 333
331 331
336 P Bb Pra 336
319 322
321 320
603 331
AbR 261
L 331 L 212
163
211 M N N
M 261 161
266 159
159 PLc1 312
514 CAb
551
524
CRb1
521
164
10
556 CRb2 511
164
556
Dr2 164
529
Pc 513
CRe 164
208 551
520 521
Bb 516
162
163
CBb 313
551
301 164
264 521
162 511
PAb
161 261
602 BbR 331
SECTION E-E 320
205 322
336
Prb 331
Boom 3 333
202
209
216 P Cc Swing 201
333 333
PBs
331 331
336 P Bc
336
322 322
321 321
602 BcR
331 331
261
261
304
Bc
162 As
511 511
521 523
LCc
LCs
551
556
164
164
163 Ac
Bs
162
162
162
264 303
PAc
264
603 PAs
205 SECTION F-F 205
AcR
Section (4/6)
10-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
201
201 333
333 Arm 2 Arm 1 331
331 PBa2 PBa1 336
340 322
328 321
321
BaR 603
331
331
550 211
261 562
525 L L
CBa 261
519 159
MU
308
PLc2 514
162
162 524
CRa
162 556
511
164
521
551 LCAT2 511
164 521
515 LCa
521 551
LCAP2
551 164
164 302
162
162 Ta Aa
163
162
510
526 CTa 604
167 264
557 PAa1
P P
264 205
210 PAa2 AaR
SECTION G-G
T2
161
511
P1
521 T1
163
CT1
551
163
164
162
P2
CT2
551
164
Section (5/6)
10-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
207
606 606 563
160
278x 5 564
266
264 264
10
SECTION N-N SECTION L-L
SECTION J -J SECTION K-K
Section (6/6)
Tightening Tightening
torque No. Name Q'TY torque No. Name Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
16 to 20
159 Plug ; M7X0.75 4 329 Spring 3
(12 to 15)
7.8 to 9.8
160 Plug ; R-1/16MEC 1 331 Spring seat 26
(5.8 to 7.2)
16 to 18 (12 to 13)
161 O-ring 5 333 Spacer bolt 13
Loctite #262
162 O-ring 21 336 Stopper 11
9.8 to 14
212 Lock valve selector sub 1 520 Sub logic valve 1
(7.2 to 10.3)
10-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
9.8 to 14
212 Lock valve selector sub 1 520 Sub logic valve 1
(7.2 to 10.3)
98 to 120
274 Socket bolt 8 527 Spring 1
(72 to 89)
25 to 34
278 Socket bolt 5 528 Spring 1
(18 to 25)
230 to 260
303 Swing spool 1 551 Plug 13
(170 to 192)
130 to 150
304 Bucket spool 1 552 Plug 2
(96 to 111)
230 to 260
305 Boom conflux spool 1 556 Plug 4
(170 to 192)
49 to 59
306 Travel spool 2 557 Plug 1
(36 to 44)
69 to 78
312 Boom 2 spool sub 1 602 Port relief valve 2
(51 to 58)
69 to 78
313 Boom 3 spool sub 1 603 Port relief valve 3
(51 to 58)
69 to 78
319 Spring 1 604 Port relief valve 1
(51 to 58)
69 to 78
320 Spring 2 606 Bypass cut valve 2
(51 to 58)
140 to 180
321 Spring 5 973 Socket bolt 8
(103 to 133)
140 to 180
322 Spring 5 974 Socket bolt 2
(103 to 133)
325 Spring 1
10-26
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
69 to 78
103 Plug 1 562 Back up ring 1
(51 to 58)
561 O-ring 1
10-27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
69 to 78
101 Body 1 541 Seat 1
(51 to 58)
69 to 78
102 Plug 1 561 O-ring 1
(51 to 58)
10-28
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Arm 2 spool
10
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
16 to 18 (12 to 13)
308 Spool 1 350 Plug 1
Loctite #638
16 to 18 (12 to 13)
317 Plunger 1 351 Plug 1
Loctite #638
319 Plunger 1 361 O-ring 2
Boom spool
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
10-29
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Boom 3 spool
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
351 361
371 312
Boom 2 spool
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
10-30
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
101 10
164
171
201
321
PLc A B Dr
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
10 to 14
101 Casing 1 171 Socket bolt 3
(7.4 to 10.3)
49 to 59
161 O-ring 4 201 Plug 1
(36 to 44)
10-31
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
101
164
171x3
201
321
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
10 to 14
101 Casing 1 171 Socket bolt 3
(7.4 to 10.3)
49 to 59
161 O-ring 4 201 Plug 1
(36 to 44)
10-32
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
102
106x4
103
10
104
101 105
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
6 to 8
101 Casing 1 104 Spring seat 1
(4.4 to 5.9)
20 to 24
102 O-ring 1 105 Lock nut; 1
(14.8 to 17.7)
10-33
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
102 101
110
114
112 113 103
120x4
Logic valve
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
13 to 17
110 Plug 1
(10 to 13)
10-34
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
106
104
107
102
10
101
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
24.5 to 29.5
101 Logic poppet 1 104 Plug 1
(18.1 to 21.8)
10-35
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
202 301
T Dr
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
69 to 78
101 Plug 1 202 O-ring 1
(51 to 58)
25 to 29
102 O-ring 1 301 Lock nut 1
(18 to 21)
25 to 29
201 Adjusting screw 1
(18 to 21)
104
107
102
101
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
20 to 29 (15 to 21)
101 Poppet 1 104 Plug 1
Loctite #262
102 Poppet 1 107 Spring 1
10-36
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Travel
straight
Boom conflux
10
Boom 3
Boom
Boom 2
Swing
Bucket
Arm 1
Arm 2
10-37
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
606
52
517
307
T1
P2
P1
309
606
55 310
(D)
Connected to low
pressure circuit of
P2 side casing
At neutral
10-38
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
A B
AL BL
306 CP2
323
324
PAL PBL
10-39
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
C M R 2 C M R 2
B P 2 B P 2
C M R 1 C M R 1
P 1 P 1
A A
3 0 7 3 0 7
3 2 7 3 2 7
3 2 9 3 2 9
P T b P T b
P 2 P 1 P 2 P 1
P T b P T b
D r D r D r D r
B A A
T o e a c h a c tu a to r B T o e a c h a c tu a to r
T o tr a v e l r ig h t T o tr a v e l r ig h t
C ir c u it ( I) C ir c u it ( II)
10-40
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
216
PAc
PCc PBc
321
322 (D) Bc LCc Ac
304 511
(R) (H)
10-41
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
216
The down stream of
the boost check valve.
PAc
PCc PBc
322
321
Bc Ac
LCc
304
511
(R) (H)
10-42
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(R) (R)
(H) (H)
520 514
Pc Dr2 321 319
Ab BH chamber
301 (D) 53
CRb1
Bb
PAb
PBb
10-43
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
P B1
326
325
305
Conflux passage
To Ab port of P1 casing
511
LCb2
56
10-44
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(R) (R)
(H) (H)
520 514
P c Dr2 321 319
Ab BH Cha mbe r
301 CRb1
Bb
PAb
PBb
BH Cha mbe r
Prb Pra
P Lc1
CBb CRe CRb2 CAb
56
322 320 313 516 513 511 312 320 322
10-45
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(R) (R)
(H) (H)
520 514
P c Dr2 321
Ab BH Cha mbe r 319
301 CRb1
Bb
PAb
PBb
BH Cha mbe r
Prb Pra
P Lc1
CBb CRe CRb2 CAb
56
320 320
322 313 516 513 511 312 322
10-46
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(R) (H)
321 AR chamber
322 211 514 302
CRa LCa
Ba 56 Aa
P1
PBa1 PAa1
(D')
(D) LCAT2 LCAP2
ARM 1
P1
RR RH HH (D'') PAa2 PBa2
52 53 Dr Dr
ARM 2 CBa
To arm 1 spool
PBa2 PAa2 Aa (HEAD)
Ba
(ROD)
To bypass cut valve
MU CTa
LCAT2 LCAP2 Ta
328 321 308 (D) 511 515
10-47
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(R) (H)
321 AR chamber
322 211 514 302
CRa LCa
Ba 56 Aa
P1
PBa1 PAa1
(D')
(D) LCAT2 LCAP2
Arm 1 P1
RR RH HH PAa2 PBa2
(D) 52 53 Dr Dr
Arm 2 CBa
To arm 1 spool
PBa2 PAa2 Aa (HEAD)
Ba
(ROD)
Ta
(D) LCAT2 LCAP2
328 321 308 511 515
10-48
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(R) (H)
321 AR chamber
322 211 514 302
CRa LCa
Ba 56 Aa
P1
PBa1 PAa1
(D')
(D) LCAT2 LCAP2
Arm 1 P1
PAa2 PBa2
RR RH HH Dr Dr
(D) 52 53
Arm 2 CBa
To arm 1 spool
Aa (HEAD)
PBa2 PAa2 Ba
(ROD)
10-49
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
PBs
PAs
303
Bs As 321 322
LCs
(D) 56 511
B A
Swing motor
Swing operation
10-50
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
A A P Lc
(a ) S a Sb (b) Dr
RH S ECTION A-A
chambe r
P Bb
301
Dr
10-51
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
A A
P Lc (a ) S a S b (b) Dr
RH cha mbe r
S ECTION A-A
P Bb
301
Dr
10-52
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(b)
520-102
520-101 (a)
(e)
(d)
(c)
10-53
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
[Normally]
The adjusting screw (201) of the bypass cut valve (606) is tightened normally and apical tapered portion of the
adjusting screw (201) is pushed to the seating portion of casing. Then, the center bypass (52) and the low-pressure
passage (D) are blocked.
As a result, in the normal operation, the center bypass (52) are always blocked from the low-pressure passage (D),
the working fluid discharged from the hydraulic pump P1 at neutral does not pass the center bypass (52), but
returns to the working fluid tank through the P1 unloading spool (309).
201
(D)
52
10-54
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
[At Failure]
When the electric control system is failed, the P1 unloading spool (309) remains at the neutral position. Because
the working fluid discharged from the hydraulic pump P1 is blocked by the P1 unloading spool (309) and the center
bypass (52) is blocked from the low-pressure passage (D) by the bypass cut valve (606), the pressure of pump P1
rise to the main relief setting pressure. However, the working fluid passed through the center bypass (52) passes to
the low-pressure passage (D) through the bypass cut valve (606) by loosing the lock nut and the adjusting screw
(201) of the bypass cut valve (606).
Thus, when the electric control system has failed, the P1 unloading spool is positioned at neutral to block the
passage to the low-pressure passage (D), but the center bypass (52) instead is communicated with the low-
pressure passage (D) through the bypass cut valve (606) to prevent the pump pressure from rising abnormally by
loosing the adjusting screw (201) of the bypass cut valve (606). 10
201
(D)
52
10-55
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
5 2 7
5 2 8
( D ')
T 2 5 1 8
T 1
1 0 2
5 1 7 (D ) 5 2 7 5 2 8
T 2 5 1 8
In n o r m a l o p e r a tio n 1 0 2 T 1
5 1 7
(D )
In m a k e u p o p e r a tio n
10-56
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10
527
528
(D') T2
518
T1
102
517
(D)
10-57
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
POR T 1, 3 POR T 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)
S e conda ry pre s s ure [MP a (ps i)]
S e conda ry pre s s ure [MP a (ps i)]
0 5 10 15 19 0 5 10 15 20 25
1 3 2 4
HYDRAULIC SYMBOL
10-58
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
312
M14
Apply Loctite #262 68.6±4.9 N .m
Application part (hatched area) (50.6±3.61 lbf .ft)
302
501 301
Apply grease on
Apply grease rotating and sliding sections.
on top section 246-1 Be careful the
212
246-2 213
assembling direction
M14
10
151 47.1±2.9 N .m
(34.7±2.14 lbf .ft)
218
211
214
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N・・m (lbf・・ft) N・・m (lbf・・ft)
10-59
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Lever in neutral
216-2
201-2
POR T (2,4) POR T (1,3)
10-60
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Lever held
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (241–2) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2,4) rises
above a set value, ports (2,4) and the P port close while
ports (2,4) and the T port open. When the pressure at
ports (2,4) falls below a set value, ports (2,4) and the P 241-2
port open while ports (2,4) and the T port close. Thus the
secondary pressure is kept constant.
T P ORT 10
Operation in the area where the tilting angle of the
P P ORT
lever is large. (varies with the model)
If the lever is inclined beyond a certain angle on certain
models, the top end of the spool contacts the bottom of POR T (2,4) POR T (1,3)
the bore of the push rod. This keeps the output pressure
connected with the P port pressure. When the lever is held
Furthermore, on a model in which a spring seat and a
spring are built in the push rod, the bottom of the bore of the push rod contacts the spring if the lever is turned
beyond a certain angle. This causes the secondary pressure gradient to change by the spring action. Thereafter,
the bottom of the bore of the push rod contacts the top end of the spring seat, keeping the output pressure
connected with the P port.
10-61
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
Specifications
P T
Item Specifications
Part No. YN30V00105F2
Type 6TH6NRZ
Primary pressure 5.0MPa (725psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
10-62
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Performance characteristics
Secondary pressure
[MPa (psi)] Secondary pressure
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30'~ 11 30'~ Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
10
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
10-63
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
5
3
8 10
3
11 12
4
10
9
9
7 6
2
10-64
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tightening
Port
Symbol Port name torque
size N.m (lbf.ft)
A,B Main port PF3/4 167 (123)
DB Drain port PF3/8 74 (54.6) B
B PB
M Make-up port PF3/4 167 (123)
M DB
DB
10
PR
PA,PB Pressure meaduring port PF1/4 36 (27.0)
A
PA
PR Parking break release port PF1/4 36 (27.0) A
Gear oil filler port
IP,L,AR serving also as level gauge PT3/4 98 (72.3)
and air breather port PB
PA
Lifting bolt 2-M12 IP, L, AR
Thread depth 24 (0.94")
Lifting capacity M
2160N (486 lbf)
A, B
PR
PR
DB
PA PB
Grease nipple
A B
Hydraulic diagram
10-65
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Specifications
Swing motor unit part No. YN15V00078F1
Type M5X130CHB-10A-4RA/295
10-66
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Swing motor
993
10
390 391
VIEW I
351
355
051
(051-1)
469
702
488
401 712
151
171 161 163 985 444 984 131
052
A A
I Arrangement of brake spring
162
451
303
985
472
707 712
702
980
706 743
100
111
742
121
400-1
123 994
052
400-2
122 400
124 443 491 101 114 301 SECTION A-A
10-67
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tightening Tightening
torque No. Parts Q'ty torque No. Parts Q'ty
N・・m (lbf・・ft) N・・m (lbf・・ft)
0.9
301 Casing 1 980 Plug ; PF1/4 1
(0.7)
1.7
303 Valve casing 1 984 Plug ; PF3/8 1
(1.3)
4.4
351 Plunger 2 985 Plug ; PF3/4 3
(3.2)
65
355 Spring 2 993 Plug ; PT1/2 1
(48)
98
390 Name plate 1 994 Plug ; PT3/4 1
(72)
391 Rivet 2
10-68
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Apply Three
Bond #1211. Apply Loctite #515.
Paint this machined surface. Apply Loctite #515.
Tightening torque
181 N .m (134 lbf .ft)
12 10 20 8 4 7 6 23 Apply Three Bond 1360K
2
LEVEL
POR T P T1/2
A
II
1 9 22 18 17 5 18 14 3 16 15 28 19
21 29 11
Be careful about
Insert 1mm(0.04") deep from installation direction
Lubricate grease.
the surface of Item 8 (spider). of retaining ring.
13 27 26 25
Wind seal tape around plug and
install it (tightening torque Wind seal tape around tube and install elbow to tube
10N .m (7 lbf .ft)) to item 26 elbow with tightening torque 30N .m (22 lbf .ft) and then make
until its surface becomes direction of elbow as shown in drawing by retightening.
the same surface of elbow end.
Wind the seal tape or
Install grease nipple apply the Locktite #577
as facing to motor side. 30 31 around the screw.
Tightening torque
10.8N .m (8.0 lbf .ft)
Leave installation angle as it is.
Punch here 2 portions to deform holes in order to
prevent spring pin (22) from coming out.
VIEW II
4 places
SECTION AA
10-69
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tightening Tightening
torque N・・m No. Parts Q'ty torque N・・m No. Parts Q'ty
(lbf・・ft) (lbf・・ft)
10-70
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10-71
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
DIRECTIONAL VALVE
10-72
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
R
Plunger (301) Orifice n Chamber g
Condition
10-73
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
1. Neutral condition
Above Fig. illustrates the relationship between the
neutral condition of the anti-reaction valve and the
hydraulic circuits. L
Now, let us consider a braking condition in which
brake pressure generates on the AM port side.
k
322 313 321 311
Neutral condition
p t
P<PS
k
322 313 g r 321 311
10-74
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
3. At anti-reaction action P Y
When inertia load stops moving (point Y below Fig.),
PS
brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the right
return side by the action of spring (321). Seat (313) PB
X
tries to move to the right by the action of spring Z
(322), but since chamber p provides damping action T
by orifice g, the return of the seat makes a time
delay with regard to the return of the plunger. Pressure change diagram of anti-reaction
Consequently, seat t opens. This makes a passage operation
connecting the AM port and BM ports or both ports 10
of the hydraulic motor by way of L→t→r→k. The result is that the pressures at the AM and BM ports become
equal (Pb), falling into the condition at point Z in below Fig.. This prevents the hydraulic motor from swing
shock by the closing pressure of the AM port.
10-75
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
P la ne ta ry pinion
Planetary mechanism
For the operation of the 1st stage planetary, the hydraulic Swing motort
motor rotates #1 sun gear (2). Sun gear (2) is engaged
with planetary pinion (3) and rotates, but since ring gear 3 2
(7) is fixed, planetary pinion (3) revolves about sun gear 7
(2) with the planetary shaft and spider (28).
The role of spider is to hold the planetary pinion and 28
planetary shaft and transmits the power from the 5
planetary pinion to the spider through the planetary
shaft. 29
The #1 spider (28) is linked with #2 sun gear (5) by the
involute spline, and transmits the power to the 2nd stage 30
planetary mechanism. For the operation of the 2nd stage 6
planetary, the power is transmitted to sun gear 12
(5)→planetary pinion (6)→spider (29) similarly to the 1st
stage.
The #2 spider (29) is linked with pinion shaft (1) by the
involute spline, and pinion shaft (1) is engaged with the
swing gear fixed on the undercarriage (lower frame) and 11 1
rotates.
10-76
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Outside view
SPROCKET
INSTALLING FACE
Pm1 P1
T
Pm2 10
A
Tin
P2
Pp
Ps
LUBRICATION PORT
Specifications
Parts No. YN15V00051F5
Item
Type MAG-170VP-3800G-K10
Reduction ratio 1/43.246
Reduction unit Lube oil Gear oil SAE #90 GL4
Oil level L (gal) 5.0 (1.3)
10-77
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Z3 Z3
17 22 23 19,20 21 24 26 23 25 17
X1 X1
28
S ECTION Z6-Z6
(1P LACE)
29
11 13 12 7 6 5 4 3 67 30 8 9 10 S ECTION Z5-Z5
(3P LACES )
65 66
Z6
Z4 Z4
Z6
33 34 15 14 14 15 34 33
18
S ECTION Z4-Z4 S ECTION X1-X1
10-78
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
18 18 18
Z5 Z5
Z5
Z5
Z5 Z5
41 44 43 42 37 45 38 40 39 48 61 73 72 75 76 74 85 86 96
10
52 87
60 90
51 91
69 92
62 88
89
93
32
31
50
68 94
95
59
56 97
98
64
83
60
84
57 63 58 55 54 1 36 46 70 47 49 53 71 99 77 78 79 80 81 82
10-79
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tight- Tight-
width width
ening ening
across across
torque No. Name Q'TY torque No. Name Q'TY
flats flats
N・・m N・・m
mm mm
(lbf・・ft) (lbf・・ft)
205
1 FLANGE 1 12 52 CAPSCREW; M14X35 10
(151)
OIL SEAL;
2 BASE PLATE 1 53 1
TCZ50X72X9
(SPOOL)
3 1 54 DISK PLATE 3
PLUNGER
4 CHECK VALVE 2 55 FRICTION PLATE 2
5 SPRING 2 56 BRAKE PISTON 1
137*
14 6 PLUG; M24,P=1.5 2 57 O-RING 1
(101)
539* Torques
26 WASHER 1 76 BOLT; M20X70 8
(398) T90
2.45
2.5 28 ORIFICE; M5X0.8 1 77 THRUST PLATE 4
(1.81)
2.45
2.5 29 ORIFICE; M5X0.8 3 78 INNER RACE 4
(1.81)
2.45
2.5 30 ORIFICE; M5X0.8 2 79 NEEDLE BEARING 4
(1.81)
10-80
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tight- Tight-
width width
ening ening
across across
torque No. Name Q'TY torque No. Name Q'TY
flats flats
N・・m N・・m
mm mm
(lbf・・ft) (lbf・・ft)
36.8
6 31 PLUG; PF1/4 4 80 PLANETARY GEAR C 4
(27.1)
47 BALL 2 95 COVER 1
73.4
48 PISTON ASSY 2 8 96 BOLT; M10X16 16
(54.1)
157
49 BALL BEARING 1 12 97 PLUG; PF3/4 3
(116)
10-81
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[10. COMPONENTS SYSTEM]
10-82
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
27
29
28
53
37 C
10-83
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Functions
The function of double counter balance valve is described below.
• Overrun prevention function to control the speed of piston motor to the speed corresponding to the supply flow
rate when the piston motor speed is higher than the speed decided by the supply flow rate (hereinafter called
pumping action) due to the outer load.
• Braking function to gradually stop the piston motor revolution by forming the brake circuit by the use of crossover
relief valve and giving the braking force to the piston motor revolution.
• Shuttle valve function for high pressure selection to release the parking brake with the aid of self pressure.
Operation
1. Stop condition
(See Fig. “Construction of double counter balance valve (stop condition)”.)
When the control valve is at the neutral position (motor is stopped), M1 and M2 ports are locked by plunger (3)
and check valve (4) (hydraulic lock) and the motor stops rotating because the pressure does not flow through
P1 and P2 ports.
OIL PASSAGE B
OIL PASSAGE C2
OIL PASSAGE C1
ORIFICE D1
ORIFICE D3
3
4
10-84
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[10. COMPONENTS SYSTEM]
OIL PASSAGE B
OIL PASSAGE C2
OIL PASSAGE C1
ORIFICE D1 ORIFICE D3
SPRING CHAMBER 2
SPRING CHAMBER 1
8 21
21 4
5 4 3
10-85
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
11-2
11
OIL PASSAGE B
11-5
OIL PASSAGE C2
OIL PASSAGE C1
ORIFICE D1
ORIFICE D3
Double counter balance valve and relief valve when piston motor is braked.
10-86
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
OIL PASSAGE D
OIL PASSAGE D
ORIFICE 50 47
10-87
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[10. COMPONENTS SYSTEM]
P RES S URE
10-88
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[10. COMPONENTS SYSTEM]
T1 T2
13,14
OIL PASSAGE B
A1
A2
PISTON
CHAMBER F
39
39 FACE B
2-SPEED FACE C M1 M2
CONTROL
PISTON THRUST (29)
PISTON
THRUST
SPRING
THRUST (34)
37
38 FACE A
1 38
10-89
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[10. COMPONENTS SYSTEM]
2. When switching the motor capacity to large capacity (low speed mode)
(See Fig. “When fixed to low speed (large capacity)”.)
When switching the motor capacity to large capacity (low speed mode), (See below Fig..) With turning the
speed control switch to low speed, by returning the pilot pressure oil acting on Ps port into the tank, 2-speed
control valves (13,14) is moved rightward by the spring (15) force until it comes into contact with plug (16).
Therefore M1 and M2 ports of the motor close, and oil passages A1 and A2 led to the 2-speed control piston
chamber F is led into motor case drain oil passages T1 and T2. And pressure oil in the 2-speed control piston
chamber F is led into the motor case drain, and the face C is pushed by the thrust of piston (29) and spring (34)
until the face B of swash plate (37) comes in contact with flange holder (1), consequently the tilt angle of swash
plate (37) becomes larger and the piston motor speed switches to low speed.
PS (PILOT PRESSURE)
16
T1 T2
OIL PASSAGE B
A1
A2
PISTON
CHAMBER F
39
FACE B
39
FACE C M1 M2
PISTON THRUST (29)
SPRING
THRUST (34)
37
38 FACE A
1 38
10-90
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
OIL
PILOT PRESSURE PASSAGE A MOTOR LOAD PRESSURE CHAMBER
OIL CHAMBER
T1 OIL T2
PASSAGE
B
Pin
M2 M1
10-91
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[10. COMPONENTS SYSTEM]
4. Low speed (large capacity) position (See Fig. “Low speed (large capacity) in Auto 2-speed”.)
The motor low speed condition at auto 2-speed position is shown in Fig. “Low speed (large capacity) in Auto 2-
speed”. When load pressure Pin to the motor is raised higher than the auto 1st speed return pressure, the
motor capacity control valve moves rightward, and is switched to the motor low speed (large capacity) mode,
that is, the motor low speed operation.
PS (PILOT PRESSURE)
T1 OIL T2
PASSAGE
B
Pin
M2 M1
10-92
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
50 47 CYLINDER CHAMBER E
10-93
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10-94
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[10. COMPONENTS SYSTEM]
D
F E A
C
10
D
VIEW Y
C
VIEW Z
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF1
Ports size
E PF1/2
F PF1/4
Length: L 371 mm (14.6 inch)
10-95
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[10. COMPONENTS SYSTEM]
VIEW Y
5
5 places
7 3 places
Tighte ning torque
3 30.4 N .m (22.4 lbf .ft)
10 Apply Loctite #242
4
11 2 places
Tighte ning torque
30.4 N .m (22.4 lbf .ft)
Apply Loctite #242
10.2.10.4 FUNCTION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal
assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove. The body
(1) and the stem (2) rotate mutually.
The oil flowing in from body (1) or stem (2) keeps on flowing to stem (2) or body (1) past the circumferential groove
between body (1) and stem (2) ; the oil flow is never shut off because of rotation. Further, an oil groove for
lubrication that connects with the drain port is provided, in order to prevent the body (1) from seizure with the stem
(2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
10-96
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[10. COMPONENTS SYSTEM]
10
VIEW I
II
VIEW II
Circuit pattern
(Pilot valve side)
10-97
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
12
A
13, 16
A
5
7 VIEW I
7
20
19
14 19
2
9
6
4
18
15, 17
3 1
SECTION AA
Tightening
Item Size torque Note
N・・m (lbf・・ft)
9 - 3 to 5 (2.2 to 3.7)
Loctite #242
13 M6 11 (8.1)
(or equivalent)
Loctite #242
14 M6 11 (8.1)
(or equivalent)
15 M8 26.5 (19.5)
10-98
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
9 Bolt 1 20 O-ring 1
10-99
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[10. COMPONENTS SYSTEM]
General view
(-)
Type of conne ctor: e quiva le nt to AMP ECONOS EAL J s e rie s conne ctors
MARK II(+) cap hausing
(+)
Cap housing 174354-2 or equivalent
ELECTRICAL CIRCUIT Te rmina l 173706-1 or e quiva le nt
t1 P t2
LCo
BoR AoR
PAo P Bo
T
Dr
Ps
PBo
Bo Ao PL
HYDRAULIC CIRCUIT
LCo
Item Specification
10-100
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10
10-101
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
701x2
901
B B
P Bo LCo
Bo
Ao
BoR
C C
D 271x2
PAo
AoR
703x4
271x2
201 321 161 302 SECTION BB
207
162
PL Ps Dr 163
PBo PAo
t1 P t2
602
BoR
AoR
PBo PAo
202
334
204 262 101 301 261 337 333 324 323 337
SECTION CC
10-102
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tightening torque
Item Size Note
N・・m (lbf・・ft)
10-103
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
A2 A1
S e conda ry pre s s ure MP a (ps i)
3
(435)
2.7
(392) T
2-M8 screw depth 12mm (0.47 inch)
2
Tithe ning torque 29N.m (21 lbf .ft) (290)
P
1
(145)
Hydraulic symbol
0
860 1500
0 900 1600mA
Input current (Average) (mA)
Control diagram
Item Specification
10-104
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
601
171
10
101
Tightening
Item Size torque Note
N・・m (lbf・・ft)
10-105
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
2-M10x1.5 VIEW B
Thread depth15
Item Specification
2.35 ( 341)
Effort to ope ra te
0 0 2 4 6 8 10 12 [de g]
Operating angle
Hydraulic circuit Control diagram
10-106
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10
10-107
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
1
2
29 5
20
8 9
11
32 12
22
16 18
28
26
3
25
Tightening
Item Size torque Note
N・・m (lbf・・ft)
18 - 24.5 (18.1)
21 M8 14.7 (10.8)
10-108
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
1 Shim 2 16 Body 2
2 Shim 2 18 Plug 1
3 Seat 1 19 Capscrew 1
5 Sleeve 2 20 Bolt 2
6 Cover 1 21 Setscrew 2
7 Piston 2 22 Washer 2
8 Spring 1 24 Pin 2
Spring
10
9 2 25 Ball 1
11 Shim 2 26 Ball 3
12 Shim 1 27 O-ring 2
13 Cam 1 28 O-ring 1
14 Boot 1 29 O-ring 2
10-109
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
General view
PF1/4
PF3/8
PF3/8
HYDRAURIC CIRCUIT
Item Specification
10-110
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10
10-111
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
208
206
208
206
208
170
10-112
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tightening torque
Item Size Note
N・・m (lbf・・ft)
10-113
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
General view
PF1/4
PF3/8
Item Specification
10-114
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10
10-115
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
208
206
208
206
208
170
10-116
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tightening torqu
Item Size Note
N・・m (lbf・・ft)
10-117
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
General view
4-M10
(P=1.5)
Depth 20 mm
(0.79 inch)
ROTATION
C-VIEW (OUTLET PORT)
Inlet port
4-M10
(P=1.5)
Full Depth 20 mm (0.79 inch)
Item Specification
Instantaneous maximum
29.4MPa (4263psi)
pressure
10-118
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10
57 52 50, 51 4 56 55
3 Gear 1 55 Capscrew 4
4 Gear 1 56 Washer 4
5 Side plate 2 57 Bushing 4
6 Rear cover 1 65 Oil seal 1
50 Back up ring 2 70 Retaining ring 1
10-119
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
General view
4-Capscrew M8-80
HYDRAULIC SYMBOL
Tighte ning torque : 20~25 N.m
(15~18lbf .ft)
Item Specification
10-120
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10
10-121
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
332
201 322
331
602
154 261
151 166 155
161 167
153
164 164
901
163 163
162
111
152
271x8 602
101 601 261
701x4
331 702x4
SECTION A-A 121
322 302
201 332
SECTION B-B
10-122
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Tightening torque
Item Size Note
N・・m (lbf・・ft)
10-123
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10.2.19 CYLINDER
10.2.19.1 SPECIFICATIONS OF CYLINDER
General View
B A
n gth ngth
ed le ed le
nd act
exte r etr
l l y ll y
Fu Fu
Specifications
Center distance of
Stroke Dry
Part No. of Cylinder bore/Rod Dia. pins Full extend B / Cushion
Use mm weight
cylinder assy mm (ft-in) Full retract A mm (inch)
(ft-in) [kg (lbs)]
mm (ft-in)
With cushion
dia. 120 / dia. ø85 1,355 3,199 / 1,844 166
Boom YN01V00151F2 on rod side
(4.72”/3.34”) (4’5”) (10’6”/6’11”) (370)
R-50 (1.97”)
With cushion
dia. 135 / dia. 95 1,558 3,637 / 2,079 on both sides 255
Arm YN01V00175F3
(5.32”/3.74”) (5’1”) (11’11”/6’10”) H-40 (1.57”), (562)
R-60 (2.36”)
With cushion
dia. 120 /dia. 80 1,080 2,675 / 1,595 143
Bucket YN01V00153F1 on rod side
(4.72”/3.15”) (3’7”) (8’9”/5’3”) (315)
R-50 (1.97”)
10-124
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
4-M10x1.5
[Effective thread depth: 18mm (0.71 inch) ]
4-M12x1.75
[Effective thread depth: 21mm (0.83 inch) ]
(-0.02")
(4.13")-0.5
105 0
22 23 23 22
PS1/8
PT1/4
10 20
9 8 7 6 3 4 5 12 11 2 1 13 14 16 17 24 19 15 21
[At installation,
pay attention to
orientation of slit.]
10-125
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
P/No : YN01V00151F2
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY
[At installation,
pay attention to
orientation of slit.] [Effective thread depth:
[Location of the slit is 21 (0.83 inch) ]
shown in the drawing.]
(-0.02")
(4.72")-0.5
120 0
26
26 27 27
P/No : YN01V00175F3
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY
10-126
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
4-M12x1.75
[Effective thread depth: 21 (0.83 inch) ]
(-0.02")
(-0.02")
(4.13") -0.5
(4.13")-0.5
10
105 0
105 0
21 22 22 21
PS1/8
PS1/8
10 19
9 8 7 6 3 4 5 12 11 2 1 13 15 16 17 18 14 20
P/No : YN01V00153F1
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY
10-127
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10-128
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(D) Diode
D-12 Diode ↑
D-13 Diode ↑
D-14 Diode ↑
D-15 Diode ↑
D-21 Diode ↑
D-22 Diode ↑
D-103 Diode ↑
D-104 Diode ↑
10-129
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(L) LIGHT
10-130
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(M) Motor
(R) Relay
10-131
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(SE) Sensor
10-132
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
(SV) Solenoid
LQ35V00008F1
SV-4 Lever lock sol. YN35V00061F1
(Solenoid valve)
(SW) Switch
10-133
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
C-1
Maker Sinko Electric Co., Ltd.
Controller
Rated voltage DC24V
YN22E00488F1
We ight 4.2 kg (9.3 lbs)
Mechatro controller
LQ16C10001–
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
C-2
Controller Maker Nippon seiki Co., Ltd.
Rated voltage DC24V
YN59S00038F1
Cluster gauge
YQ15–20001-
LL16–10001-
C-4
Controller Maker SANDEN Co., Ltd.
Rated voltage DC24V
LQ20M00088F1
Rated imput power 215W
Air conditioner amplifier
YQ15–20001-
LL16–10001-
10-134
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
C-5
Controller Rated voltage DC24V
Maker's (Hino) P/No. S8347-01230
S8347–01230
Radiator coolant level
controller
10
YQ15–20001-
LL16–10001-
C-7
Controller Manufacturer JRC Nihon Musen
Manufacture model number JRN-130K/JRN-230K
YN22E00532F2
IT controller
(JRN-230K) (satellite)
YN22E00623F1
IT controller
(JRN-130K) (mobile)
LL16–10001-
C-8
Rated voltage DC24V
Controller
Maker's (Hino) P/No. 89661-E0066
89661E0066
Engine controller
YQ15–20001-
LL16–10001-
10-135
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
C - 12
Controller Maker's (Hino) P/No. 89550-E0161
We ight 850g(187lbs)
89550-E0161
DCU Controller
YQ15–20001-
LL16–10001-
D - 4, 23, 25
Diode Maker's part No. 7321-9822
Repetitive peak voltage 400V
YN02D01001P1(2P)(4P)
Mean output current 3A
Glow, Switch etc. Surge current 200A
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
10-136
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
E-1
Fuse capacity and circuit
Fuse & relay box
YN24E00036F1
Fuse & relay 10
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001- Front side of machine
LL16–10001-
E-2
Alternator
27060-E0040
Generator
YQ15–20001-
LL16–10001-
E - 5, 6 Bottom L : Low sound
Type H : High sound
Horn
Rated voltage DC24V ST AMP
LC53S0001D1(high)
LC53S0001D2(low)
Operating voltage range DC20~30V
Sound level 113+5dB(A)/2m
Warning sound 420+20Hz high sound
Basic frequency
350+20Hz low sound
LQ16C10001-
Insulation resistance More than 3M /DC500V
LQ16H10001-
LL16C10001-
LL16H10001- 8.5
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
E-7
Tuner Maker TORICA Co,.Ltd.
YN54S00078P1 Part name AM/FM radio
Radio (AM&FM)
YQ15–20001-
LL16–10001-
10-137
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 8, 9
Model
Speaker
Rated input
LQ54S00003S002
Impedance
Radio Frequency
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
E - 10
Receiver dryer Maker SANDEN Co., Ltd.
Model 51440-A1300
LQ54S00005P1
IN SIDE
Air-conditioner
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001- OUT SIDE
YN15C10001-
PRESSURE SW .
YN15H10001-
APPLICABLE HOUSING MAKER’S P ART No.
YQ15C10001-
SUMITOMO WIRING SYSTEMS L TD. No. 6189-0094
YQ15H10001-
YQ15–20001-
LL16–10001-
10-138
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 11
Maker's part No. 7360-6000
Air compressor
Rated voltage DC24V
YX91V00001F1
Max. revolution 4000rpm
Air-conditioner V belt Type B
LQ13-07001- Refregerant R-134a 10
LL13-06001- Oil SP-20:135cc(8.24cu .in)
YF06-02501-
Cover (Clutch)
YU06-03001-
YF07-03001-
YU07-04001-
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
E - 12
Type 145F51
Battery
Volta ge 12V
YN72S00016P1
Capacity (5HR) 112Ah
Power We ight (Incl. fluid) Approx. 33kg (72.8 lbs)
YQ15–20001-
Negative Positive
LL16–10001- terminal terminal
(0.67")
(0.67")
Ta pe r
Ta pe r
17
17
17.9 19.5
(0.705") (0.768")
10-139
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 13
Alarm Model BA3111A
Rated voltage DC 12V~36V
YN53S00002F1
Travel alarm
YQ15–20001-
LL16–10001-
Vinyl tube
VIEW A
E - 15
Fusible link Type Slow blow fuse
Allowable current 100A
YB73S00001P1
Fuse
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
10-140
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 22
Converter Maker New-era Co.,Ltd.
Type DDH-203
YT77S00011P1
Input voltage 24V
DC-DC Converter
Output voltage 12.5~14.5
YQ15–20001- Output current 12V ACC 3A / 12V MAIN 3A 10
LL16–10001-
E - 23
Rated voltage DC12V
socket
More than 10M
YN81S01002P1 Insulation at 500V megger
12V Power socket
YQ15–20001-
LL16–10001-
TERMINAL, GND
OP EN OR
CLOS E
POSITIVE TERMINAL DIRECTION
E - 24
Antenna Type NAY-3700G
Frequency band 1575.42 ±1.023MHz
YN54S00052P1
Rated voltage DC 2.7 ~3.3V
GPS Antenna
Quiescent current 5~20mA
YN12-56001-
YQ12-08001-
YN13-70001-
YQ13-10001-
YQ15–20001-
LL16–10001-
10-141
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 27
Accel redundant volume Rated voltage DC 5V
Parts Volume TOCOS RV24YN
YN52S00106P1
Engine redundant device
Furukawa Denko equivalent
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
HOUSING : 172131-5
Fix resistor with the harness tape TERMINAL : 170340-1
after fixing the PVC tube.
NUT
VIEW I
SPRING W ASHER
PLAIN WASHER
E - 38
Resistor Maker Nihon Te ikouki.Co.Ltd.
Rated voltage 40W
LC22E01001D1
Insulation resistance DC500V /
Resistor 20M or more
LQ16C10001- Dielectric strength AC1500V .1Minute
LQ16H10001-
LL16C10001- CONNECTOR YAZAKI
LL16H10001- HOUSING
YN15C10001- TERMINAL
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
10-142
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 46
Rear camera Maximum rating
power-supply voltage GND-0.5~ 10V
YN55S00009F1
Camera
LC12-15001– 10
YC12-10001–
LS12-03001–
YS12-
YN13-70001–
YQ13-10001—
YQ15–20001-
LL16–10001-
E - 49
P in 1 +24V Input Volta ge Input volta ge to the conve rte r.
Converter P in 2 Ignition S witche d output control le a d, a ctive high.
P in 3 Ground Syst e m ground.
YN77S00069P1 P in 4 +12V Uns witche d Uns witche d output volta ge .
S witche d output volta ge , controlle d by
P in 5 +12V S witche d
DC24V→DC12V P in 2 a bove .
P in 6 Ground Syst e m ground.
YQ15–20001-
LL16–10001-
VIEW I
E - 63
DC-DC Converter Use conditions
power-supply voltage 20~32V
(for camera)
YN77S00040P1
DC24V→DC8V
LC12-15001–
YC12-10001–
LS12-03001–
YS12-
YN13-70001–
YQ13-10001–
YQ15–20001-
LL16–10001-
BODY
PC-GF20
CONNECT OR
AMP 175783
10-143
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 78 HINO
NO. YAZAKI P RT NAME QTY.
ASSEMBLY PART NO.
Resistance X TYP E 2P RES IS TOR CONNECTOR HOUS ING MALE 1
82890-E0020A X TYP E 2P RES IS TOR CONNECTOR INNER P LATE 1
X TYP E 2P RES IS TOR CONNECTOR TERMINAL 2
External resistance 82890-E0020-A X TYP E 2P RES IS TOR CONNECTOR PACKING 1
RES IS TOR (2.0K 1/2W) 1
YQ15–20001- LABEL 1
FILLING RES IN -
LL16–10001-
We ight 11g
A A
We ight : 11g(0.024lbs )
SECTION A-A
E - 101
Resistance Maker DEUTSCH JAP AN LIMIITED
Maker's part No. DT04-3P-P006
PY26E01001P1
CAN resistor 1
YQ15–20001-
LL16–10001-
E - 123
Dosing module Maker's (Hino) P/No. S17J0-E0030
We ight 250g (0.55 lbs)
S17J0-E0030
DEF/AdBlue dosing
module
YQ15–20001-
LL16–10001-
10-144
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
E - 124
Dosing module Maker's (Hino) P/No. S17H0-E0041
We ight 3150g (6.95 lbs)
S17H0-E0041
DEF/AdBlue supply
module 10
YQ15–20001-
LL16–10001-
E - 127
Antenna Maker Japan Radio Co., Ltd.
Type 0J-AH26K
YN54S00064P1
GSM antenna (DB-BRO)
YQ15–20001-
LL16–10001-
10-145
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
L - 1, 6
Type BL84-130
Light (Halogen)
Bulb 24V,70W
YW80S00001F1
Boom working light (LH,
RH)
CA104
YQ15–20001-
LL16–10001-
M14×1.5
L-2
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effe ctive a re a of le ns 69.2cm 2
Deck working light (RH)
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
10-146
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
L-3
Swing flusher Meker Knight beam (Imasen)
Type BL46-146
YM80S00001F1
Bulb DC 24V, 25W
Working light (left) Lighting cycle 90 times / min
YN15C10001- 10
YN15H10001-
YQ15C10001-
YQ15H10001-
SWING LIGHT(1) REAR WORKING
YQ15–20001- AMP PART NO. LIGHT
LL16–10001- HOUSING : 174259-2
TERMINAL : 171661-1
L-4 HARNESS SEAL : 176886-2 GND SWING LIGHT(2)
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001- SECTION A-A
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
L-5
Volta ge 24V
Light
Type RL-8700 Body
Lens
LQ02C00031S020
Room light Room light BATT
LQ16C10001- OFF ON
LQ16H10001- DR S W
ON
LL16C10001- 24V (Door)
LL16H10001- 10W (Connector) OFF
YN15C10001- DR
YN15H10001- Bulb
Circuit
YQ15C10001-
YQ15H10001-
YQ15–20001-
YQ15–20001-
LL16–10001-
10-147
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
M-3
Motor Type 191-1 1H0-D
LQ53C00003S001
Wiper motor
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
M-4
Rated voltage DC 24V
Motor (Tank)
Injection flow 1.2L (0.32 gal) / min or more
YT54C00003F1 Capacity 1.5L(0.4 gal)
Washer motor Time ra te d Max. continuous 60 sec.
LQ16C10001- Injection nozzle 1 X 2 pcs.
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
PUMP
YQ15H10001-
YQ15–20001-
LL16–10001-
10-148
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
PSV - A, B, C, D, 23, 24
YN35V00048F2
Proportional solenoid YN35V00049F1 YN35V00051F1 YN35V00061F1
valve assy YN35V00048F2
Hydraulic symbol 10
See A2, A4-A8
(LQ35V00008F1)
YN35V00048F2
YN35V00049F1
YQ15–20001-
LL16–10001-
Le ve r lock
Arm 2nd s pe e d
Boom2
Boom3
P 2 unloa d
S wing pa rking
P 1 unloa d
PSV - E, I
Proportional solenoid Type of conne ctor
Equivalent to AMP econoseal J series connectors MARKII ( ) cap hausing
YN22V00035F1 Cap Housing 174354-2
Te rmina l 173706-1 Air.bleeder plug
OPT. relief adjustment Width across flats17 1/2-20UNF-2B
proportional sol. Tighte ning torque : 23N.m(17 lbf.ft)
YQ15–20001-
LL16–10001-
Specifications
1. Working pressure range(Pressure in port P) :
15~40MPa(2175~5800psi)
2. Max, back pressure (Pressure in port T) :
1.0MPa(145psi)
3. Max, flow : 300L/min(79.3gal(US)/min)
4. Electrical Specifications:
Hydraulic symbol Rated current : 700mA
Coil resistance : 19.5 (at 20 (68 F) )
Recommended dither : 200Hz 100mAp-p
10-149
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
YQ15–20001-
SLEEVE
LL16–10001-
O-RING O-RING O-RING SEAL NUT
SOLENOID
O-RING M6
Type of conne ctor 7.4N .m(34.2lbf .ft)
Equivalent to AMP econoseal J series connectors
MARKII ( ) cap hausing
Cap Housing 174354-2
Te rmina l 173706-1
Specifications
1. Working pressure range(Pressure in port P) :
13.7MPa(1987psi)
2. Max, back pressure (Pressure in port T) :
1.0MPa(145psi)
3. Max, flow : 10L/min(2.6gal(US)/ min)
Hydraulic symbol 4. Electrical Specifications:
Rated current : 1.6A
Recommended dither : 80Hz 600mAp-p
Coil resistance : 19.5 (at 20 (68 F) )
10-150
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
R-1
At start 24V2000A(0.1 sec) VIEW A
Te rmina l A
Relay Ra te d volta ge / curre nt
At charge 28V120A(Continuous)
YN24S00008F1 Exciting current 0.4A or less / 24V Lock section
R-2
Maker's (Hino) P/No. Length of coupler harness
Relay S2830-01271
(From outlet to coupler)
Rated voltage DC24V L=215mm (8.46inch)
S2830-01271
Rated time 30 sec 18 o4 MAX
Starter relay Exciting current 3A or more (a t 20 (68 F)) Vynil tube (Re d)
YQ15–20001- Min operating voltage DC18V or less (at 20 (68 F))
LL16–10001- Insulation resistance 1M or more
Black
Blue
Vynil tube (Bla ck)
M6
Te rmina l C Te rmina l B
Electric diagram
M8
10-151
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
R-3
Maker's (Hino) P/No. S2862-01420
Relay
Rated voltage DC 24V
S2862-01420
Rated load 100A flow
Glow relay Min. operating voltage DC 18V or less
YQ15–20001-
LL16–10001-
Te rmina l-S
(RED)
Na me pla te
Te rmina l-F
R - 4, 5, 6, 8-11, 23-26,
28, 94 Maker TYCO ELECTRONIC AMP Co,.Ltd.
YQ15–20001-
LL16–10001-
10-152
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
R - 19
Rated voltage DC 24V
Relay
Maker MITSUBA
YY24S00001P2
Flasher relay
LQ16C10001- 10
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001- Electric diagram
YQ15–20001-
LL16–10001- Swing fla s he r & re a r work light unit
Flash e r drive r
Contr ol s igna l
Rear work light
Rear work light
Flash e r L
Flash e r L
Drive circuit
Flash e r R
Flash e r R
Drive circuit
TERMINAL NUMBER
10-153
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
M16×1
Hexagon two surface width:17mm(0.67inch)
2 GND BLACK
1 SIG YELLOW
10-154
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SE - 15
Float operation
Fuel sensor
Float Resistance
YN52S00094F1 +0.1
FULL 10 -0.6
Fuel level 3/4 (19)
LQ16C10001- 1/2 32+5 10
LQ16H10001- 1/4 (49.5)
LL16C10001-
EMPTY 85 +10
0
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
Float
VIEW A
SE - 16
Tota l re s is ta nce
Accel potentio CONNECT OR (AMP)
Effe ctive e le ctrica l a ngle CAP HOUSING : 174359-2
LQ52S00025P1 TAB : 171661-1
RUBBER PLUG : 172888-2
Accel dial DOUBLE LOCK PLATE : 1-174360-1
M4×0.7 -5.9
m
10-155
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SE - 22, 23
Pressure range 0~50MPa(7250psi)
Pressure sensor (High
pressure) Ma x.a llowa ble pre s s . 120MPa(17400psi)
Operating source voltage 5+0.5V DC
YN52S00103P1
Insulation resistance 100M or more/DC50V megger
P1 PUMP (Between casing and terminal)
P2 PUMP
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
SE - 24, 25
Type KM16-F06 27mm
Pressure sensor (High
pressure) (1.06inch)
Specifications
YN52S00104P1 Pressure.range : 0~50MPa (10~7250psi)
Max.allowable press. : 120MPa (17400psi)
Boom head Brake down press :
Boom rod 200MPa (29000psi) or more
YQ15–20001- Source voltage : 5.0VDC
LL16–10001- Max source voltage : 6.0VDC
Output : 1/10Vs~9/10Vs
Insulation resistance : 100M or more
(Case~terminal 50V DC)
Consumption current : less than 10mA DC
Volta ge which is fit for us e : 150V AC (1min)
PF TIGHTENING TORQUE
73.5N .m(54.2ft-in)
10-156
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SE - 60
Sensor Fluid Mineral hydraulic oil(ISO VG32,46,68)
Pro of pre s s ure 7.0MPa (1015psi)
YN52S00107P1
Range of oil temp -30 ~ 120 (-22~248 F)
Hyd. oil filter clogging
Port size JIS B2351 G1/2
sensor
Setting pressure 0.1±15 MPa (15±15 psi) 10
LQ16C10001-
Electric rating DC30V
LQ16H10001-
LL16C10001- Contact rating 100mA (Resistance load)
LL16H10001-
YN15C10001-
YN15H10001-
(1.06inch)
YQ15C10001- 27mm
YQ15H10001- G1/2
YQ15–20001-
LL16–10001-
High pressure
SE - 61
Maker's(Hino)P/No. S8939-01090 Absolute maximum rating
Pressure sensor
We ight 149g(0.33lbs) Item Symbols Rating Units
S8939-01090 Permissible voltage - 6 V
Differential pressure Supply voltage Vc 4.75~5.25 V
sensor Pi(MIN/MAX) -20/150 KPa
YQ15–20001- (P HI.P REF) (-2.9/21.8) (psi)
Permissible pressure
LL16–10001- Pi(MIN/MAX) -20/150 KPa
(P HI.P REF) (-2.9/21.8) (psi)
Vc 200k
GND ±5% Vc
Vp
P HI Pressure 10k
Vp sensor
PREF
Vc GND
Measuring circuit
2×M8×1.25
P HI P REF (Attachment bolt)
10-157
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SE - 62
Maker's(Hino)P/No. 22204-E0010
Sensor
We ight 31g(0.07lbs)
22204-E0010
Intake air temperature Fc E 2 c +B THA
E2
sensor/
Air flow meter
YQ15–20001-
LL16–10001-
VIEW A
Conne ctor la yout dra wing(2:1)
O-ring
Cover Housing
(EPDM)
(PBT) (PBT)
VIEW A
SE - 90
Maker's(Hino)P/No. S8862-51 110-A PBT-G30-1(BLACK) PBT-G10-1(BLACK)
Sensor
We ight 12g(0.03lbs) [TSMS604-1B]
S8862-51110-A
Ambient temp. sensor
YQ15–20001-
LL16–10001- THERMISTOR
SPECIFICA TIONS
(5.6V)
ITEM STANDARD REQUIREMENT (4.4V)
RESISTANCE
OPERA TING VOLTAGE RANGE 4.4~5.6V
(4.7K )
OPERATING TEMPERATURE RANGE -30~80 (-22~176 F)
STRAGE TEMPERATURE RANGE -40~90 (-40~194 F) sensor
RESIST ANCE 1700±85 PP2-N-2(BLACK)
(GND)
B CONST ANT 3900±195K [TSM5514-2]
ALLOWABLE OPERATION CURRENT 1.6mA MAX OP ERATING CIRCUIT
10-158
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SE - 99
Swing speed sensor Type TAG 209
LQ52S00032P1
Sensor
LQ16C10001- 10
LQ16H10001-
LL16C10001-
LL16H10001- HOUSING 7122-2830(Y AZAKI)
YN15C10001- CONTACT 7114-2630(Y AZAKI)
Electrical wire for automobiles AVS 0.5s q
YN15H10001-
A
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
A
Te rmina l function
SE - 110
Maker's(Hino)P/No. 89425-E0050
Sensor
We ight 35g(0.08lbs)
89425-E0050
Part number : 89425-E0050 Ye llow pa int line
DPF inlet temperature
sensor
YQ15–20001-
Guide pipe
LL16–10001- (SUS304) Tube prote ction Cover connector TOYOTA pa rt numbe r 90980-10899 (Da rk gra y)
(SUS304) (Alumina)
Connector to be fitted HINO part number : 82560-3980A
Sheath pin Ring spacer YAZAKI pa rt numbe r : 7382-7020-10
(SUS310S) Nipple
(SUS304)
(SUS304)
Bushing
Cover Band Grommet
(Fluororubber)
(SUS310S) Wire (NY-66) (Silicone rubber)
(Nickel plated copper wire and SUS wire/T eflon sheath)
Rib
(SUS304)
Basic performance and quality *1 Recommended measurement circuit
10-159
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SE - 112
Maker's(Hino)P/No. 89425-E0060
Sensor
We ight 47g(0.10lbs)
89425-E0060
Part number : 89524-E0060 Ye llow pa int line
DPF outlet temperature
sensor
YQ15–20001- TOYOTA pa rt numbe r 90980-10899 (Da rk gra y)
SE - 113
Maker's(Hino)P/No. 89429-E0100
Sensor
We ight 54g(0.12lbs)
89429-E0100
SCR temperature sensor
YQ15–20001-
LL16–10001- M12×1.25
10-160
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
Heating pipe
Suction pipe
Float
aa UQS
P in As s ign I/O
1 VB(24V)
2 CAN-L
Filter
3 CAN-H
4 GND
De ta il a a 5 NC
6 S IO
Schematic block diagram of system
Te mpe ra ture
S e ns or
CAN circuit
He a te r
S e ria l
Exte rna l
Te rmina l conne ction
LEVEL
G3 circuit s ubs tra te s ubs tra te S IC OP EN
NC OP EN
10-161
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
SV - 1, 4
Rated pressure 5.0MPa(725psi)
Solenoid valve
(8sectional) Solenoid operated directional control valve Rated voltage:DC24V
P1,P2,T ,A1,A8Port PF3/8
Selector valve assy Dither current 100Hz,200mA P-P A2~A7Port PF1/4
Electromagnetic proportional valve
Hydraulic symbol 9Coil resistance 17.5Ω (at20 (68 F)) AMPmarkII
AMP mark II
See A1-A3 HOUSING Part No 174354-2 equivalent
Conne ctor s pe cifica tion
TERMINAL PartNo 173706-1 equivqlent
(LQ35V00008F1)
YN35V00051F1
YN35V00061F1
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
SV - 2, 3, 105
Rated pressure 5.0MPa(725psi)
Solenoid valve
(3sectional) Solenoid operated directional control valve Rated voltage:DC24V
Selector valve assy
Hydraulic symbol
See A1-A3
(LQ35V00007F1)
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001- A3 A2 A1
T1 T2
PAC P
Circuit diagram A3 A2 A1 T
T
P
PAC
10-162
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SV - 13
Emergency manual screw
Solenoid Max.Tightening torque
Retaining ring 2.0N .m(1.47lbf .ft) or less
YN35V00050F1
Spool Spring Slit width1.0×Depth1.3
OPT. selector switching (-)s ide (+)s ide
Seal nut
sol.
Sleeve
M6
7.4N .m(5.46lbf .ft)
10
YQ15–20001-
LL16–10001-
O-ring
O-ring Tightening torque
O-ring 7.4N .m(5.46lbf .ft) Type of conne ctor
O-ring
Width across flats Equivalent to AMP econoseal J series connectors
Solenoid MARKII ( ) cap hausing
12mm(0.47inch)
Cap Housing 174354-2
Te rmina l 173706-1
Specification
1.Working presuure range(Pressure in port P) : 13.7MPa(1987psi)
2.Max,working pressure(Pressure inport T) : 1.0MPa(145psi)
3.Max.flow : 16L/min(4.2gal/min)
4.Electrical specifications : Rated voltage:DC24V
SV - 68
Valve Maker's(Hino)P/No. 87240-E0020
We ight 565g(1.25lbs)
87240-E0020
Coolant shut-off valve SUMITOMO DENSO6188-0470 equivalent configuration
HINO PART 82580-7170
YQ15–20001- Part to be Fitted 82580-9250
LL16–10001-
Specification
1. Rated voltage : DC24V
2. Working voltage range : DC20V~DC32V
3. Rated energization : Under continuous operation (285 s ON and 15 s OFF at -8 (-17.6 F) or less)
After 2 H operation and 15 s OFF , the valve is operated again at the rated voltage
4. Current : 1.0A or less/DC24V at 20 (68 F)
5. Working temperature range : -40~100 (-40~212 F) (atmosphere)
-35~98 (-31~208.4 F) (COOLANT)
6. Insulation resistance : The insulation resistance between the terminal and the body is
10M or more by a 500 V insulation resistance tester
10-163
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
SW - 1
OFF AC
Switch C
Connection
ON
YN52S00026F1 Terminal
Position
Starter switch
S TA
Auto return
LQ16C10001-
RT
LQ16H10001- VIEW A
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
Te rmina l
YQ15C10001- arrangement
YQ15H10001-
YQ15–20001-
LL16–10001-
SW - 4
Switch Rated voltage DC 24V
Type Single-pole,single-throw type(alternate)
YN50S00040D7
Insulation resistance 1M or more/DC500Vmegger
Swing parking release
switch
LQ16C10001-
Connection
LQ16H10001-
LL16C10001- Term ina l
Positi on
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
SW - 8
Switch
YY11P01002F1
Clogged air filter switch
YQ15–20001-
LL16–10001-
BLACK
RED
10-164
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SW - 10
Switch
PW03M01960F1 Switch1
Horn switch (left)
YQ15–20001- 10
LL16–10001-
2 1
SUMITOMO WIRING SYSTEMS.Ltd. HM series 090(2pin)
HOUSING : M(6090-1031)
TERMINAL : M(8230-4282)
Specification
Rated switch (atresistance load) : DC30V/3A Orange
1
SW1 Gray Switch1
(At inductive load) : DC30V/1A 2
Min.current : DC5V/160mA~DC30V/26mA
Operating Quantity/Force : 1mm/4N(0.04inch/0.9lbf) Electrical diagram
SW - 11
Switch Type Panasonic coporation:ABV19440F
YN50S00058P1
Lever lock switch
LQ16C10001-
LQ16H10001-
BLACK
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001- WHITE RED
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
10-165
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SW - 20, 99
Switch TYCO ELECTRONICS AMP
SWITCH3 ECONOS EAL J S ERIES MARKII(+)
YY03M01239F1 SWITCH1 CAP HOUS ING : 174264-2
DOUBLE LOCK P LATE : 174265-7
Attachment power boost TER MINAL : 171631-1
WIRE S EAL : 172746-1
switch (right)
Nibbler open-close
switch (right)
YQ15–20001-
LL16–10001-
3 2 1 S UMITOMO WIRING S YS TEMS .Ltd.
HM s e rie s 090(2pin)
HOUS ING : M(6090-1031)
Specifications TER MINAL : M(8230-4282)
6 5 4
1. Proportional output
1. Power source voltage : DC9V~16V 2
2. Current consumption(No load) : 0.1A 1 CONNECTOR
Le a d wire color
(Max load) : 1.0A(at DC12V) P IN ARRANGEMENT
RED
3. Output Current : 0~1.4A +V 1 P OWER S OURCE(+12V)
BLACK
4. Adaptable solenoid coil resistance:Standard3.2 P 2 GND
5. Te mp ra nge : -40~75 (-40~167 F) GND WHITE
3 S OLENOID1
2. ON/OFF Switch(SW3) BROWN
4 S OLENOID2
1. Operating quantity/Force:1mm/4N(0.04inch/0.9lbf) S W3
GREEN
5 S OLENOID RETURN1
S W3
3. ON/OFF Switch(SW1) GND
GREEN
6 S OLENOID RETURN2
1. Rating of switch(At resistance load) : DC30V/3A ORANGE
1
(At inductive load) : DC30V/1A S W1 GRAY S WITCH1
2
2. Min.current : DC5V/160mA~DC30V/26mA
3. Operating Quantity/Force : 1mm/4N(0.04inch/0.9lbf) CONNECTOR
ELECTRIC CIRCUIT
SW - 22 SUMITOMO
HOUSING : 6098-0258
Switch
TERMINAL : 8230-4282
YX50S00004F1
Release switch (KPSS)
YQ15–20001-
LL16–10001- VIEW I
ON 1 SIDE
( NORMAL)
ON 2 SIDE
(KPSS RELEASE)
UNIT SHAPE OF SWITCH
Specifications
CHARACTERISTICS OF CIRCUIT NUMBER OF
1.Rating : AC 125V 10A AC 250V 7A
CONTACY POSITION CIRCUIT DIAGRAM TERMINALS
DC30V 10A
2.Initinal contact resistance
CENTER
: 20m or less at DC2~4V 1A
3.Insulation resistance
ONqq NONE ONrr
:The valve between insulated terminals
18
and between terminal frames to be 100 M
or more at DC500V megger .
4.Dielectric strength
:Insulations between insulated terminals and
between terminal frame must be endured against
AC2000V for one minutes.
10-166
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SW - 27
Purpose Coolant level detection
Switch
Working te mpe ra ture -40 ~130 (-40~266 F)
S8346-01510 Type of conne ctor
Engine cooling coolant Hino P/No. : S82580-7170
Sumitomo P/No. : 6188-01 10
level switch Electrode side
(To controlle r)
10
YQ15–20001-
LL16–10001-
Housing side CONNECT OR
(To ground)
Mating connector
Hino P/No. : S82580-7180
Sumitomo P/No. : 6189-0189
SW - 35
Switch Rated voltage DC 24V
Single pole single throw
YN50S00040D5 Type (alternate)
More than 1M /
Heavy lift switch Insulation resistance DC500V megger UP
YQ15–20001-
LL16–10001- Te rmina l conne ctor
Connector
Position
SW - 37
Switch Rated voltage DC 24V
Single pole single throw
YN50S00040DB Type (alternate)
More than 1M /
Independent travel Insulation resistance DC500V megger UP
switch
YQ15–20001-
Te rmina l conne ctor
LL16–10001- Connector
Position
SW - 55
Switch Rated voltage DC 24V
Single pole single throw
YN50S00040D1 Type (alternate)
More than 1M /
Boom work light switch Insulation resistance DC500V megger UP
LL16C10001-
LL16H10001- Te rmina l conne ctor
Connector
YN15C10001- Position
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
10-167
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SW - 96
Switch Rated voltage DC 24V
Single pole single throw
LV50S00003D5 Type (alternate)
More than 1M /
Drain pressure switch Insulation resistance DC500V megger UP
YQ15–20001-
LL16–10001- Te rmina l conne ctor
Connector
Position
SW - 131
Switch Rated voltage DC 24V
Single pole single throw
LV50S00003D9 Type (alternate)
More than 1M /
Manual regeneration Insulation resistance DC500V megger UP
switch
WB02-00101- Te rmina l conne ctor
LQ14-09001- Connector
Position
LL14-
YQ15–20001-
LL16–10001-
SW - 137
Switch Rated voltage/current DC 12V / DC 24V UP
Volta ge drop 0.02V or less/20A
LP50S00003P1
Insulation resistance 1M or more
Battery disconnect
ON
switch
DOWN
LQ16C10001- OFF Installation position
LQ16H10001-
Terminal2 Terminal1
LL16C10001-
LL16H10001-
YN15C10001- Internal structure shown at ON position.
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
10-168
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
SW - 181
Switch O-RING
NUT FLANGE
YN50S00059P1 M12
B S IDE
Engine stop switch
YQ15–20001-
A S IDE
10
LL16–10001-
B S IDE A S IDE
10-169
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[10. COMPONENTS SYSTEM]
10-170
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
11-1
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
11-2
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
11
11-3
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air blows
off from grille through duct.
Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows in
the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the operation
is controlled by air mixing damper on the air-con unit.
11-4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
25. 0 COMPRESSOR
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
11-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
6
4
1-1-15 1-1
1-1-1
5
1-3
1-2
7
7-2
3
7-1
7-7
7-8
7-3 7-6
Air-conditioner group
11-6
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
16
33 48 23 22 26 35 11
49
50 25 47 20 36
31
34 32 10
20 47
35
30 24
47 29 27 36
1 28 29
14
35
47 11
15 47 39
51
47
38 4
45
47 37
44
40
17
51
42
7 41
6
3 5
47
8 2 12
47 43
20 13
47
18
21 46
19
11-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
11-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
Receiver dryer
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
3
4
5
11
6
Receiver dryer
No NAME Q'ty
1 PRESSURE SWITCH 1
2 SIGHT GLASS 1
3 DESICCANT 1
4 SUCTION PIPE 1
5 FILTER 1
6 RECEIVER TANK 1
11-9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
24
TIGHTENING
TORQUE
16.7~18.6N .m
(12.3~18.6 lbf .ft)
28
(1.18”)
(1.18”)
30
30
13
14
1-7-1 1
15 (0.59”)
20 (0.79”)
1
TIGHTENING TORQUE
8~12N .m (5.9~8.9 lbf .ft)
30
30 1-7-3
32
11-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
36 39
TIGHTENING TORQUE
11N.m(8.1 lbf .ft)
(1.97”)
50
(1.97 inch)
TIGHTENING TORQUE
7.8~1 1.8N .m(5.9~8.7 lbf .ft)
7
TIGHTNING
1-7-2
30
25 TORQUE
23N m(17.0 lbf .ft)
. 11
9
(3.15”)
80
TIGHTNINGTORQUE 25
23N .m(17.0 lbf .ft) 10
1-7-6
7
7
30 25
TIGHTENING TORQUE
23N .m(17.0 lbf .ft)
30 1-7-3
32
30
32
1-7-2 41
TIGHTENING TORQUE
20~25N .m(14.8~18.4 lbf .ft)
25 42
TIGHTENING TORQUE
TIGHTENING TORQUE
23N .m (17.0 lbf .ft)
4.9N .m (3.6 lbf .ft)
1-7-6
TIGHTENING TORQUE
12~15N .m(8.9~1 1.1 lbf .ft)
11-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
35
(1.38”)
40
TIGHTENING
TORQUE
20~25N .m
(14.8~18.4 lbf .ft)
7
7 TIGHTENING
TORQUE
20~25N .m
(14.8~18.4 lbf .ft)
30 30
30
30 27
30 32 34
TIGHTENING TORQUE
46.5N .m (34.3 lbf .ft)
28 15
30
(0.79 inch)
30 30
(1.18”) (1.18”)
23 2 0 ”)
28
79
(0 .
28
27 TIGHTENING TORQUE
33 46.5N .m (34.3 lbf .ft)
30
32
27 TIGHTENING TORQUE
33 46.5N .m (34.3 lbf .ft)
31
11-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
TIGHTENING TORQUE
46.5N .m (34.3 lbf .ft)
4 8 (5.39 lbf)
(0.09 inch)
30
(4 (2 .9 )
(1 . 3 ) 9 ”)
(7 6
”)
69
37 85
11 38 (3.35”)
TIGHTENING TORQUE
23N .m (17.0 lbf .ft)
32
14 1-7-1 30
13
35
13 1-7-1 11
38
TIGHTENING 1-7-3
TORQUE 30
23N .m
(17.0 lbf .ft)
1-7-3
1-7-1 14
30 13
30
30 14
30
13 30 14 1-7-3
30 1-7-3
1-7-2 1-7-3 14 1-7-1 13 13
1-7-1
1-7-1 1-7-1
13
2
1-7-2
1-7-2
1-7-6 3
30
15 1-7-2
1-7-1 1-7-3
11-13
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[11. AIR-CONDITIONER SYSTEM]
13 30 34 30 1-7-2
27 30
32 1-7-1 1-7-2 32
1-7-2 32
1-7-2 1-7-3
1-7-1 1-7-3
30
1-7-2
1-7-3 6
1
1
5
31
31
30
15~17mm
(0.59~0.67 inch)
11-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
S-HOSE : 1-7-1
2930 (9’ 7”)
(0.94”)
(1.18”)
24
30
31
31 18
64 10 10
(2.52”) (0.39”) 2800 (9’ 2”) (0.39”)
D-HOSE : 1-7-2
2240 (7’ 4”)
970 (38.2”)
710 (28.0”)
11
910 (35.8”) 430 (16.9”)
7 32 600 (23.6”) 100 32
(1.26”) (3.94”) (1.26”)
(0.75”)
(0.94”)
23.8
19
31
26 10 19 31 10
(1.02”) (0.39”) 2150 (7’ 1”) (0.39”)
L-HOSE : 1-7-3
2730 (8’ 11”)
1580 (5’ 2”)
1130 (3’ 8”)
870 (34.3”)
460 (18.1”) 870 (34.2”)
30 140 570 (22.4”) 30
7 (1.18”) (5.51”) (1.18”)
(0.59”)
(0.94”)
23.8
15
31 20
70 10 31 10
(2.76”) (0.39”) 2600 (8’ 6”) (0.39”)
L-HOSE : 1-7-6
340 (13.4”)
30 30
7 (1.18”) (1.18”)
31 43 31
30 10 10
(1.18”) (0.39”) 250 (9.84”) (0.39”)
11-15
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[11. AIR-CONDITIONER SYSTEM]
HEATER HOSE : 13
2600 (8'6")
1740 (5'9")
1330 (4'4")
950 (37.4")
610 (24.0") 550 (21.7")
320 (12.6") 290 (11.4")
13
(0.83")
(1.06")
21
27
31 16 31
(250) 10 10
(9.84") (0.39") (2300) (7'7") (0.39") 50
(1.97")
HEATER HOSE : 14
3000 (9'10")
1270 (4'2") 1300 (4'3")
980 (38.6") 1030 (3'5")
610 (24.0") 750 (29.5")
330 (13.0") 430 (16.9")
14
(0.83")
(1.06")
21
27
(150)
31 17 31
10 10
(5.91") (0.39") (2800) (9'2") (0.39")
50
(1.97")
HEATER HOSE : 15
700 (27.6")
410 (16.1")
15
(0.83")
(1.06")
21
27
31 21 31
50 10 10 (100)
(1.97") (0.39") (550) (21.7") (0.39") (3.94")
11-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
5 Filter 1 28 Clip 6
6 Panel 1 30 Clip 21
8 V-belt 1 32 Clip 6
9 Bracket 1 33 Clip 2
10 Bracket 1 34 Clip 1
11 Bracket 1 35 Capscrew 4 11
13 Hose:L=2600 (8ft-6in) 1 36 Capscrew 4
11-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
4 2
6
1
4 Capscrew: M8 X 25 2
5 Capscrew: M6 X 25 2
11-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
Flammability Nonflammable
Ozone destruction coefficient 0
*1 : 1MPa (mega pascal) equals 10.1972 kgf/cm2 (145psi)
11-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
Characteristics of Refrigerant
In general, the fluid (general term of gas and liquid) has the following qualities:
1. As a gas under certain pressure is cooled down, it
PRESSURE
begins to condensate at a certain temperature to MPa(psi)
take a liquid state. The temperature at which R134a
4(580)
condensation begins is unique to each substance
(fluid) at a given pressure. The temperature 3(435)
determined by a given pressure is called saturation LIQUID
temperature. 2(290)
1(145) GAS
0.5(75)
TEMPERATURE
[ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
2. Inversely to 1) above, the pressure at which a gas condenses is determined by a given temperature. This
pressure is called saturation pressure. The graph in the figure “Pressure-temperature characteristics of R134a”
shows the relationships between the saturation temperature and the saturation pressure in the case of
refrigerant R134a used in the air-conditioner. At the temperature and the pressure on the lower righthand side
of the curve in the figure “Pressure-temperature characteristics of R134a” the refrigerant take a gaseous state,
while at the temperature and the pressure on the upper lefthand side of the curve, the refrigerant takes a liquid
state.
Let us think of a case where an air-conditioner is operated in the midst of summer. As the refrigerant
evaporates, it absorbs evaporation heat from the air of the operator’s station. In order to cool the inside of the
operator’s station down to 25C degrees (77F degrees), the refrigerant must transform (evaporate) from a liquid
to a gaseous state at a temperature lower than that. It can be seen from the figure “Pressure-temperature
characteristics of R134a” that R134a under a pressure above the atmospheric pressure is capable of cooling
the inside of the compartment sufficiently. (If a refrigerant that requires a pressure below the atmospheric
pressure to cool the air to a required temperature is used, air is mixed into the circuits, thereby deteriorating the
performance of the cooling unit.) In the process in which gaseous refrigerant is brought back to a liquid state,
the refrigerant is cooled and condensed by the outer air exceeding 35C degrees (95F degrees). Therefore the
refrigerant is capable of condensing at the pressure of 1 MPa (145psi) or more, as seen from the figure
“Pressure-temperature characteristics of R134a”.
11-20
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[11. AIR-CONDITIONER SYSTEM]
11-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
11-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
The feed rate is controlled automatically so that under the pressure in the evaporator, the refrigerant is properly
overheated (3 to 8C degrees ) and goes out of the evaporator. This action is carried out by sensing the
refrigerant temperature at the outlet of the evaporator as against the inlet pressure of the evaporator and
consequently controlling the feed rate of the refrigerant.
This means that if the refrigerant pressure drop in
the evaporator is excessive, it is difficult to control
the overheating or the feed rate of the refrigerant.
For this reason, the smaller the pressure drop of the
evaporator, the better.
The expansion valve senses the pressure and the
temperature at the outlet of the evaporator and
controls the overheating of the refrigerant and the
refrigerant supply to the evaporator more securely.
The air-conditioner of this machine adopts a block
type expansion valve. Expansion valve outside view
Compressor
The compressor performs the following three functions in the cooling circuit: 11
1. Suction action
The suction action, as combined with the throttling D HOSE
action, works to decrease the refrigerant pressure in
the evaporator. This permits the refrigerant to
vaporize at low temperature in order to perform
S HOSE
cooling effect.
Compressor
2. Pumping action
The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This enables
continuous cooling.
3. Compressive action
The compressive action, as combined with the action of the condenser which is mentioned hereunder,
transforms vaporized refrigerant back to a liquid state again.
The saturation temperature gets higher as the pressure increases. Because of this, for instance, cooling down
the refrigerant by the use of external air of 35C degrees (77F degrees) to liquefy the refrigerant become
possible. The compressive action of the compressor works to turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then serves to cool down the refrigerant. Moreover, since the
compressive action takes place only for a short period, the refrigerant hardly exchanges heat with external air.
That is to say, it takes a form of close to adiabatic compression, so that the refrigerant discharged by the
compressor is high-temperature high-pressure vapor and is delivered to the condenser.
11-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
Condenser
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by the
use of external air and condenses the refrigerant. The
direction in which heat moves is from the refrigerant to
air, the opposite to the case of the evaporator. Fins are
equipped on the external air side to improve thermal
transfer. If the refrigerant is not cooled well by the
condenser, the air in the compartment can not be cooled
sufficiently by the evaporator. For that purpose, it is
necessary to secure ventilation required for the cooling
of the refrigerant.
Condenser
11-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
Receiver dryer
1. Receiver Tank
REFRIGERANT SIGHT GLASS
On the air-conditioner, the revolution of the INLET
compressor varies greatly which causes the proper
flow of refrigerant in the cooling circuit to vary. It is REFRIGERANT
OUTLET
the receiver tank that receives the variations. When
the cooling circuit does not need much refrigerant,
the receiver tank stores extra refrigerant temporarily
and supplies it when the cooling circuit needs much
refrigerant. The receiver tank also stores an extra
amount of refrigerant to be used for filling balance
and supplement small amounts of leakage of the
PRESSURE SWITCH
refrigerant through penetration into rubber hoses.
2. Dryer
If water is mixed in the cooling circuit, it deteriorates
the compressor valves and oil, corrodes the metallic
parts of the circuit or clogs the circuit as the water
freezes in the expansion valve. It is desirable that 11
the amount of water mixed in the refrigerant should
be held below a concentration of 30 ppm. The air-
conditioner uses a molecular sieve as desiccant DESICCANT
suited for the circuit, in order to absorb water
content that intrudes into the circuit when the dryer SUCTION
is installed or when refrigerant is charged. PIPE
3. Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the only FILTER
means of confirming the inside of the circuit visually.
4. Filter
5. Pressure Switch
This machine employs pressure switches of high/
low pressure type.
The pressure switch protects the circuit by cutting RECEIVER
off the power supply to the compressor when high TANK
pressure increases abnormally high [more than 3.14
MPa (460psi) ]. The pressure switch also detects
the leakage of refrigerant by cutting the power
supply to the compressor when the pressure of the
circuit falls below 0.2 MPa (28psi).
Receiver dryer
11-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
11-26
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
2) Assembly
11
• Assemble the A/C unit in the reverse order of disassembly.
2. Disassembly and assembly of internal/external actuator
1) Disassembly HVAC Unit
• Remove the connector. Groove of
damper lever
• Loosen 3 tapping screws.
Lever pin
• Remove actuator as shown. Actuator
Ta pping s cre w
Conne ctor
2) Assembly
• Assemble the actuator in the reverse order of disassembly.
11-27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
2) Assembly
• Assemble the relay in the reverse order of disassembly.
When performing the above-mentioned relay installation, put the cable of the inner air sensor in the position in the
following figure.
Inner sen s or A
SECTION AA
Con ne ctor 1
Connector 2
2) Assembly
• Assemble the inner air sensor in the reverse order of disassembly.
11-28
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
When performing the above-mentioned relay installation, put the cable of the inner air sensor in the position in the
following figure.
Inner sen s or A
SECTION AA
11
5. Disassembly and assembly of fan driver
1) Disassembly
• Disconnect connector from fan driver. Connector
• Loosen 2 tapping screws.
HVAC Unit
• Remove fan driver as shown.
2) Assembly
• Assemble the fan driver in the reverse order of disassembly.
6. Disassembly and assembly of link cover
1) Disassembly
• Loosen 4 tapping screws.
• Remove link cover as shown.
Link cover
HVAC Unit
Tapping screw
2) Assembly
• Assemble the link cover in the reverse order of disassembly.
11-29
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
M o d e a c tu a to r
Mode actuator
HVAC Unit Tapping screw
2) Assembly
• Assemble the actuators in the reverse order of disassembly.
8. Disassembly and assembly of heater core
1) Disassembly
• Remove link cover. HVAC Unit
See the paragraph of “Disassembly and assembly Connector
of link cover”
• Disconnect connector from air mix actuator.
Air mix actuator
• Remove heater core as shown.
Heater core
11-30
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
2) Assembly
• Assemble the heater core in the reverse order of disassembly.
11
HVAC Unit
Connection area of
evaporator sensor connector
2) Assembly
• Assemble the inner air sensor in the reverse order of disassembly.
To avoid damage, pull out evaporator sensor cord from groove of HVAC unit carefully.
11-31
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
Thermistor holder
73mm
(2.87 inch)
Stay
Harness holder
Evaporator sensor
O-ring 1/2
O-ring 5/8
Expansion valve
Socket bolt
20mm
(0.79 inch)
Enlarged illustration of sensor
and thermistor holder
2) Assembly
• Assemble the expansion valve in the reverse order of disassembly.
• Prior to assembly, apply PAG oil to O-ring.
2) Assembly
• Assemble the evaporator sensor in the reverse order of disassembly.
• Install the harness holder and thermistor holder as shown.
11-32
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
11
11-33
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
HANDLING OF REFRIGERANT
Charging
1. When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low
pressure valve of the gauge manifold and warm the can in warm water of 40C degrees (104F degrees) or
below. If the can is put in hot water or heated by a direct fire, the pressure of the can may rise sharply,
thereby the can explodes.
2. When charging refrigerant while running the engine, to avoid explosion, do not open the high pressure valve
(HI) of the gauge manifold.
If the high pressure valve is open, it is very dangerous because a high pressure gas flows in the reverse
direction, causing the service can and the charging hose to explode.
Others
• Reuse of service cans is prohibited by the regulation, so never reuse them.
• Do not allow foreign materials to enter the air conditioner circuit.
• Air, water, and dust are detrimental to the refrigeration cycle. Install the components of the air conditioner
correctly and speedily. Pay full attention to prevent water and dust from entering the refrigerant cycle.
11-34
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
11
11-35
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
Operation Chart
More tha n Le a ve it a s it is ,
30 min. for five minute s .
Be gin va cuum S top va cuum Che ck Cha rge Che ck for Cha rge
ma king ma king air-tightness re frige ra nt ga s le a k re frige ra nt
Lowe r tha n
-750mmHg Ga uge indica te s
a bnorma lity
Cha rge re frige ra nt ga s to a ga uge
Che ck a nd corre ct joints pre s s ure of 0.098 MP a (14.2 ps i)
Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1 23.5mm
(0.93 inch) side
Gauge
1 1
manifold
For service
5 T joint 1
can valve
Red :
high pressure
side
Blue :
Charging Service can For service
2 3 low pressure 6 2
hose valve can
side
Yellow :
vacuum pump
side
Vacuum
For vacuum
3 Quick joint 1 7 pump 1
27.5mm pump
(1.08 inch) adapter
11-36
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
CHARGING
HOSE
(GAS VALVE)
• Do not mistake the high pressure hose for the low pressure hose in any circumstances when connecting them.
Put the hose in firmly till a clicking sound is heard.
• Some kinds of gauge manifolds are not equipped with an open/close valve in the center.
2. Vacuum making
LOW PRESSURE VALVE(OPEN) (CLOSE)
1) Open the high pressure valve (HI) and the low HIGH PRESSURE VALVE(OPEN) More than (CLOSE)
pressure valve (LO) of the gauge manifold. 30 min
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes.
GAUGE MANIFOLD
3) When vacuum making for a specified duration is
over (degree of vacuum : less than - 750 mmHg),
close the high pressure valve and the low
pressure valve of the gauge manifold.
4) Then turn off the vacuum pump. DIS
SUC
3. Air-tightness Check
Close the high pressure valve and the low pressure valve of the gauge manifold, leave it as it is for more than
five minutes and make sure that the gauge indication does not return toward 0.
11-37
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
If the gauge indication goes toward 0, there is somewhere that is leaking. Retighten pipe joints, make vacuum again
and make sure of no leakage.
BLUE RED
2) Air purge
Open the service can valve. (However, close the
high and low pressure valves of the gauge
manifold.) LOW PRESSURE HIGH PRESSURE VALVE
Then push the gas valve of the side service port VALVE(CLOSE) (OPEN) (CLOSE)
on the low pressure side of the gauge manifold, RED FILL IN 1~1.5 CANS
using a screw driver, in order to let out the air in BLUE OF REFRIGERANT
the charging hose by the pressure of the
DIS
refrigerant. YELLOW
(The operation ends when a hissing sound is SERVICE CAN
VALVE
heard.) (OPEN) (CLOSE)
CHARGE
SUC
3) Open the high pressure valve of the gauge manifold and charge in refrigerant. [Charge in gaseous
refrigerant to a gauge pressure of 0.098 MPa (14.2 psi).]
After charging, close the high pressure valve of the gauge manifold and the service and valve.
Use the leak tester for R134a. (Do not use one for flon gas service as it provides poor sensitivity.)
11-38
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[11. AIR-CONDITIONER SYSTEM]
2) Start the engine and run the revolution from 1400 to 1600rpm and close the cab door and the windows.
3) Turn on the air-conditioner switch, set the fan switch to Max and the temperature control switch to cool Max.
4) When charging gas, set the discharge pressure of the compressor from 1.37 to 1.57 MPa (199 to 228psi).
5) Open the low pressure valve of the gauge SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver disappear.
[Total amount of gas to be charged: 800 to 900g
(1.76 to 1.98 lbs)]
RECEIVER DRYER
Receiver dryer
6) When refrigerant charge is completed, close the low pressure valve of the gauge manifold and the service
can valve.
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[11. AIR-CONDITIONER SYSTEM]
HANDLING OF REFRIGERANT
• If the air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor.
• If the refrigerant is charged too much (overcharged), the cooling performance is deteriorated. Moreover, the
circuit pressure gets abnormally high:
Always keep a proper level.
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[11. AIR-CONDITIONER SYSTEM]
11
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[11. AIR-CONDITIONER SYSTEM]
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
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[11. AIR-CONDITIONER SYSTEM]
11
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[11. AIR-CONDITIONER SYSTEM]
2 3
Blower controller
Relay
Four-electrode relay is used for the blower OFF relay
and compressor relay.
1. Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2. Compressor relay
The relay ON-OFF is switched by the control
amplifier and electronic thermostat control.
3. Relay specification and inspection
1) Coil resistance: 320Ω
2) Specified voltage: DC20V to 30 V
3) Be careful about the coil polarity of relay.
4) Inspection: Inspect the continuity between terminals 3 and 4 as follows.
20 to 30 V applied between terminals 1-2: Continued
20 to 30 V not applied between terminals 1-2: Not continued
11-44
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[11. AIR-CONDITIONER SYSTEM]
Motor actuator
Air mix actuator is located in at the center of air-con unit,
and opens and closes air mix damper through the link
motion.
The air mix actuator incorporates potentiometer which is
switched by linked shaft with actuator.
When the target air mix door position is determined Control panel Motor actuator
through the temperature control switch, the control unit
M
reads the level of potentiometer of the actuator. And it
determines the rotating direction of motor in either
normal rotation or reverse rotation. And the motor
rotates, the contact point is moved, and when the
contact point is detached or the output signal of control
unit turns OFF, the motor stops. Both motor actuators
(+ a t (6 ) a n d - a t (4 ))
O u tp u t v o lta g e
C ir c u it b o a r d c h a r a c te r is tic
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[11. AIR-CONDITIONER SYSTEM]
11-46
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[11. AIR-CONDITIONER SYSTEM]
A s now ma rk ( ) on A s now ma rk ( )
the panel is flashing. on panel is flashing. Check and correct or replace parts.
NO YES
11
. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporator sensor are
disconnected or shorted.
See paragraph of monitor mode. . Controller failed.
A
NO YES
NO YES
NO YES
M/A stops halfway . Inspect and correct
ON/OFF and power circuit
of compressor clutch. Controller is faulty Check duct or
or inner air sensor eliminate cause for
is faulty. cool air intrusion.
Refer to troubleshooting
for refrigeration cycle.
Check and replace.
NO YES
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[11. AIR-CONDITIONER SYSTEM]
NO YES
NO YES
Check and replace.
Replace.
11-48
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[11. AIR-CONDITIONER SYSTEM]
NO YES
NO YES
Battery voltage is applied on between
white/green wire of blower motor relay
and ground wire. Eliminate cause Check and
of failure and then repair harness.
NO YES replace blower amplifier .
Note 1)
In the connector connected condition, measure the voltage.
Note 2)
When connecting the wires directly , turn of f the air conditioner , starter switch,
and light switches for safety .
11-49
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[11. AIR-CONDITIONER SYSTEM]
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 to 9.
NO YES
No Ye s
Re fe r to trouble s hooting
for re frige ra tion cycle .
Che ck clutch Check air conditioner
fus e s . harness for possible failure.
No Ye s
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[11. AIR-CONDITIONER SYSTEM]
11
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[11. AIR-CONDITIONER SYSTEM]
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
NO YES sight glass. is low.
Cooling does not work Oil comes out from
if refrigeration circuit is piping and parts.
operated at high speed. Compre s s or cylinde r Compressor cylinder
NO YES doe s not ge t hot. gets extremely hot.
NO YES
Expansion valve Expansion valve Natural Gas leaks
is clogged. is frozen or leak from from pipe
intruded by water. hose. joints and Expansion valve is Compressor does
parts. maladjusted. not discharge well.
Replace After performing (too much open)
expansion valve. air purge by Charge gas. Retighten
vacuum, refill or replace
refrigerant and parts. Replace Replace compressor
replace receiver. expansion valve.
High pressure
is low.
11-52
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[11. AIR-CONDITIONER SYSTEM]
Recirculation and
Recirculation and fresh air display is flashing
fresh air selection
Failure part of
Display of failures
sensor
18 degrees C: LO.E
·“E” is indicated on first decimal
Evaporator sensor 25 degrees C: 25.E
place of temperature indication
32 degrees C: HO.E
Detection of each sensor error by monitor mode function (for obtaining failure control status from the
control panel)
• When the air conditioner is in operating condition, press the internal and external air selector switch and main
power switch for one second or more simultaneously. And the display of monitor mode begins. To return the
display to previous display, perform the same operation.
• Normal condition, disconnection and short circuit of inner air sensor, evaporator sensor and solar sensor are
indicated in segment of display.
11-53
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[11. AIR-CONDITIONER SYSTEM]
11-54
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[12. DISASSEMBLING AND ASSEMBLING]
12
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[12. DISASSEMBLING AND ASSEMBLING]
12-2
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[12. DISASSEMBLING AND ASSEMBLING]
12
12-3
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[12. DISASSEMBLING AND ASSEMBLING]
ATTACHMENTS
1. Removing and Installing
2. Disassembling and Assembling
1) Cylinder
UPPER STRUCTURE
1. Removing and Installing
2. Disassembling and Assembling
1) Hydraulic Pump
2) Control Valve
3) Pilot Valve (ATT)
4) Pilot Valve (Travel)
5) Slewing Motor
6) Swivel Joint
TRAVEL SYSTEM
1. Removing and Installing
2. Disassembling and Assembling
1) Travel Motor
12-4
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[13. ATTACHMENTS]
13. ATTACHMENTS
13.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.............................................................13-3
13.2 PREFACE ............................................................................................................................13-4
13.3 REMOVING AND INSTALLING ATTACHMENT ......................................................................13-5
13.3.1 ATTACHMENT ASSEMBLY AND NAME .............................................................................13-5
13.3.2 BUCKET............................................................................................................................13-6
13.3.3 ARM..................................................................................................................................13-9
13.3.4 BOOM ............................................................................................................................. 13-13
13.4 DISASSEMBLING AND ASSEMBLING ............................................................................... 13-18
13.4.1 CYLINDER ...................................................................................................................... 13-18
13
13-1
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[13. ATTACHMENTS]
13-2
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[13. ATTACHMENTS]
13
13-3
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[13. ATTACHMENTS]
13.2 PREFACE
• This Manual describes all the procedures from removing to attaching, arranging them by item.
• This Manual consists of mainly 2 sections of "REMOVING AND INSTALLING ATTACHMENT" and
"DISASSEMBLING AND ASSEMBLING".
• The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
• The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
• Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
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[13. ATTACHMENTS]
(D) (C)
(A)
1
4
(F)
(E)
(J) 2
5
(G)
3
8 6
7 (K) (B)
(I)
(H)
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[13. ATTACHMENTS]
13.3.2 BUCKET
13.3.2.1 REMOVING BUCKET
1. Put the machine in position to remove bucket.
SECTION OF BOSS
13-6
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[13. ATTACHMENTS]
13
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.
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[13. ATTACHMENTS]
• When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).
• Remove shims (9), push out bushing (7) rightwards by means of three capscrews (11) and adjust clearance (B)
so it settles within the standard value evenly all round.
13-8
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[13. ATTACHMENTS]
13.3.3 ARM
13.3.3.1 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.
OIL PAN
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[13. ATTACHMENTS]
DETAIL bb
H 7
DUST SEAL
cc Apply Molybdenum
SHIM added grease
SHIM Install resin shim DUST SEAL
in the inner surface.
to bucket link side.
SECTION DD
DETAIL cc
G
Apply
Molybdenum
added grease
in the inner surface. 3
SECTION AA DETAIL aa
13-10
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[13. ATTACHMENTS]
aa 2
E
SHIM
SHIM SHIM
Tota l cle a ra nce of
3 Install resin shim
both side to be to cylinder side.
0.6~2.0mm (0.02~0.08in)
after adjusting by shims.
SECTION BB DETAIL aa
aa
SHIM
Tota l cle a ra nce of both s ide
to be 0.5mm (0.02in) or less
after adjusting by shims.
F
SECTION AA
13-11
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[13. ATTACHMENTS]
(0.02")
CLEARANCE
147 (108)
M16
Metric threads 279 (206)
13-12
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[13. ATTACHMENTS]
13.3.4 BOOM
PREPARATION
When removing and attaching the boom in the position shown in the figure "Position to remove boom", to remove
and install boom foot pin (A), removing and attaching of the cab and the guard on the upper structure are required.
BLOCK
STAND 13
13-13
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[13. ATTACHMENTS]
A A
7. Removing boom foot pin (A) Tota l cle a ra nce of both s ide s to be
0.5mm (0.02in) after adjusting by shims.
1) Remove capscrew (4) M20×40 and plate (3). SHIM
Tools: Spanner: 30mm
13-14
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[13. ATTACHMENTS]
D
D
SHIM
Tota l cle a ra nce of
both side to be
0.6~1.0mm
(0.02~0.04in)
after adjusting by shims. SECTION DD
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[13. ATTACHMENTS]
4) Removing boom cylinder foot pin (B) Tota l cle a ra nce of both s ide to be
(See the figures "Removing and installing boom 0.6~1.0mm (0.02~0.04in)
after adjusting by shims.
cylinder head pin (B)" and "Installing boom foot SHIM
pin (A)".) 5 SHIM
Remove nut (6) and capscrew (5) M16×150 and
B
pull out pin (B). SHIM
6 aa
Tools: Spanner: 24mm Install resin
shim to
5) Sling boom cylinder (2) and remove it. Apply Molybdenum cylinder side.
Weight of boom cylinder: 166kg (366 lbs) added grease
in the inner surface. DETAIL aa
5
6) Remove another boom cylinder the same way. Apply Molybdenum added
grease in the inner surface. B
6
SECTION AA
13-16
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[13. ATTACHMENTS]
13
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[13. ATTACHMENTS]
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.
APPARATUS
The following equipment are required for disassembly:
1. Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
2. Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in
its most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder
head and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently
large.
3. Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to
prevent damage of seals.
4. Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil
leak tests after completion of assembly.
5. Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
6. Cleaning bath, cleaning oil and detergent
7. Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
8. Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
13-18
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[13. ATTACHMENTS]
NECESSARY TOOLS
The tools and jigs to be used depend on the cylinder to work with. Prepare necessary tools referring to the table
below as a rough guideline.
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)
• For the details of special tools and jigs, refer to the back pages of this manual.
EXTERNAL CLEANING 13
The cylinder taken off the excavator has dust and foreign
matter, and grease is usually adhered to the clevis part.
For this reason, remove external soil and contamination
from the cylinder with water and steam before bringing it
into the workshop. Cylinder gauge
• The following describes the construction of boom
cylinder. When disassembling and servicing the cylinder, confirm the construction of cylinder referring to Parts
Manual.
13-19
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[13. ATTACHMENTS]
DISCHARGING OIL
Place a wooden-block on the work bench and place the WOODEN BLOCK
cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the
PORT B
hydraulic oil in the cylinder is drained out. At this time,
V BLOCK
connect a suitable hose to each port so that the hydraulic
oil may not gush out. PORT A
AIR
OIL PAN
Preparation
13-20
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[13. ATTACHMENTS]
PS1/8
PT1/4
SLIT 15
ONE HOLE
DETAILA DETAIL B
DETAIL C
Piston with piston nut type
9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 *20 *21 22 23
C
A
13
In case of piston with piston nut type, the parts with * are not used.
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[13. ATTACHMENTS]
13.4.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder, check the construction and the availability of service parts as
well as necessary tools and jigs on separate Parts Manual.
• The figures in parentheses after part names correspond to those in 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.
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.
3. Loosen and remove socket bolts (12) of the rod cover in sequence.
Cover the extended piston rod (2) with cloths to prevent it from being accidentally damaged during operation.
4. Strike the corner of the rod cover flange by means of ALLEN WRENCH 12
a plastic mallet till rod cover (3) comes off.
Turn counterclockwise
3
Cover here with cloths
2
• At this time, the weight of piston rod (2) is loaded on KNOCK THIS EDGE
rod cover (3). Therefore, lift the top end of the piston WITH A PLASTIC MALLET.
LIFT HERE.
rod with a hoist to the extent that only the rod weight
may be held.
3
2
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[13. ATTACHMENTS]
5. Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
HORIZONTALLY
OIL PAN
Since the piston rod assy is heavy in this case, lift the tip of the piston rod (2) with a hoist and draw it out. However,
when piston rod (2) 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 (2) is lifted, do not use a wire rope which may score the
surface, but use a strong cloth belt or a rope.
WOODEN V-BLOCK
(PLACE CLOTHS)
19
18
13-23
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[13. ATTACHMENTS]
WOODEN V-BLOCK
(PLACE CLOTHS)
• Note that the tightening torque differs with the type, the working pressure and the mounting method of the piston
(15), though the rod diameter is the same.
• It is also necessary to place a suitable supporting block near the piston (15). In case a V-block is used, put cloths
or something over the rod to prevent it from damage.
21
23
TURN COUNTER
CLOCKWISE.
15
EYE WRENCH
21
13-24
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[13. ATTACHMENTS]
• Since piston nut (21) and piston (15) is tightened by a strong torque, use an eye wrench of proper size for the
outside diameter of piston nut (21) and "piston (15) hexagonal part" and use a power wrench using a hydraulic
jack or hydraulic cylinder.
• In case that piston and piston nut are combined, apply the eye wrench to hexagonal part of piston and loosen the
piston directly.
4 15
In case that piston and piston nut are combined, the shim (20) is not used.
3 4 6 8,7 9 2
Take care so rod bushing (4) and the lip of packings (6,7,8,9) may not be damaged by thread of the piston rod (2).
13-25
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[13. ATTACHMENTS]
Cut the seal ring (16) by tapping it with a screwdriver or a chisel. Take care not to strike it too hard, otherwise the
groove may be damaged.
11
2. Remove buffer ring (6), U-ring (7) and back-up ring GIMLET
(8). 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. 8
3 7
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[13. ATTACHMENTS]
3. Remove wiper ring (9). When taking out wiper ring HAMMER SCREW- 3
(9), fix rod cover (3) in a vise. DRIVER
WOOD PIECE
WOOD PIECE
VISE
BLOCK TOOL C
13
24 BASE
2. Push out pin bushing (24) press fitted in cylinder tube (1) and piston rod (2) with press.
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[13. ATTACHMENTS]
13.4.1.4 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.
13-28
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[13. ATTACHMENTS]
2. Press fit wiper ring (25) in the upper and lower sides of cylinder tube (1) and piston rod (2) respectively with
press.
• Before press fitting, apply grease on wiper ring and boss hole.
• Before press fitting the pin bushing, align the position of oil hole.
13
ASSEMBLING OF PISTON ASSY
1. The fitting of seal ring (16) requires special tool as PRESS HERE METAL (G)
shown in right Fig. Seal ring (16) is pushed in by
PRESS JIG (E)
press, etc. with pushing in tool as shown in the
figure. (The O-ring of seal ring (16) and back-up ring
(17) on one side should be installed beforehand.) SLIDE JIG (F)
15
16 O-RING
17
Heat them, and they may be soften. But never heat them over 100C degrees (212.0F degrees) or more.
13-29
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[13. ATTACHMENTS]
2. Fit back-up ring (17) on the other side. After fitting it, PRESS HERE
correct seal ring (16) immediately by correctional jig 16 17
(H) as shown in the figure "Correcting seal ring (16)"
to prevent it from remaining in an expanded CORRECTIONAL
condition. JIG (H)
• For piston, stop it once tentatively (for 3 to 5 seconds), and then push it in fully.
• After fitting, wind tape around seal ring (16) 2 or 3 times, and remove it immediately before piston (15) is inserted
in cylinder tube (1).
• Fit slide rings (18) (19) at the same time when piston (15) is inserted in cylinder tube (1).
The snap ring (5) can not be fitted when the bushing (4) is not press-fitted fully to the stop end.
2. Apply grease to wiper ring (9), and fit wiper ring (9), PRESS HERE. (STRAIGHT DOWN)
directing the lip side toward the groove of retainer
tool (D). And set retainer tool (D) on rod cover (3) RETAINER TOOL (D)
and press fit wiper ring (9) with press.
U-RING GROOVE
13-30
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[13. ATTACHMENTS]
3. Fit buffer ring (6), back-up ring (8) and U-ring (7) in PUSH BAR (WOOD OR PLASTIC)
their grooves in that order. Before setting packings, 10
coat them with hydraulic oil (or vaseline if not
11
available). If you forget the coating, the packings Tube side
may be scored. 3
When attaching seals, deform them in a heart shape
as illustrated.
7
8
9
13
• U-ring (7) 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 ring (6) 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 U-ring.
• If U-ring (7) is set upside down, the lip may be damaged. Check the correct orientation of U-ring (7) shown in the
figure "How to fit U-ring (7)"
• Attach back-up ring (11) on the open air side of O-ring (10).
13-31
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[13. ATTACHMENTS]
2. Install rod cover (3) on piston rod (2) by using inserting guide jig (I) as shown in the figure "Inserting rod cover
(3)" paying attention for the lip sections of the wiper ring and the U-ring not to be caught on the stepped
section.
• 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.
2. When cushion is installed on the retraction side, fit Direct slit toward
cushion bearing (13) and cushion seal (14) by the thread side
following procedure. THREADED PART
13-32
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[13. ATTACHMENTS]
• Cushion seal and cushion bearing should be fitted taking care of the fitting direction.
If they are fitted in reverse directions, the cushion does not effective.
• After installing cushion, be sure that the cushion bearing moves up and down, and right and left.
• In case that piston and piston nut are combined, the shim (20) is not used. Apply the eye wrench to hexagonal
part of piston and loosen the piston directly.
• Always correct the threads in piston nut (21) or [piston (15)] before fixing piston nut, using a tapping.
• Insufficient tightening torque causes an inner leak and a damage of thread. And over tightening torque causes a
bulge of cushion bearing and a deformation of piston contacted surface.
• Clean and decrease (with solvent) the parts of piston assembly, and dry it, then tighten this piston assembly.
13
4. Put steel ball (23) into hole and tighten setscrew ANTI-LOOSENING
(22). 22 CAULKING 20
2
Tools: Allen wrench: 6mm 23
After tightening the setscrew to a specified torque,
caulk the two places of the thread of the piston nut
side to secure the setscrew. See "TIGHTENING
TORQUE" described later for the tightening torque.
V-BLOCK
21
13-33
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[13. ATTACHMENTS]
21 V-BLOCK
OVERALL ASSEMBLY
1. Place a V-block on a work bench (A wooden V-
1
block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar LIFT
through the clevis pin hole to lock the assy.
STRAIGHT
PREVENT TURNING
WITH WOODEN BAR.
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 slide rings (18), (19) on the perimeter of the piston is not out of the groove.
3. Tighten socket bolt (12).
12
Match the bolt holes of the rod cover flange to the
threaded holes in the cylinder assy, and screw in PLACE CLOTH
socket bolts (12) one by one. Tighten the bolts to a
specified torque, taking care so the bolts may not be
tightened unevenly. See "TIGHTENING TORQUE"
described later for the tightening torque.
Tools: Allen wrench: 14mm
ALLEN WRENCH
TURN CLOCKWISE
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.
13-34
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[13. ATTACHMENTS]
H R
HYDRAULIC CYLINDER
• Do not raise the hydraulic pressure above the maximum pressure of 37.8MPa (5480psi) 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.
LEAK TEST
1. Apply a test pressure to the retracting and extending
sides of the cylinder for 3 minutes independently to MEASURE THE
check the rod part, the welded part and others for INTERNAL LEAK. 13
external leakage and permanent deformation.
Furthermore, regarding an internal leak test,
perform it by connecting the cylinder with a test unit
as shown in the figure "Internal leak test".
2. After completing the test, apply a plug to each port
and store the cylinder. (See the figure "Cylinder FROM DIRECTIONAL VALVE
storing method".)
Internal leak test
PLUG PLUG
13-35
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[13. ATTACHMENTS]
Inspection Item
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.
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).
13-36
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[13. ATTACHMENTS]
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.
TIGHTENING TORQUE
B A C A B C
Cylinder Piston nut or
Socket bolt Setscrew
[Piston]
13-37
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[13. ATTACHMENTS]
13.4.1.8 TROUBLESHOOTING
Trouble Failed Parts Cause Remedy
Oil leak through sliding Back-up ring Foreign matter is trapped in the Remove foreign matter.
surface of piston rod. Oil ring bore of back-up ring.
is formed on piston rod, and
Lips on outer and inner diameter Replace back-up ring.
the ring grows up to oil drops,
surfaces of back-up ring are
and they drip.
scored.
Other back-up ring are failed. Replace back-up ring.
OIL LEAKS FROM HERE U-ring Foreign matter is trapped in the Remove foreign matter.
bore of U-ring.
Piston rod Score is present on the sliding Smooth out the sliding surface with an
surface of piston rod. oilstone. If leakage occurs even if the sliding
surface is finished below 1.6S, rod packings
may be scored. Disassemble and inspect it
and replace rod packings as required. If leak
will not stop by that treatment, replace piston
rod.
Hard chromium plating has Replate.
peeled off.
Oil leaks from welds. Cylinder tube Welds of cylinder are broken. Replace cylinder tube.
WELDS
Cylinder falls by it-self. Piston seal Foreign matter is trapped in the Remove foreign matter.
[When the rod is loaded with sliding surface of seal ring.
a static load equal to the
Score is present on the sliding Replace seal ring.
maximum working pressure
surface of seal ring.
multiplied by the area of the
cylinder bore, the maximum Slide ring Sliding surface of slide rings is Replace slide ring.
movement of the piston is scored.
more than 0.5mm (0.02") in
Piston rod Piston rod and piston are Replace piston rod.
ten minutes.]
elongated. (Loose nut)
13-38
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[13. ATTACHMENTS]
Application Shape
A D
D
For press fitting wiper ring
E H
F
I
For inserting rod cover 13
13-39
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[13. ATTACHMENTS]
13-40
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[13. ATTACHMENTS]
12-S
5(0.20 ") Unit : mm (inch)
C2(0.08 ") R2(0.08 ") R0.2 (0.008 ")
10 12-S d D Cylinder Used
-0.008"
-0.4 -0.016"
-0.158"
-0.020"
-1 -0.040"
-0.118"
D -0.2
D -0.5
D -3-4
Unit : mm (inch)
B Cylinder Used
13
13-41
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[13. ATTACHMENTS]
4 5 (0.197")
(CHUCK)
13-42
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[13. ATTACHMENTS]
A L L E N W R E N C H
A
13
3. Attaching tools for retainer
Put retainer on the press bench directing the wiper
ring fitting section of rod cover upward, then put D
retainer tool (D) on the rod cover.
FLANGE
• Fit retainer tool as shown in the right figure directing
large diameter section (flange section) upward.
• Clean the surface of press bench, and take care for
the tool bottom face not to be damaged by foreign
matter like dust, chip, etc.
13-43
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[13. ATTACHMENTS]
CHUCKING JIG A
D
15 (0.59") 15 (0.59")
d 10
10
Unit : mm (inch)
Class
d D h
(Nominal size)
13-44
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[13. ATTACHMENTS]
6. Removing of bushing
1) Move block (C) and rod cover (3) with tool under
the press.
2) Press the upper part of retainer tool (D) slowly
until bushing (4) is take out from rod cover (3)
D
(until there is a sound that the chuck tool (A)
drops on the work bench)
The force of 3 tons (6615 lbs or less) is
necessary to press it out.
The stroke of press ram is about 32 to 52 mm
(1.26 in to 2.04 in).
(But it varies according to the difference of
dimension of cylinder head.)
• Press it with retainer tool (D)
When the block and rod cover assy are not
aligned, interrupt the work and align the block
and rod cover assy.
13
13-45
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[13. ATTACHMENTS]
8. Removing of bushing
1) Place chuck tool (A) with bushing (4) sideways,
and loosen adjuster bolt with allen wrench and
lever.
A D J U S T E R B O L T
C H U C K
13-46
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[13. ATTACHMENTS]
13
3
ADJUSTER BOLT
WEDGE
13-47
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[13. ATTACHMENTS]
S T E P O F W E D G E
RETAINER(D)
CHUCK(A)
BUSHING(4)
BUSHING PRESS-
FITTING PART
13-48
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[13. ATTACHMENTS]
5. Press-fitting of bushing
Push the head of retainer (D) with press, and press
fit bushing (4) to the specified position of rod cover
(3) slowly.
• The pressing force should be held 5 tons (11025 lbs)
or less, keeping the required force for the press-fitting. STEP OF WEDGE
• Raise the pressure gradually adjusting the force by
means of pressure adjusting valve of press unit.
• Be sure that the end face of bushing is located on the
interior of the groove for snap ring. When it is located
on near place, press fit and adjust the location again.
LIFTING THREAD
ADJUSTER BOLT
WEDGE
13
CHUCK TOOL ASSY (A)
CHUCK
13-49
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[13. ATTACHMENTS]
13-50
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[14. UPPER SLEWING STRUCTURE]
14-1
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[14. UPPER SLEWING STRUCTURE]
14-2
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[14. UPPER SLEWING STRUCTURE]
14
14-3
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[14. UPPER SLEWING STRUCTURE]
14.2 FOREWORD
1. This manual describes all the procedures from removing to attaching, arranging them by item.
2. This chapter consists of the first half, "REMOVING AND INSTALLING ASSEMBLY", and the second half,
"DISASSEMBLING AND ASSEMBLING COMPONENT".
3. The removing and installing can be performed in the order specified in TABLE OF CONTENTS, but in view of
actual repairing or time saving, some processes can be omitted.
4. The removing and installing procedures of assembly parts do not completely cover all possible situations
because of differences of field condition and defective section, and limitation of editing. We hope for your
understanding about this.
5. Recognize well that a service man must decide a work procedure before proceeding to repair.
When removing, installing, disassembling, or assembling procedure is required, choose an item that is needed,
familiarize yourself with the contents of the work and itemize the work procedure, before starting work.
14-4
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove head rest (A1-1) of operator's seat (A1) for easy handling.
• Move the whole control stand to its foremost position.
• Move the operator's seat to its forward end.
• Incline the reclining seat as forward as possible.
Rail displacement
Upper rail.....Fixed at the lower surface of the seat (forward direction: 80 mm (3.15 inch) and rear direction: 80 mm
(3.15 inch))
Lower rail.....Fixed at the seat stand (forward direction: 60 mm (2.36 inch) and rear direction: 60 mm (2.36 inch))
Adjustment amount of seat height: (upper: 23 mm (0.91 inch) and lower: 37 mm (1.46 inch))
B2
14
Tightening torque
Name
N·m (lbf·ft)
14-5
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[14. UPPER SLEWING STRUCTURE]
FOR WARD
14-6
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[14. UPPER SLEWING STRUCTURE]
14
14-7
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[14. UPPER SLEWING STRUCTURE]
D6
D5
14-8
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[14. UPPER SLEWING STRUCTURE]
I
E3 E1
E4
E6 E1
E5
A A
E4 E3
SECTION AA VIEW I
F3
F3
14
14-9
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[14. UPPER SLEWING STRUCTURE]
Slinging cab
14-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[14. UPPER SLEWING STRUCTURE]
Follow the procedures for removing and installing the battery cable.
Disconnect the battery cable at the ground side first but when connecting the battery cable, connect it to the ground
side last. If these procedures are not followed, it may cause a short circuit resulting in spark.
B1 B2
B6 B3
C1
14-11
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[14. UPPER SLEWING STRUCTURE]
1) Install cable (A3) last. Check carefully that the grounding face of the machine body is free from painting and
rust, etc.
Tools: Wrench: 13 mm
14-12
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[14. UPPER SLEWING STRUCTURE]
4) Loosen three sems bolts (B15) M12 x 25 and remove duct (B17).
Tools: Socket: 19 mm
5) Loosen seven sems bolts (B15) M12 x 25 and remove cover (B3).
Tools: Socket: 19 mm
Weight: 6kg (13 lbs)
6) Loosen seven sems bolts (B15) M12 x 25 and remove cover assembly (B4).
Tools: Socket: 19 mm
Weight: 9 kg (20 lbs)
14
14-13
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[14. UPPER SLEWING STRUCTURE]
B2
I
B1
B3
B15
B4
II
B2
A
B15
VIEW I
B15,B17
3 PLACES
B3,B15
B4,B15 7 PLACES
4 PLACES
B1
B17
B12
SECTION AA 2 PLACES VIEW II
Removing and installing bonnet assemblies (B1) and (B2), cover assembly (B4), cover (B3), and
duct (B17)
14-14
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[14. UPPER SLEWING STRUCTURE]
D4
D13
FOR WARD
D2,D14
B6 B1
B8
14
A B
14-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[14. UPPER SLEWING STRUCTURE]
To open and fix the bonnet, hook up stay (B6) at the A position of beam (D8) and even if beam (D8) is removed, by
hooking up stay (B6) to the second holder (B position), bonnet (B1) can be kept open.
The second holder (B position) is located at the front of the counterweight. Use this as required such as when
maintaining the area around the muffler.
5) Loosen four sems bolts (D13) M12 x 30 and remove beam (D7).
Tools: Socket: 19 mm
6) Loosen six sems bolts (D13) M12 x 30 and remove bracket assembly (D9).
Tools: Socket: 19 mm
Weight: Bracket assembly (D9): 7kg (15 lbs)
7) Loosen two sems bolts (D14) M12 x 25 and remove pillar (D5).
Tools: Socket: 19 mm
8) Loosen four sems bolts (D13) M12 x 30 and remove beam (D4).
Tools: Socket: 19 mm
9) Loosen three sems bolts (D14) M12 x 25 and remove cover assembly (D25).
Tools: Socket: 19 mm
14-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[14. UPPER SLEWING STRUCTURE]
7. Removing guard assembly (D10), cover (D24), and D14 D10 D15 2 PLACES
FOR WARD
brackets (D11), and (D12), and pillar (D6) D11,D14
1) Loosen two sems bolts (D13) M12 x 30 and
D12,D14
remove pillar (D6). 2 PLACES
Tools: Socket: 19 mm
4) Loosen two sems bolts (D14) M12 x 25 and Removing guard assembly (D10), cover (D24),
remove bracket (D12). brackets (D11) and (D12), and pillar (D6)
Tools: Socket: 19mm
5) Loosen two sems bolts (D14) M12 x 25 and remove bracket (D11).
Tools: Socket: 19 mm
8. Removing beams (A5) and (A6), pillars (A1) and A12
(A2), guard assembly (A3), and cover (A4) A12
A11 A12
1) Loosen four sems bolts (A12) M12 x 25 and
remove beam (A5). A6
2) Loosen three sems bolts (A12) M12 x 25 and
remove beam (A6).
A12
VIEWéé
VIEWèè
14-17
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[14. UPPER SLEWING STRUCTURE]
E4,E7
E12 E5
14-18
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[14. UPPER SLEWING STRUCTURE]
9
9
11
9 FOR WARD
14
14-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the guards and the components which need to be removed to remove the fuel tank. (See Paragraphs
"REMOVING AND INSTALLING GUARDS", "REMOVING AND INSTALLING AIR CLEANER", and "REMOVING
AND INSTALLING RADIATOR AND OIL COOLER".)
1. Draining fuel
B1
A6
A3,A4,A5
A7,A8
A9
A1
14-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[14. UPPER SLEWING STRUCTURE]
If the clearance (gap) between the tank mounting base and the frame is 1 mm (0.04 inch) or more, adjust the
clearance with shim (A3) and then tighten the bolts.
• At installation, use the reverse order of removal with the tightening torques in the tightening torque table.
Tank mounting bolt (A1) M20 x 50
Tools: Socket: 24 mm, apply Loctite #262
Tightening torque
Tightening torque
Item Name
N·m (lbf·ft)
14
14-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the guards which need to be removed to remove the hydraulic oil tank. (See Paragraphs "REMOVING
AND INSTALLING GUARDS".)
1. Releasing tank internal pressure
Cap
Remove the cap on the air breather and press the
internal valve (the head of the bolt) to release the Push Air breather
internal pressure.
Element No.
YN57V00010S002
14-22
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[14. UPPER SLEWING STRUCTURE]
A14
A13 A3
14-23
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[14. UPPER SLEWING STRUCTURE]
B4
14-24
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[14. UPPER SLEWING STRUCTURE]
D3,D4,D5
D2
D1
14
14-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[14. UPPER SLEWING STRUCTURE]
Preparation
• Clean the hydraulic oil tank.
• Clean the suction hose.
• Clean the tank mounting base in the upper frame.
1. Install four mounting cap screws (D1) M20 x 45.
(See the figure "Removing and installing hydraulic oil tank".)
Tools: Socket: 30 mm, apply Loctite #262
Tightening torque: 370N·m (273 lbf·ft)
If the clearance (gap) between the tank mounting base and the frame is 1 mm (0.04 inch) or more, adjust the
clearance with shims (D3), (D4), and (D5) and then tighten the bolts.
Replace the O-ring at the back side of the tank cover with a new one.
14-26
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the guards, the pipes, and the harnesses which need to be removed to remove the DEF/AdBlue tank.
(See Paragraphs "REMOVING AND INSTALLING GUARDS" and Chapter "ENGINE".)
• Drain DEF/AdBlue in the DEF/AdBlue tank.
Tank capacity: 83 L (22 gal)
1. Loosen two nuts (7) M10.
Tools: Socket: 17 mm
Tools: Whirl-stop jig (See Chapter "TOOLS".)
2
2. Loosen two cap screws (4) M10 x 65 and remove
band assemblies (2) and (3). aa 3
Tools: Allen wrench: 8 mm
Tools: Whirl-stop jig (See Chapter "TOOLS".)
3. Remove the DEF/AdBlue tank.
Weight: DEF/AdBlue tank: 14 kg (31 lbs)
4
FOR WARD
7
DETAIL aa
• At installation, tighten cap screw (4) first and then nut (7).
• Install the band, aligning it to the center of the tank groove.
• Install the band so as not to twist the band.
At installation, use the reverse order of removal with the tightening torques in the tightening torque table.
14
1. Install band assemblies (2) and (3).
Tools: Allen wrench: 8 mm
Tools: Socket: 17 mm
Tools: Whirl-stop jig (See Chapter "TOOLS".)
Tightening torque
Tightening torque
Item Name
N·m (lbf·ft)
7 Nut 35 (26)
14-27
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the guards and the muffler assembly which need to be removed to remove the hydraulic pump.
1. Release the internal pressure of the hydraulic oil
B9
tank. (See Paragraph "REMOVING AND
INSTALLING HYDRAULIC OIL TANK".)
2. Remove six sems bolts (B9) M10 x 25. B3
Suction
3. Remove cover (B3).
stopper
Tools: Socket: 17 mm
Suction strainer
4. Take out the suction strainer.
5. Install the suction stopper.
See Chapter "TOOLS" for the suction stopper.
6. Removing muffler assembly
Hydraulic oil tank
1) Remove the pipes and harnesses. (See Chapter
"ENGINE".)
6) Put a special sling to the lifting eyes and remove the muffler assembly. (See Chapter "TOOLS".)
14-28
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[14. UPPER SLEWING STRUCTURE]
25
44 71
71
a
a
25
a
21
14
Sling the muffler taking care not to allow the sling chains to interfere with the muffler body, the pipes, and the
harnesses and damage them.
14-29
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[14. UPPER SLEWING STRUCTURE]
2
B2
B1
Hose Tool
Port Remarks
No. (mm)
14-30
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[14. UPPER SLEWING STRUCTURE]
PSV -P2:
P2 pump
CLIP proportional
SEMS BOL T solenoid valve
Tighte ning torque SE-21:
25.5N .m (18.8 lbf .ft) Hydraulic oil
CLIP
Fix white taping part. Fix harness to temperature sensor
pipe fitting with Tighte n a cce s s ory nut
CLIP cable tie. of hydraulic oil
Fix harness to lifting temperature sensor .
eye with cable tie. Tighte ning torque of M4 s cre w is
0.49N .m (0.36 lbf .ft) or less and
no spinning is allowed at mold part.
CLIP
CLIP
Fix corrugated part of harness SE-23:
to pressure sensor with cable tie. Pressure sensor: P2 pump
14-31
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[14. UPPER SLEWING STRUCTURE]
6) Remove four cap screws (2-5) M18 x 55 mounting insert MAs (2-3) from the engine side flywheel and
remove insert MAs (2-3), as required. Furthermore, remove spring pins (2-7) form insert MAs (2-3).
Tools: Allen wrench: 14 mm
14-32
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[14. UPPER SLEWING STRUCTURE]
14
14-33
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[14. UPPER SLEWING STRUCTURE]
Dimension between
4
10. Install suction hose (A3) with each two clips (A13) hub end surface and
spline end surface
d 1
and (A14). (See the figure "Removing and installing Coupling hub
can be assembled VIEW I
delivery and suction hoses".) DETAIL aa reversely .
Tools: Flat-head screwdriver
Tightening torque: 5.39N·m (3.98 lbf·ft)
Installing hydraulic pump
11. Install hose (3) with two clips (11). (See the figure
"Removing and installing other hoses")
Tools: Flat-head screwdriver
Tightening torque: 5.39N·m (3.98 lbf·ft)
12. Install the hydraulic pipes by referring to Chapter "HYDRAULIC SYSTEM".
13. Installing each hose (See the figure "Removing and installing other hoses")
14. Install the connectors of the pressure sensors and the proportional valves.
15. Install the muffler assembly.
21 Bolt 17 59 (44)
14-34
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[14. UPPER SLEWING STRUCTURE]
When replacing the pump, be sure to supply the hydraulic oil of 1 L (0.26 gal) or more form drain port (Dr).
14
14-35
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the guards which need to be removed to remove the air cleaner.
FOR WARD I 5 Unit; mm (inch)
2
5 FOR WARD
3
5
III
aa
1-7
(B) (A)
40
(1 .
57
5 (A)
”)
1 (0
.2 0
(B)
”) bb
4 05 7 ”)
(1 .
(0 . 5
20 32 (1.26”)
”)
17 (0.67”)
5 (B)
(C)
5
7 (C) 10
2-M4X0.7
(D)
VIEW III
4
5 9 II
(C) (B) (A)
o
VIEW I 32 (1.26”)
65 17 (0.67”)
A
7 5
5 A
(C) 5
DETAIL bb 6 SECTION AA DETAIL aa VIEW II
14-36
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[14. UPPER SLEWING STRUCTURE]
Tightening torque
Tightening torque
Item Name
N·m (lbf·ft)
Preparation 14
• Remove the guards which need to be removed to remove the muffler.
• See Chapter "ENGINE".
14-37
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[14. UPPER SLEWING STRUCTURE]
Lifting counterweight
1) Remove four cap screws (A1) M33 x 350. A3, A4, A5, A6
Tools: Socket: 50 mm 10 (0.39”)
Adjus t cle a ra nce be twe e n Adjus t cle a ra nce with
counte rwe ight a nd de ck from 1 to 2 s hims .
to 10mm (0.39 inch).
2) Remove shims (A3), (A4), (A5), and (A6).
A1, A2
(Selection)
14-38
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[14. UPPER SLEWING STRUCTURE]
14
14-39
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[14. UPPER SLEWING STRUCTURE]
Do not loosen or remove the connecting parts of the hoses related to the air conditioner. It will cause leakage of
coolant.
14-40
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[14. UPPER SLEWING STRUCTURE]
25
aa
14
A2 A3
1) Loosen hose band (25) of water hose (2).
Tools: Flat-head screwdriver A4 14
A1
2) Remove hose (2). A4
14-41
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[14. UPPER SLEWING STRUCTURE]
4 2
25
25
FOR WARD
26
5 25
FOR WARD
20
12
20
13
14-42
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[14. UPPER SLEWING STRUCTURE]
10. Separating hydraulic oil hoses (1) and (2) O/C OUT -
TANK 9
Place a container for hydraulic oil under the
1
connecting part of the hose and remove four sems FOR WARD
bolts (9) M12 x 40 and then separate hoses (1) and OUT
(2).
Tools: Socket: 19 mm
11. Removing radiator assembly (See the figure
"Removing and installing radiator stays".)
Tools: Wrench: 19 mm 9
Tools: Socket: 19 mm
IN
2) Move the radiator outward so as not to contact
with the engine fan when the radiator is being
lifted.
C/V T1-
3) Plug the pipe opening with clean waste clothes, 2 O/C IN
etc.
4) Put a sling to the lifting eyes of the radiator Separating hydraulic oil hoses (1) and (2)
assembly and remove the radiator assembly by a
crane.
Weight: Approx. 104 kg (229 lbs)
14
14-43
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[14. UPPER SLEWING STRUCTURE]
I Unit; mm (inch)
FOR WARD bb
3
aa
FOR WARD
(A) (B)
7 ”)
25
.5 7
4 0 (1
II 3
50
(1 .
9 7 ”)
Tighte ning torque 19.6N .m (14.5 lbf .ft)
Apply Loctite #262.
21
24
Tighte ning torque 39.2N .m (28.9 lbf .ft)
Apply Loctite #262.
5
DETAIL bb
25 (A) 25
Install clip in 25
orientation
shown in figure. 7 ”)
(1 .
9 (A)
50
6600 6 ”)
(2 .
3
40
”)
(A) (1 .5 7
7 21
Tighte ning torque 19.6N .m (14.5 lbf .ft)
Apply Loctite #262. 27
DETAIL a a (B)
3 7 2
4
(1.97”)
5
50(1.97”)
(1.57”)
(A)
40
50
50 (1.97”)
(A)
(1.57”)
(0.63”)
16
(A) (A)
40
26
(B)
(0.63”)
16
14-44
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[14. UPPER SLEWING STRUCTURE]
Put a sling to the lifting eyes of the radiator assembly and place the radiator assembly in place temporarily.
Then install the hydraulic hose, the radiator hose, and the intercooler hose. Regarding the insertion standard
for each hose, see the figure "Hose insertion standard".
2. Radiator mounting bolt
Apply Loctite #262 to four cap screws (A5) M12 x 30 and tighten them.
Tools: Socket: 19 mm
Tightening torque: 121N·m (89 lbf·ft)
3. Adjust the whole circumference of the clearance between the fan and the radiator shroud according to the
figure "Adjustment position of front and rear of radiator".
4. Clean the fitting surface for the insulation completely and then attach the insulation.
5. Refilling hydraulic oil and LLC (Long Life Coolant)
After installing radiator
After finishing the other installation works, refill shroud as clearance
hydraulic oil and coolant. Radiator shroud towards fan becomes
90±5mm 90±5mm (3.59±0.20 inch),
Amount of coolant in engine body: 9.5 L (2.5 gal) (3.59±0.20 inch) tighten cap screw (A5) with
for whole circumference specified torque.
Amount of radiator coolant: 7.6 L (2.0 gal)
32mm Fan rubber
Amount of hydraulic oil in oil cooler: 4.8 L (1.3 gal) (1.26 inch)
Put fan rubber of engine
side over fan ring projection
in whole circumference
Fan Fan ring
(engine side)
10mm Do not set fan rubber
(0.39 inch)
on this projected part
of fan ring.
14
Adjustment position of front and rear of radiator
14-45
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[14. UPPER SLEWING STRUCTURE]
14.3.13.3 REMOVING AND INSTALLING RADIATOR, INTERCOOLER CORE, AND OIL COOLER
Preparation
• Remove one under cover under the radiator.
FOR WARD Tighte ning torque 23.5N .m (17.3 lbf .ft)
• Wait until the engine coolant temperature goes down 13
to a temperature that will not cause burns, then
remove the radiator cap, open the drain cock at the
lower rear side, drain the coolant, and receive it with a 4
container.
* When only the intercooler is to be pulled out, the
above work is unnecessary.
1. Removal
8 9
1) Disconnect the wiring connector of radiator
coolant level switch (B12).
10) Sling the cooler by using the flange on the upper part of the cooler and lift the cooler temporarily.
14-46
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[14. UPPER SLEWING STRUCTURE]
There is no specified removal order among the radiator core, the intercooler core, and the oil cooler, so that remove
those components as required.
2. Installation
Installation should be done in the reverse order of removal.
Tightening torque
Tightening torque
Item Name Remarks
N·m (lbf·ft)
14
14-47
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the battery ground cable (See Paragraph "REMOVING AND INSTALLING BATTERY").
• Remove the bonnet and the guards (See Paragraph "REMOVING AND INSTALLING GUARDS") and remove
the under cover (See Paragraph "REMOVING AND INSTALLING UNDER COVER").
• Remove the air cleaner hose (See Paragraph "REMOVING AND INSTALLING AIR CLEANER").
• Remove the counterweight (See Paragraph "REMOVING AND INSTALLING COUNTERWEIGHT").
• Remove the radiator hoses and the intercooler hoses (See Paragraph " REMOVING AND INSTALLING
RADIATOR AND OIL COOLER").
• Remove the fuel hose and the heater hose, and remove the air conditioner hose as required
• Remove the pump, the muffler, and the radiator as required.
• Remove the harnesses and the connectors. (See Chapter "ELECTRIC SYSTEM".)
– Engine ground cable
– Starter cable of starter B terminal
– Connectors of ECU harness and engine accessory harness
– Upper harness
P5 and P22 - Alternator B terminal
CN-136F - Engine speed sensor
CN-141F and CN-142F - Pump proportional valve
CN-139F and CN-140F - P1 and P2 pump pressure sensors
CN-212F - Glow
P3 - C terminal of starter motor
Prepare a cradle which can support the weight of the engine and keep the removed engine at a stable condition.
(See Chapter "TOOLS".)
Thermostat
Alternator
Starter
Fuel filter element
Appearance of engine
14-48
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[14. UPPER SLEWING STRUCTURE]
Projection
51 6 PLACES
cc
38 2 P LACES
35
*
OUT
25 ee
dd
*
41 4 29
IN
DETAIL bb DETAIL dd 24
42
40
1
30
DETAIL aa 26
5 (0.20”)
5 (0.20”)
44 44
20
Detail of engine mount ins ta lla tion (front) 19
seeing form fan side 43
4 P LACES
20
14
39
19
5 (0.20”)
5 (0.20”)
37
45
DETAIL ee DETAIL cc
Detail of engine mount ins ta lla tion (re a r)
seeing form fly wheel side
14-49
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[14. UPPER SLEWING STRUCTURE]
FOR WARD 44
20
19
37
39
44
ff
20
45
DETAIL ff
gg 19
36 43
4 P LACES
3 P LACES 12
57 45
DETAIL gg
10 56
55 58
58
Fa
(6 n d
52 d ia 5 0 m ia m
m e
Install fan ring with e t m ( te r
e r 25
drain hole side down. ) .6
DETAIL jj VIEW V in c
h)
14-50
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[14. UPPER SLEWING STRUCTURE]
1. Check that the whole circumference of the clearance between fan (50) and fan ring (52) is 7±3 mm (0.28±0.12
inch).
If it is not within the tolerance range, adjust the fan ring mounting position as described in the following.
2. Loosen bolt (58) and adjust the position of the fan ring.
If the position cannot be adjusted only by this procedure, loosen bolts (55) and (56) to adjust it.
3. After the adjustment, tighten each fixing bolt according to "Fan ring installation procedure".
Prepare a cradle which can support the weight of the engine and keep the removed engine at a stable condition.
(See Chapter "TOOLS".)
1) Put a wire with hook to the lifting eyes at the front and rear of the engine.
Weight: Approx. 516 kg (1138 lbs)
Wire: 6 mm (0.24 inch) diameter x 1 m (3.94 inch), 2 pcs.
5. Place the engine on the engine cradle in a stable condition.
14
14-51
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[14. UPPER SLEWING STRUCTURE]
Tightening torque
Tightening torque
Item Name Remarks
N·m (lbf·ft)
55 Bolt 25 (18)
56 Bolt 47 (35)
58 Bolt 25 (18)
26 PF1/4 — 29 (21)
14-52
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[14. UPPER SLEWING STRUCTURE]
1-20
Tighte ning torque
5.0N .m (3.69 lbf .ft)
14
1-10
1-20
Tighte ning torque
5.0N .m (3.69 lbf .ft)
Tightening torque
Item Name
N·m (lbf·ft)
1-18
Sems bolt M6 5.0 (3.69)
1-20
14-53
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Release the internal pressure of the hydraulic oil tank (Refer to Paragraph "REMOVING AND INSTALLING
HYDRAULIC OIL TANK").
• Remove the guards and covers which need to be removed to remove the multi-control valve.
1. Put a tag, on which a hose name and a number from
P1 to P8 are written, to each hose between the A
multi-control valve and the pilot valve and then
remove the P1 to P8 hoses at the multi-control valve A
side and plug them.
P4
See Section "PLUGS" in Chapter "TOOLS".
Tools: Wrench: 19 mm and 22 mm P8
P5
P6
P2
P3
P7
P1
SECTION AA
14-54
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[14. UPPER SLEWING STRUCTURE]
C2
C1
C6 C5
C8
C4
I
C3
3 1
VIEW I
14-55
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[14. UPPER SLEWING STRUCTURE]
Related parts of hoses between pilot valve and multi control valve
Hose Multi
Pilot valve ISO control control Embossed
port Size Color pattern valve No.
port
Tightening torque
14-56
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[14. UPPER SLEWING STRUCTURE]
14
14-57
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[14. UPPER SLEWING STRUCTURE]
Function Port name Upper side (base machine) port Port name Function
P 1 P1 pump
P 2 P2 pump
Bucket cylinder rod side (bucket out) Bc Bb Boom cylinder rod side (boom down)
Boom cylinder head side (boom up) Ab Br Right travel motor (rearward)
Power boost PL
14-58
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[14. UPPER SLEWING STRUCTURE]
Function Port name Left side (base machine) port Port name Function
T1 Return to tank
Tra ve l le ft (re a rwa rd) pilot PBL Left side Right side
PTb Tra ve l s tra ight pilot
Unload valve (P2 side) pilot PCa PBr Tra ve l right (re a rwa rd) pilot
14-59
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[14. UPPER SLEWING STRUCTURE]
Tightening torque
Size Port name
N·m (lbf·ft)
14-60
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[14. UPPER SLEWING STRUCTURE]
Preparation
• Lower the attachment to the ground, stop the engine, and release the pressure in the hydraulic oil tank.
• Remove left console covers (1-8) and (1-9) according to Paragraph "REMOVING AND INSTALLING CONSOLE
COVER".
• Attach tags to the hoses to make the assembly work secure and easier.
1. Disconnect the connector for the horn harness.
2. Remove each hose in order from the nearest hose to the farthest hose.
Tools: Wrench: 19 mm and 22 mm
3. Move boot (3) upward and loosen nut (6). (See the
figure "Removing and installing boot and lever".)
Tools: Wrench: 22 mm
3
4. Turn lever (1-2) and remove the lever parts as a set.
(See the figure "Removing and installing boot and
6
lever".) 1-2
"F" stamp
PF3/8
PF1/4
P port conne ctor
Hose side (with filter)
1 to 4 and 5 to 6 T port conne ctor
14-61
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[14. UPPER SLEWING STRUCTURE]
As the pilot valve is made of aluminum, use caution with the tightening torque.
14-62
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Release the internal pressure of the hydraulic oil tank
(Refer to Paragraph "REMOVING AND INSTALLING
HYDRAULIC OIL TANK").
• Release under cover (1) (Refer to Paragraph
"REMOVING AND INSTALLING UNDER COVER"). A1
A9
A2 A8
A5
A8
A6
B1
A9
14
14-63
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[14. UPPER SLEWING STRUCTURE]
1. Remove floor mat (B1). T: Tighte ning torque N.m (lbf.ft) A13 A10
2. Separate the wires for two pressure sensors SE-9 A1
(A10) and SE-10 (A10) and then remove two SE-9
pressure sensors (A10) form the pilot valve. 6
Tools: Wrench: 19 mm T=30 (22)
A10 5 T
T=30 (22)
3. Put tags to hoses (A1), (A2), (A3), (A4), and (A5)
P A1
and separate the hoses and the connectors.
Tools: Wrench: 19 mm
3 A5
SE-10 PT
(T port, P port, and 1 to 4 ports) A2 PT T
C/V P
T=30 (22) 4
PAr
4. Plug each hose. 1 A3
Plug PF1/4
2
C/V BLOCK
B5
5. Remove four sems bolts (A9) M8 x 25 and then PAL
A4
remove left and right pedals (A5) and (A6). BLOCK
Width across flats 19mm B6
Tools: Wrench: 13 mm A3
PF1/4 PF1/4
6. Remove four sems bolts (A8) M10 x 25 and then
remove left and right levers (A1) and (A2).
Tools: Socket: 17 mm Va lve s ide Hose side
7. Remove four sems bolts (A13) M10 x 30. Va lve s ide T port conne ctor
Tools: Wrench: 17 mm PF3/8
8. Pull up the pilot valve and remove it. Width across flats 19mm
Va lve s ide Hos e s ide
PF1/4
9. Attach plugs PF 1/4.
P F3/8 P F1/4
Hose side
P port conne ctor
1 to 4 port connector (with filter)
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Park the machine on a level and firm ground and place the attachment on the ground.
• Remove the guards which need to be removed to remove the swing motor unit. (See Paragraph "REMOVING
AND INSTALLING GUARDS".)
• Operate the switch on the gauge cluster and change the machine to the pressure release mode and operate the
control lever to release the pressure inside the circuit. (See Section "PRESSURE DRAINING" in Chapter
"HYDRAULIC SYSTEM".)
• Release the internal pressure of the hydraulic oil tank and put a tag on which a port name is written to each
hose.
1. Removing hoses 4
1) Remove hose (3) from the connector of make-up S/J HYD. TANK
port M. E
Tools: Wrench: 36 mm 5
2) Remove two hoses (4) and (5) from the tee of
drain port DB. 3
Tools: Wrench: 27 mm DB M
B
4) Remove two hoses (A1) and (A2) from the
connector of ports A and B.
Tools: Wrench: 32 mm PR
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[14. UPPER SLEWING STRUCTURE]
14
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[14. UPPER SLEWING STRUCTURE]
A B
C D
(Tra ve l motor) (Tra ve l motor)
P2(Lower)Rearward P1(Lower)Rearward
(Left side) A,B,C,D-PF1 (Right side)
P1(Upper)Forward P2(Upper)Forward
E-PF1/2
F-PF1/4
A2
Swivel joint
D A4
B
A7
F
A1 B2
F
C
E A16
A
B2
A16 A7
A3
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[14. UPPER SLEWING STRUCTURE]
A5
B25
B5
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[14. UPPER SLEWING STRUCTURE]
B1
C1
Swivel joint
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[14. UPPER SLEWING STRUCTURE]
Tightening torque
Thread N·m (lbf·ft)
Tool
diameter
mm O-ring type Hydraulic
PF
connector hose
1/4 19 36 (27) 29 (21)
2. Check the swivel joint for oil leakage and hydraulic oil level.
3. Check the swivel joint for operation.
14
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[14. UPPER SLEWING STRUCTURE]
Preparation
• Remove the attachment/equipment
(See Chapter "ATTACHMENT").
• Remove the cab (See Paragraph "REMOVING AND INSTALLING CAB").
• Remove the guards (See Paragraph "REMOVING AND INSTALLING GUARDS").
• Remove the counterweight
(See Paragraph "REMOVING AND INSTALLING COUNTERWEIGHT").
• Remove the swivel joint
(See Paragraph "REMOVING AND INSTALLING SWIVEL JOINT").
1. Sling the upper frame temporarily.
Match mark
2. Attaching match mark to swing bearing
Make match marks on the upper frame and the
swing bearing.
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[14. UPPER SLEWING STRUCTURE]
*Mark 1 place
7 8
Apply Loctite #262. Apply Loctite #262.
Tightening torque Tightening torque
392N .m (289 lbf .ft) 392N .m (289 lbf .ft)
Detail of bearing mounting section
14
Make sure the position of the reamer bolt by the figure "Reamer bolt position (*) and apply Loctite on hatched area".
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[14. UPPER SLEWING STRUCTURE]
Main pump
534
792
702
983 532
981 548
886 214
530
490
732
789
535
537 808
806 954
251
953 901
490
726
419 468
272
531
212
406
261
774
710
111
123
723 724 127
824
490
141
313
724 271
013
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[14. UPPER SLEWING STRUCTURE]
The marks (W), (X), (Y), and (Z) in Fig. "Structural exploded view of regulator" show the position where regulator is
installed.
111 Drive shaft (F) 1 414 Socket bolt; M10 X 20 4 *806 Nut; M16 2
113 Drive shaft (R) 1 419 Socket bolt; M16 X 35 4 *808 Nut; M20 2
127 Bearing spacer 2 531 Tilting pin 2 901 Eye bolt; M10 2
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[14. UPPER SLEWING STRUCTURE]
TOOL
The tools necessary to disassemble/reassemble K7V
pump are shown in the following list.. B
The size of bolts and plugs depend on the pump type.
○: Necessary
Tool name and size Tool Part name
Pump model
ROH plug
Hexagon socket Hexagon socket
Names B K7V125 VP plug
head cap screw head set screw
(Parallel thread)
2 ― ― M4
2.5 ― ― M5
3 ― ― M6
4 M5 ― M8
5 M6 ― M10
6 ○ M8 PF1/4 M12, M14
19 M24, M27 ― ―
21 ― ― ―
22 M30 ― ―
Adjustable angle wrench ― ○ Medium size 1set
Disassembling Procedures
1. Selection of a place for disassembling
• Select a clean place.
• Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
2. Cleaning
Remove dust, and rust, etc., from the pump surfaces with cleaning oil or so on.
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[14. UPPER SLEWING STRUCTURE]
3. Draining oil
Remove drain port plugs (468) and let the oil out
from pump casings (271) and (272).
Tools: Spanner: 36 mm
• Drain the oil from each plug opening of the front and
rear pumps.
4. Removing regulator
Remove socket bolts (414) (See Figures "Structural exploded view of main pump" and "Structural exploded
view of regulator") and remove the regulator.
Tools: Allen wrench: 8 mm
• Refer to Paragraph "REGULATOR" for dissembling the regulator.
5. Removing PTO unit and PTO cover (326)
Place the pump horizontally on a workbench with its
regulator-fitting surface down, and remove the PTO
unit by removing flange socket (435).
• Before bringing the regulator-fitting surface down,
spread a rubber sheet on the workbench to avoid
damaging the fitting surface.
• Check the PTO unit maintenance manual for
disassembling or assembling the PTO unit.
14
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[14. UPPER SLEWING STRUCTURE]
14
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[14. UPPER SLEWING STRUCTURE]
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[14. UPPER SLEWING STRUCTURE]
Assembling Procedures
1. Precautions of assembling
Perform assembling procedures in the reverse order of disassembling procedures by taking care of the
following items.
• Be sure to repair the parts damaged during disassembling, and repair replacement parts in advance.
• Clean each part fully with cleaning oil and dry it with compressed air.
• Be sure to apply clean hydraulic oil to the sliding portions and the bearings, etc. before assembling them.
• Always replace the sealing parts, such as the O-ring and the oil seal, in general.
• Prepare a torque wrench for mounting socket bolts or plugs at each part and tighten them with the specified
torques shown in "Tightening torque for hydraulic pump".
• In case of a tandem pump is used, take care not to mix up parts of the front pump with those of the rear pump.
2. Installing swash plate supports (251)
Install swash plate support (251) to positioning pin
(886) of the casing (271) and (272). 14
• If the servo piston, stopper (L), stopper(S), and servo
cover are removed, fit them to pump casing in
advance for reassembling.
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14
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[14. UPPER SLEWING STRUCTURE]
Installing regulator
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[14. UPPER SLEWING STRUCTURE]
Recommended
Standard
replacement
Part name and inspection dimension Countermeasures
value
mm (inch)
mm (inch)
Play between piston and shoe-caulking 0 to 0.1 0.3 Replace assembly of piston &
(δ)
section (0 to 0.0039) (0.0118) shoe.
5.0 4.8 Replace assembly of piston &
Thickness of shoe (t)
(0.197) (0.189) shoe.
41.8 41.0
Free height of cylinder spring (L) Replace cylinder spring.
(1.65) (1.61)
Combined height of set plate and 25.0 24.0 Replace set plate or spherical
(H-h)
spherical bushing. (0.98) (0.94) bush.
d D
(L)
H
h
t
P la y be twe e n pis ton $ shoe caul king pa rt ( ) Combi ned hei ght of set pl ate $
Thickne s s of s hoe (t) Spheri cal bushi ng (H-h)
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[14. UPPER SLEWING STRUCTURE]
Tightening B
Part name Size torque dimension Tool
N·m (lbf·ft) mm (inch)
14
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[14. UPPER SLEWING STRUCTURE]
14.4.1.1.5 TROUBLESHOOTING
Troubleshooting
1. Overload of engine
The torque setting of the regulator is Adjust the regulator. See the instruction manual of the
higher than specified value. regulator.
Seizure or damage of a part inside the Replace the damaged part. Check the filter and drain oil for abnormal
pump. worn metal particles.
2. Extreme Decrease of Pump Oil Level or Delivery Pressure Does Not Increase.
Seizure or damage of a part inside the Replace the damaged parts. Check the filters and drain oil.
pump.
Failure of the attached pump. Replace the damaged parts. Remove the attached pump and check
the shaft coupling.
Failure of the accessory valve. Replace the accessory valves. See the instruction manual of the
(Especially, check the poppets, seats accessory valves.
and springs.)
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[14. UPPER SLEWING STRUCTURE]
Hunting of the regulator. Repair the regulator. See the instruction manual of the
regulator.
14
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[14. UPPER SLEWING STRUCTURE]
14.4.1.2 REGULATOR
(874)
876
611
642
643
898
728
418
641
079
412 467
466
412 728
755 801
412 924
402
497
466 656
755 728
497 645
646
644
726
601
658 414 614
729
468 874
497
887
497
758
755
758
708
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[14. UPPER SLEWING STRUCTURE]
The marks (W), (X), (Y), and (Z) in the figure above show the pump casing mounting position. (See Fig. "Structural
exploded view of main pump".)
418 Socket bolt; M5 X 12 2 644 Spring seat (Q) 1 801 Nut; M10 1
466 ROH plug; PF1/4 2 645 Adjusting stem (Q) 1 874 Pivot Pin 1
NOMINAL
Tightening torque
No. DESIGNATION OF
N·m (lbf·ft)
SCREW THREAD
402 M6 12 (9)
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[14. UPPER SLEWING STRUCTURE]
Tools
Tool and dimension Part name
Required tool
(Marked with ○) Socket bolt ROH plug Hex head socket
Name B
(Flange bolt) (PF screw) set screw
2 - - M4
2.5 - - M5
3 ○ - - M6
4 ○ M5 - M8
5 ○ M6 ROH-1/8 M10
6 ○ M8 ROH-1/4 M12, M14
Allen wrench
8 M10 ROH-3/8 M16, M18
10 ○ M12 ROH-1/2 M20
12 M14 - -
14 M16, M18 ROH-3/4 -
19 M24, M27 - -
22 ○ - VP-3/8 -
24 M16 - -
27 ○ M18 VP-1/2 -
Eye wrench 30 M20 - -
Socket wrench
36 - VP-3/4 -
Double (single) end
wrench 41 - VP-1 -
46 M30 - -
50 - VP-1 1/4 -
55 - VP-1 1/2 -
Adjustable wrench - ○ Middle-sized, 1 pc.
Disassembling procedure
1. Selection of a place for disassembling
• Select a clean place.
• Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
2. Cleaning
Remove dust, and rust, etc. from surfaces of the regulator with clean oil.
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[14. UPPER SLEWING STRUCTURE]
3. Removing regulators
Remove socket bolts (412) and (414), and remove the regulator from the pump.
Tools: Allen wrench: 6mm
• When disassembling the pump body, check the maintenance manual for K7V series axialpiston pump.
• Take care not to lose O-rings while removing the regulator.
4. Removing proportional pressure reducing solenoid valve (079)
Remove hexagon socket head cap screws (418) and remove the proportional pressure reducing solenoid
valve (079).
• When removing the proportional pressure reducing solenoid valve, do not damage the connector of it.
5. Loosen pilot plug (641).
• Do not remove the pilot plug (641). If it is removed,
the pilot spring (646) and the sprig seat (Q) (644) will
fall from the casing.
• Be careful about falling down of the workpiece while
loosening pilot plug (641) because it was tightened
with a high torque.
• Do not damage the regulator mating surface while
using a vise.
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[14. UPPER SLEWING STRUCTURE]
14
Removing restrictor (658)
Since component parts are small, take care not to lose them.
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[14. UPPER SLEWING STRUCTURE]
ASSEMBLING PROCEDURES
Perform assembling procedures in the reverse order of disassembling procedures by taking care of the following
items.
• Be sure to repair the parts damaged during disassembling, and repair replacement parts in advance.
• If foreign materials enter the regulator, it will cause malfunction. Clean each part fully with cleaning oil, dry it with
air blow, and then perform work at a clean place.
• Prepare a torque wrench for mounting bolts or plugs at each part and tighten them with the specified torques
shown in " Tightening torque of bolt, plug, and nut ".
• Be sure to apply clean hydraulic oil to the sliding portions before assembling them.
• Always replace the sealing parts such as the O-ring etc., in general.
1. Selection of a place for assembling
• Select a clean place.
• Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
2. Installing restrictor (658)
Fully wash out casing (601) and restrictor (658).
Remove oil from the restrictor (658) completely.
Then, apply a drop of *adhesive to only the thread
part of the restrictor (658), and tighten it into the
casing.
Tools: Allen wrench: 5mm
Tightening torque: 6.9N·m (5.1 lbf·ft) (466)
• Do not operate this pump for approximately three
hours after installing the restrictor (658). (The
hydraulic oil will wash out the adhesive before it is
hardened and it may cause the restrictor to lose its
effect.)
• If adhesive is adhered to other parts, wipe off the
adhesive at once.
*adhesive
Product name: Loctite#241
Maker: Henkel Japan Ltd.
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[14. UPPER SLEWING STRUCTURE]
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[14. UPPER SLEWING STRUCTURE]
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[14. UPPER SLEWING STRUCTURE]
14
Installing spring seat (Q) (644) and pilot spring
(646)
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[14. UPPER SLEWING STRUCTURE]
T2
PAL P BL
J
P B1 P Ca
Pra Prb
P Bs PAs
PBa 1 PAa 1
154 164
P1 102
974
973
P Tb P Cb
974
973
P Br PAr
14
973
PAb P Bb
973 973
PAc
973 P Cc
P Bc
PAa 2 PBa 2
973 973
SECTION B-B
Section (1/6)
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[14. UPPER SLEWING STRUCTURE]
T2
H 273x1 0 H
P1 unload P Cb PAL Travel left
C 273x10 C
PAr P B1 977
Travel right Boom conflux
D D
978x2
Boom P Bb Pra
Boom 2
E
E
P Bs
Bucket Swing
F F
P Cc
PBa 2 PBa 1
Arm 2
Arm 1
G G
MU
K K
B A
PBa 2 PBa1
274x 4 274x4
Dr2
Pc
213 213
PAa 1
PAa 2
Section (2/6)
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[14. UPPER SLEWING STRUCTURE]
331 331
261 MR 261
309
601
PL 306
AL 163
511
512
521
522 CP2
CMR2 551
552 164
562
CMR1 162
BL
552
522 163
Dr1
512
307
261
331 PBL 264
327 205
329
336
331 SECTION C-C
333
202 PTb
Travel straight
331 331
261 261
306
305
161
Ar
511
521
511
521 14
CP1 LCb2
551
551
164 164
163 Br
310
161
(T3)
164
264 154
PBr
261
205 331
327
SECTION D-D
329
336
PCa 331
P 2 unload 333
202
Section (3/6)
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[14. UPPER SLEWING STRUCTURE]
203 202
333 Boom Boom 2 333
331 331
336 P Bb Pra 336
319 322
321 320
603 331
AbR 261
L 331 L 212
163
211 M N N
M 261 161
266 159
159 PLc1 312
514 CAb
551
524 521
CRb1 164
556 CRb2 511
164
556
Dr2 164
529
Pc 513
CRe 164
208 551
520 521
Bb 516
162
163
CBb 313
551
301 164
264 521
162 511
PAb
161 261
602 BbR 331
SECTION E-E 320
205 322
336
Prb 331
Boom 3 333
202
209
216 P Cc Swing 201
333 333
PBs
331 331
336 P Bc
336
322 322
321 321
602 BcR
331 331
261
261
304
Bc
162 As
511 511
521 523
LCc
LCs
551
556
164
164
163 Ac
Bs
162
162
162
264 303
PAc
264
603 PAs
205 SECTION F-F 205
AcR
Section (4/6)
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[14. UPPER SLEWING STRUCTURE]
201
201 333
333 Arm 2 Arm 1 331
331 PBa2 PBa1 336
340 322
328 321
321
BaR 603
331
331
550 211
261 562
525 L L
CBa 261
519 159
MU
308
PLc2 514
162
162 524
CRa
162 556
511
164
521
551 LCAT2 511
164 521
515 LCa
521 551
LCAP2
551 164
164 302
162
162 Ta Aa
163
162
510
526 CTa 604
167 264
557 PAa1
P P
264 205
210 PAa2 AaR
SECTION G-G
T2
161
511
P1
T1
14
521
163
CT1
551
163
164
162
P2
CT2
551
164
Section (5/6)
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[14. UPPER SLEWING STRUCTURE]
207
606 606 563
160
278x 5 564
266
264 264
Section (6/6)
Tightening Tightening
torque Item Part Name Q'ty torque Item Part Name Q'ty
N・・m (lbf・・ft) N・・m (lbf・・ft)
16 to 20
159 PLUG M7*0.75 4 329 SPRING 3
(12 to 15)
7.8 to 9.8
160 PLUG R-1/16 MECH 1 331 SPRING SEAT 26
(5.8 to 7.2)
16 to 18
161 O-RING 5 (12 to 13) 333 SPACER BOLT 13
LOCTITE #262
162 O-RING 21 336 STOPPER 11
163 O-RING 9 339 STOPPER 1
164 O-RING 20 340 STOPPER 1
167 O-RING 1 510 POPPET 1
201 COVER 4 511 POPPET 11
202 COVER 7 512 POPPET 2
203 COVER 1 513 POPPET 1
205 COVER 6 514 POPPET 2
BOOST CHECK VALVE
207 1 515 POPPET 1
COVER
25 to 34
208 LOGIC CONTROL VALVE 1 516 POPPET 1
(18 to 25)
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[14. UPPER SLEWING STRUCTURE]
Tightening Tightening
torque Item Part Name Q'ty torque Item Part Name Q'ty
N・・m (lbf・・ft) N・・m (lbf・・ft)
98 to 120
274 SOCKET BOLT 8 527 SPRING 1
(72 to 89)
25 to 34
278 SOCKET BOLT 5 528 SPRING 1
(18 to 25)
230 to 260
303 SWING SPOOL 1 551 PLUG 13
(170 to 192)
130 to 150
304 BUCKET SPOOL 1 552 PLUG 2
(96 to 111)
230 to 260
305 BOOM CONFLUX SPOOL 1 556 PLUG 4
(170 to 192)
49 to 59
306 TRAVEL SPOOL 2 557 PLUG 1
(36 to 44)
TRAVEL STRAIGHT
307 1 562 O-RING 3
SPOOL
ARM 2 SPOOL SUB- 13 to 17
308 1 563 PLUG 1
ASSEMBLY (9.6 to 12.5)
69 to 78
319 SPRING 1 604 PORT RELIEF VALVE 1
(51 to 58)
69 to 78
320 SPRING 2 606 BYPASS CUT VALVE 2
(51 to 58)
140 to 180
321 SPRING 5 973 SOCKET BOLT 8
(103 to 133)
140 to 180
322 SPRING 5 974 SOCKET BOLT 2
(103 to 133)
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General Precautions
• The hydraulic components are all precision-machined, so a particularly clean place needs to be selected for
disassembling and assembling.
• Thoroughly be careful in handling the control valve also to prevent dust, dirt and sand from entering inside.
• In removing the control valve from the machine, apply a cap to each of the ports, confirm thorough application of
the caps prior to disassembling, and then cleanse the assembly outside. Besides, use an appropriate work
bench for working by spreading a clean sheet of paper or a rubber mat on it.
• In carrying and moving the control valve, politely handle it by supporting it at the body portion, but never the
lever, exposed spool, or end cover portions.
• Besides, conducting various tests (such as the relief valve characteristics, leakage test, overload valve setting,
and flow rate resistance, etc.) is desired after disassembling and assembling, but a hydraulic test device is
needed for these. Therefore, do not disassemble components unable to be tested or adjusted even though
disassembling is technically possible. In addition, prepare clean washing oil, hydraulic oil, and grease, etc. in
advance.
Tools
Prior to disassembling of the control valve, prepare the following tools.
d Wrench 1 24 mm, 32 mm
e Loctite #262 1
f Scraper 1
g Tweezers 1
h Adjustable wrench 1
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Perform disassembling in a clean place, and avoid damaging flange faces and plate faces.
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When removing the spool assembly, be careful not to damage casing B (102).
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When removing the spool assembly, be careful not to damage casing A (101) or casing B (102).
2) Remove boom conflux spool (305), spring seat (331), springs (325) and (326), stopper (339), and bolt (333)
in an assembled condition out of casing A (101).
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When removing the spool assembly, be careful not to damage casing A (101).
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When removing the spool assembly, be careful not to damage casing B (102).
3) Fix the boom 2 spool assembly to the vise applying a protection plate (aluminum plate and the like) in
between them, remove bolt (333), and then disassemble spring seat (331), springs (320) and (322), and
stopper (336) from boom 2 spool (312). Do not disassemble boom 2 spool (312) any further.
6. Disassembling boom spool
1) Loosen socket bolts (273), and remove spring
cover (203) and O-rings (261) and (266) of the
boom spool.
2) Remove boom spool (301), spring seat (331), springs (319) and (321), stopper (336), and bolt (333) in an
assembled condition out of casing B (102).
When removing the spool assembly, be careful not to damage casing B (102).
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2) Remove swing spool (303), spring seat (331), springs (321) and (322), stopper (336), and bolt (333) in an
assembled condition out of casing A (101).
When removing the spool assembly, be careful not to damage casing A (101).
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When removing the spool assembly, be careful not to damage casing B (102).
4) In case disassembling of spring cover (209) of the bucket spool is necessary, loosen plug (551) with the
condition that the cover is installed to casing B (102). After removing spring cover (209) from casing B (102),
removes plug (551), and take out piston (216).
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9. Disassembling arm 1 spool
1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of the arm 1 spool.
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2) Remove arm 1 spool (302), spring seat (331), springs (321) and (322), stopper (336), and bolt (333) in an
assembled condition out of casing A (101).
When removing the spool assembly, be careful not to damage casing A (101).
2) Remove arm 2 spool (308), spring seat (331), springs (321) and (328), stopper (340), and bolt (333) in an
assembled condition out of casing B (102).
When removing the spool assembly, be careful not to damage casing B (102).
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2) Remove travel straight spool (307), spring seat (331), springs (327) and (329), stopper (336), and bolt (333)
in an assembled condition out of casing B (102).
When removing the spool assembly, be careful not to damage casing B (102). 14
3) Fix the travel straight spool assembly to the vise
applying a protection plate (aluminum plate and
the like) in between them, remove bolt (333), and
then disassemble spring seat (331), springs
(327) and (329), and stopper (336) from travel
straight spool (307).
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2) Remove P2 unload spool (310), spring seat (331), springs (327) and (329), stopper (336), and bolt (333) in
an assembled condition out of casing A (101).
When removing the spool assembly, be careful not to damage casing A (101).
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When removing the spool assembly, be careful not to damage casing A (101).
3) Fix the boom 3 spool assembly to the vise applying a protection plate (aluminum plate and the like) in
between them, remove bolt (333), and then disassemble spring seat (331), springs (320) and (322), and
stopper (336) from boom 3 spool (313).
14. Removing spool covers
1) Travel, boom, bucket, swing, and arm 1
Loosen socket bolts (273), and remove spool
covers (205) and O-rings (264).
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Removing spool covers (205) and (210)
2) Arm 2
Loosen socket bolts (273), and remove spool cover (210) and O-ring (264).
Do not disassemble spool cover (210) any further.
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• Port relief valves (602), (603) and (604) have the same external shape with different pressure settings, so put
identification tags to them for avoiding mistake at reassembling.
• Do not disassemble the relief valve themselves.
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When placing the control valve, be careful not to damage the spool cover surface.
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2) After removing the plate, remove all of O-rings (162) remaining in the casing.
22. Removing check valve
1) Load check valve and conflux check valve
Remove plugs (551), and then poppets (511) and
springs (521).
• Be careful not to mistake the plugs and springs of (3) for those of (1) when reassembling them because they are
different from those of above-mentioned (1).
• Be careful not to mistake the poppet of (4) for that of (1) when reassembling them because it is different from
above-mentioned (1).
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• Be careful not to mistake the poppet of (5) for that of (1) when reassembling them because it is different from that
of above-mentioned (1).
• Be careful not to mistake the parts of (6), (7), and (8) for those of (1) when reassembling them because all of
them are different kinds from those of above-mentioned (1).
• Be careful not to mistake the poppet and spring of (9) for those of (8) when reassembling them because they are
different from those of above-mentioned (8).
• Be careful not to mistake the parts of (10) for the above-mentioned parts when reassembling them because the
all parts of (10) are different kinds from the above-mentioned parts.
The plugs not described in the disassembling procedure above are those for plugging unnecessary holes and
casting holes, so do not disassemble them unless it is required specifically.
23. Disassembling casing
Do not disassemble the casing any further.
24. Inspection after disassembling
Thoroughly cleanse all the disassembled parts with clean mineral oil, dry them with compressed air, and put
the parts on a clean sheet of paper or cloth for inspection.
Control valve
• Inspect all the surfaces of the parts for burrs, scratches, carved damage, or other defects.
• Check that the faces of the O-ring grooves of the casing and the covers are smooth without dusts, dents, and
rust.
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• In case dents or scratches are found on the check valve seat surface of the casing, remove them by lapping.
• Check the periphery of the sliding portion of the spool for scratches and dents and if small ones are found,
remove them using an oil stone or cloth applied lapping agent.
• Check the sliding and fitting parts for easy movement by hand and all the grooves and passages for foreign
materials.
• In case springs are broken or deformed, replace them with new ones.
• In case the relief valve does not work properly, replace it with a new one.
• Replace all the O-rings with new ones.
Relief valve
• Check that the main plunger and the seat face of the seat tip have uniform contact faces with no defects.
• Check the main plunger and the seat for easy and smooth movement by hand.
• Check the main plunger orifice for clogging by foreign materials. (Main relief valve)
• In case minor scratches are found in the inspections above, remove them by lapping.
• In case a failure part or relief valve malfunction is found, replace them with a new one.
• Replace the O-rings with new ones. (Sealing portions with the casing)
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The parts of (1) — (10) have similar shapes, so be careful not to assemble wrong parts and not to assemble parts in
wrong places.
2. Assembling plate
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• Then, place the control valve so that the plate mounting surface faces downward.
3. Assembling boost check valve and bypass check valve
1) Assemble boost check valve poppet sub-assembly (517), bypass check valve poppet (518), and springs
(527) and (528).
2) Attach O-rings (264) and (266) to boost check valve cover (207), assemble them to casing A (101), and
tighten socket bolt (278) to the specified tightening torque.
4. Assembling lock valve selector sub-assembly
Install lock valve selector sub-assemblies (211) and (212) to the casing, and tighten socket bolts (211-171) and
(212-171) to the specified torque.
5. Assembling manual emergency lowering valve and lock valve selector sub-assembly (Europe Specification)
Put lock valve selector sub-assembly on manual emergency lowering valve and install them to the casing, and
tighten socket bolts to the specified torque.
6. Assembling logic valve poppet and logic control valve
1) Assemble logic valve poppet (520) to the casing.
2) Assemble logic control valve (208) to the casing holding the spring seat of logic valve poppet (520-103) and
tighten socket bolts (208-120) to the specified torque.
In assembling logic control valve (208) to the casing, be careful not to let spring (520-106) and spring seat (520-
103) of the logic valve poppet to fall off.
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Port relief valves (602), (603) and (604) have the same external appearance, so be careful not to choose a wrong
part by seeing the identification tags attached at the time of disassembling.
Assemble the boom 3 spool assembly into the casing A (101) carefully and slowly and never push it in forcefully.
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3) Install spring cover (202) with O-ring (261) installed to the spring side of the boom 3 spool assembly, and
tighten socket bolt (273) to the specified torque.
10. Assembling P2 unload spool
1) Fix the central portion of P2 unload spool (310) to the vise applying a protection plate (aluminum plate and
the like) in between them, attach spring seat (331), springs (327) and (329), and stopper (336), and tighten
bolt (333) to the specified torque.
Assemble the P2 unload spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the P2 unload spool assembly, and
tighten socket bolt (273) to the specified torque.
11. Assembling travel straight spool
1) Fix the central portion of travel straight spool (307) to the vise applying a protection plate (aluminum plate
and the like) in between them, attach spring seat (331), springs (327) and (329), and stopper (336), and
tighten bolt (333) to the specified torque.
2) Assemble the travel straight spool assembly described in 1) into casing B (102).
Assemble the travel straight spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (202) with O-ring (261) installed it to the spring side of the travel straight spool
assembly, and tighten socket bolt (273) to the specified torque.
12. Assembling arm 2 spool
1) Fix the central portion of arm 2 spool (308) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (321) and (328), and stopper (340), and tighten bolt
(333) to the specified torque.
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Assemble the arm 2 spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the arm 2 spool assembly, and
tighten socket bolt (273) to the specified torque.
13. Assembling arm 1 spool
1) Fix the central portion of arm 1 spool (302) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (321) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
Assemble the arm 1 spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the arm 1 spool assembly, and
tighten socket bolt (273) to the specified torque.
14. Assembling bucket spool
1) Fix the central portion of bucket spool (304) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (321) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
Assemble the bucket spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (209) with O-ring (261) installed to the spring side of the bucket spool assembly, and
tighten socket bolt (273) to the specified torque.
4) Assemble piston (216) into spring cover (209), attach O-ring (164) to plug (551), and then tighten it with the
specified tightening torque.
15. Assembling swing spool
1) Fix the central portion of swing spool (303) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (321) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
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Assemble the swing spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the swing spool assembly, and
tighten socket bolt (273) to the specified torque.
16. Assembling boom spool
1) Fix the central portion of boom spool (301) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (319) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
Assemble the boom spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (203) with O-rings (261) and (266) installed to the spring side of the boom spool
assembly, and tighten socket bolt (273) to the specified torque.
17. Assembling boom 2 spool
1) Fix the central portion of boom 2 spool (312) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (320) and (322), and stopper (336), and tighten bolt
(333) to the specified torque.
Assemble the boom 2 spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the boom 2 spool assembly, and
tighten socket bolt (273) to the specified torque.
18. Assembling boom conflux spool
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1) Fix the central portion of boom conflux spool (305) to the vise applying a protection plate (aluminum plate
and the like) in between them, attach spring seat (331), springs (325) and (326), and stopper (339), and
tighten bolt (333) to the specified torque.
2) Assemble the boom conflux spool assembly described in 1) into casing A (101).
Assemble the boom conflux spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the boom conflux spool assembly,
and tighten socket bolt (273) to the specified torque.
19. Assembling travel spools (travel left and right spools)
1) Fix the central portion of travel spool (306) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (323) and (324), and stopper (336), and tighten bolt
(333) to the specified torque.
2) Assemble the travel spool assembly described in 1) into casing A (101) or casing B (102).
Assemble the travelspool assembly into casing A (101) or casing B (102) carefully and slowly and never push it in
forcefully.
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the travel spool assembly, and
tighten socket bolt (273) to the specified torque.
14
20. Assembling P1 unload spool
1) Fix the central portion of P1 unload spool (309) to the vise applying a protection plate (aluminum plate and
the like) in between them, attach spring seat (331), springs (327) and (329), and stopper (336), and tighten
bolt (333) to the specified torque.
Assemble the P1 unload spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
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3) Attach spring cover (202) with O-ring (261) installed to the spring side of the P1 unload spool assembly, and
tighten socket bolt (273) to the specified torque.
21. Assembling spool covers
1) Travel, boom, bucket, swing, and arm 1
Attach O-ring (264) to spool cover (205), and tighten socket bolt (273) to the specified torque.
2) Arm 2
Attach O-ring (264) to spool cover (210), and tighten socket bolt (273) to the specified torque.
Part Inspection
Part Name Inspection Item Criterion and Measures
Casing Existence of scratches, rust, or corrosion In case damage occurs at portions below,
correct them or replace casing.
• Sliding portion of casing hole and spool, in
particular, land where holding pressure is
applied
• Sealing portions contacting with O-rings
• Sealing portions and seats of main and port
relief valves
• Seats and sliding portions of poppets
• Sealing portions of plugs
• Other damages likely to cause malfunctions
Spool Existence of scratches, galling, rust, or In case scratches are felt by your nails at
corrosion peripheral sliding portion (in particular, portions
contacting seals), replace spool.
Insert spool into casing hole, and rotate it to In case spool movement is not smooth, correct
confirm smooth stroke. or replace it.
Insert poppet into casing, and operate it. Poppet is normal if it moves lightly and
smoothly without sticking.
Spring and related parts Rust, corrosion, deformation, and breakage of Replace severely damaged parts
spring, spring seat, stopper, spacer bolt, and
cover
Main relief valve External rust and breakage Replace if required
Port relief valve
Valve seat contact face Replace if damage is found
Bypass cut valve
O-ring Replace in principle
(Sealing portion contacting with casing)
Troubleshooting
• In case an abnormal phenomenon has been found, check if it is a failure of the control valve itself or a matter of
the pump body or the circuit. To check this, measurement of the pilot pressure, pump delivery pressure, and load
pressure, etc. is necessary. In case disassembled inspection is made even partially, follow the disassembling
and assembling procedures described above.
• Dust is very harmful to the hydraulic components, so be very careful about dust prevention. In case even a part
of the component is disassembled, perform it by taking dust prevention measures.
• Handle movable parts carefully. If they are damaged even slightly, correct the damage with an oil stone or
something.
• Work carefully not to damage the gasket surfaces of the O-rings. These damages are sure to cause oil leakage.
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Control Valve
Travel or swing Malfunction of main relief valve Pressure measurement of main relief valve
operations cannot be • Foreign materials between main poppet and • Disassembling, cleansing, and replacement
made. seat of assembly if damage is severe
Slow operation
• Foreign materials between poppet and seat • Same as above
(insufficient power) or
slow response • Sticking of main poppet • Replacement of assembly
• Breakage or permanent set in fatigue of • Replacement of assembly
spring
• Clogging of main poppet orifice • Replacement of assembly
• Loosening of adjusting screw • Readjustment and tightening of lock nut to
specified torque
Bypass cut valve seat failure Tightening of adjusting screw of bypass cut
(When electric control system is normal) valve
Simultaneous operation Malfunction of travel straight spool Measurement of pilot secondary pressure
of travel and other • Sticking of spool • Correction of sticking portion by oil stone or
attachments causes replacement of spool
travel deviation
• Breakage or permanent set in fatigue of • Replacement of spring
spring
• Excessive clearance between casing and • Replacement of spool
spool
Bypass cut valve seat failure Tightening of adjusting screw of bypass cut
(When electric control system is normal) valve
Cylinder falls significantly Excessive clearance between casing and Replacement of spool
by its own weight with spool
spool in neutral position
Incomplete return of spool to neutral Measurement of pilot secondary pressure
• Foreign materials or sticking between • Disassembling, cleansing, correction by oil
casing and spool stone, or replacement of spool
• Breakage or permanent set in fatigue of • Replacement of spool
spring
• Clogging of pilot circuit • Removing of foreign materials
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Bucket, boom, and arm, Malfunction of main spool Measurement of pilot secondary pressure
and swing operations are • Excessive clearance between casing and • Replacement of spool
impossible spool
Slow operation
• Foreign materials between casing and spool • Disassembling and cleansing
(insufficient power) or
slow response • Sticking of spool • Correction of sticking by oil stone or
replacement of spool
• Breakage or permanent set in fatigue of • Replacement of spring
return spring
• Clogging of pilot circuit • Removing of foreign materials
Bypass cut valve seat failure Tightening of adjusting screw of bypass cut
(When electric control system is normal) valve
Boom conflux operation is Malfunction of conflux spool Measurement of pilot secondary pressure
impossible. • Excessive clearance between casing and • Replacement of spool
spool
• Sticking of spool • Correction of sticking by oil stone or
replacement of spool
• Breakage or permanent set in fatigue of • Replacement of spring
return spring
• Sticking of conflux check valve poppet • Correction of sticking by oil stone or
replacement of poppet
Relief Valve
Pressure does not rise at Relief valve remains open due to sticking of Checking for catching foreign materials
all main plunger or pilot poppet, or foreign Main plunger and seat must slide smoothly
materials at valve seat Replacement of assembly if failure is found
Unstable pressure Damaged seat of pilot poppet of relief valve Replacement of assembly
Sticking of main plunger and seat due to dust Checking for scratches or foreign materials
Replacement of assembly if failure is found
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312
M14
Apply Loctite #262 68.6±4.9 N .m
Application part (hatched area) (50.6±3.61 lbf .ft)
302
501 301
Apply grease on
Apply grease rotating and sliding sections.
on top section 246-1 Be careful the
212 assembling direction
246-2 213 M14
151 47.1±2.9 N .m
(34.7±2.14 lbf .ft)
218
211
214
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
Tightening Tightening
torque torque
No NAME Q'TY No NAME Q'TY
N・・m N・・m
(lbf・・ft) (lbf・・ft) 14
101 Casing 1 218 Seat 4
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[14. UPPER SLEWING STRUCTURE]
302
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[14. UPPER SLEWING STRUCTURE]
Installing Jig A
JI G A
301
14
When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in jumping out
of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with two fingers.
14-137
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[14. UPPER SLEWING STRUCTURE]
211
To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring (221) force is
completely released.
211
221
101
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[14. UPPER SLEWING STRUCTURE]
Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.
201-1
or 201-2
Never push down spring seat (216-1) in 7 mm (0.28 inch) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.37 inch) or more. (For port 2,4)
217
201-1
or 201-2
14
Disassembling pressure reducing valve
212
211
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[14. UPPER SLEWING STRUCTURE]
212
213
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[14. UPPER SLEWING STRUCTURE]
217
201-1
or 201-2
Never push down spring seat (216-1) in 7 mm (0.28 inch) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.37 inch) or more. (For port 2,4)
101
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[14. UPPER SLEWING STRUCTURE]
‚n -RING (214)
PUSH ROD
(212) Apply hydraulic oil
211
214 213
246-1
212 211 246-2 218
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[14. UPPER SLEWING STRUCTURE]
101 211
151
• Install spool (201) straight and evenly into the hole of casing (101).
• Take care so that plug (211) and plate (151) do not jump out of casing (101).
7. Install joint (301) on casing (101) with jig A securely.
Jig (A): See Paragraph "JIG FOR PILOT VALVE
(ATT)".
Tightening torque : 47.1N·m (34.7 lbf·ft) 14
101
JI G A
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[14. UPPER SLEWING STRUCTURE]
312
302
9. Screw adjusting nut (312) in until it touches circular plate (302), and tighten it applying spanner to stop circular
plate returning.
Tools: Spanner: 32 mm
Tools: Socket: 22 mm
• Apply Loctite #277 to threads of joint.
Tightening torque: 68.6N·m (51 lbf·ft)
301
212
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[14. UPPER SLEWING STRUCTURE]
Push rod When the wear of top is 1 mm (0.04 inch) or more, replace it with new one.
Secondary pressure springs (241) are broken or fatigued. Replace with new ones.
Secondary pressure Clearance between spool (201) and cas-ing (101) is Replace spool (201).
does not rise. abnormally large.
Secondary pressure is Tank line pressure varies. Bring pressure directly to oil tank.
unstable.
Air has mixed into pipeline. Bleed air by operating it several
times.
Secondary pressure is Tank line pressure is high. Bring pressure directly to oil tank.
high. Sliding parts are caught. Correct.
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[14. UPPER SLEWING STRUCTURE]
(1.14”)
(1)
Material ; SCM415 (N)
(1.04”) Carburizing and Quenching
(0.93”) (2) BUSHING
Material ; S45C (0.51”)
SECTION AA
(0.75”)
(2.72”)
(2.13”)
(1.97”)
(1.81”)
(0.98”)
A A
(0.67”)
(0.91”)
(1.06”)
(1.22”)
(0.26”)
(0.61”)
(0
.
23
(0 .
”)
1 8 ”) (0.02”)
(0.49”)
(0.37”)
(0.02”)
Material ; SCM415 (N)
(0.46”) Carburizing and Quenching
Q'ty ; 2
Detail of bushing
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[14. UPPER SLEWING STRUCTURE]
12-o
7-h
12-o
12-y
5 12-y
12-x 12-x
13
6 8
f
d
Loctite 262 10
g
T=3 (2.2)
g
14
q 11
T=5 r 15
(3.7)
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3-5 (2.2-3.7)
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[14. UPPER SLEWING STRUCTURE]
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[14. UPPER SLEWING STRUCTURE]
Boot replacement
The pilot control unit does not need to be removed from the machine to perform this operation.
R e ta in in g p la te
Boot replacement
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[14. UPPER SLEWING STRUCTURE]
1 L o c k in g s c r e w
3 A x is h o le
S w itc h p la te
a x is
4 5
2. Remove the screw locking the axis using a 2mm socket wrench. (See No. 1 of Fig. "Switch plate removal")
Reassembly:
1) Apply a droplet of Loctite #262 on the locking screw thread.
2) Tightening torque: 1.2N·m (0.9 lbf·ft)
3. Fit a M3 screw on the switch plate axis in order to remove it
(Using pliers if necessary). (See No. 2 of Fig. " Switch plate removal")
Reassembly:
Position the axis so that the hole is aligned with the locking screw as shown on the picture (See No. 3 of Fig. "
Switch plate removal")
4. Mark out the position of the switch plate before removing it.
5. Repeat the operation for the second switch plate.
6. Reassemble parts in reverse order.
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[14. UPPER SLEWING STRUCTURE]
Do not misadjust the two damping screws. (See Fig. "Switch plate (seeing from backside)")
14
Regulation Damping screws
screws to already adjusted
adjust and glued
SWITCH PLATE
The figure is shown
from the backside.
5. Repeat the operation for the second switch plate making sure both switch plates are parallel.
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[14. UPPER SLEWING STRUCTURE]
2. Unscrew simultaneously both screws holding the retaining plate using a 8mm socket wrench.
(See Fig. "Retaining plate removal")
Reassembly:
1) Apply a droplet of Loctite #262 on the screw thread.
2) Tightening torque: 30N·m (22 lbf·ft)
3. Lift the retaining plate to remove it. (See Fig.
"Condition with retaining plate removed")
Reassembly :
Use the retaining plate to insert the 4 guides into the
body simultaneously and perpendicularly. (See Fig.
"Condition with retaining plate removed")
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[14. UPPER SLEWING STRUCTURE]
D A M P IN G P L U N G E R
T H 6 N R B O D Y
D A M P IN G S P R IN G
Always place the damping plunger prior to the wiper ring, and make sure the wiper ring is correctly positionned.
3 4 B O D Y
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[14. UPPER SLEWING STRUCTURE]
5 6
7 8
2) Insert the seal within the groove with your fingers (lip in bottom position). (See No. 6 and 7 of Fig. "Damping
plunger seals replacement")
3) Push the seal against the side using the round head of a small socket wrench. (See No. 8 of Fig. "Damping
plunger seals replacement")
5. Repeat the operation for the other 3 assemblies.
6. Extract the damping springs from the body (using flat nose pliers).
7. Inspect the damping springs. If defects are detected, replace the 4 springs.
8. Reassemble parts in reverse order.
During the reassembly, make sure the seal is correctly positionned, and pay attention not to damage nor twist it.
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[14. UPPER SLEWING STRUCTURE]
2. Guide/plunger replacement
Insert the end of a thin screwdriver between the guide and the body, carefully lift the guide to remove it from the
body.
3. Remove the guide / plunger assembly.
14
4. Repeat the operation for the other 3 sub-assemblies.
5. Visually check that the guides / plungers are in good condition. If defects are present, replace the 4 sub-
assemblies.
Hold the guides with the other hand during the extraction operation to limit the effect of the return spring.
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[14. UPPER SLEWING STRUCTURE]
14-156
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[14. UPPER SLEWING STRUCTURE]
SCREW
THROTTLE
2. Unscrew the screw using a 3mm socket wrench. (See Fig. "Throttle kit replacement")
Reassembly:
1) Apply a droplet of Loctite #262 on the screw thread.
2) Screw on until it sets just above the body. (See Fig. "Throttle kit replacement")
3. Unscrew the throttle using a 3mm socket wrench.
Reassembly:
Tightening torque: 4N·m (3 lbf·ft)
4. Repeat the operation for the other 3 assemblies.
5. Replace with new screws and new throttles.
6. Reassemble parts in reverse order.
14
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[14. UPPER SLEWING STRUCTURE]
The pilot control unit does not need to be disassembled to perform this operation.
2. Unscrew the shuttle valve using a 4mm socket wrench. (See Fig. "Shuttle valve kit removal")
Reassembly:
1) Thoroughly clean the body to remove any trace of loctite.
2) Apply a droplet of Loctite #242 on the shuttle valve thread.
Tightening torque: 4N·m (3 lbf·ft)
Wait for 8 hours before using the machine to let the Loctite #242 dry completely.
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[14. UPPER SLEWING STRUCTURE]
14
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[14. UPPER SLEWING STRUCTURE]
The pilot control unit does not need to be disassembled to perform this operation.
C H E C K V A L V E
P L U G
B A L L
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[14. UPPER SLEWING STRUCTURE]
14
14-161
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[14. UPPER SLEWING STRUCTURE]
Swing motor
993
390 391
VIEW I
351
355
051
(051-1)
469
702
488
401 712
151
171 161 163 985 444 984 131
052
A A
I Arrangement of brake spring
162
451
303
985
472
707 712
702
980
706 743
100
111
742
121
400-1
123 994
052
400-2
122 400
124 443 491 101 114 301 SECTION A-A
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[14. UPPER SLEWING STRUCTURE]
Tightening Tightening
torque torque
No. Parts Q'ty No. Parts Q'ty
N·m N·m
(lbf·ft) (lbf·ft)
0.9
301 Casing 1 980 Plug ; PF1/4 1
(0.7)
1.7
303 Valve casing 1 984 Plug ; PF3/8 1
(1.3)
4.4
351 Plunger 2
(3.2)
985 Plug ; PF3/4 3
14
65
355 Spring 2 993 Plug ; PT1/2 1
(48)
98
390 Name plate 1 994 Plug ; PT3/4 1
(72)
391 Rivet 2
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[14. UPPER SLEWING STRUCTURE]
Apply Three
Bond #1211. Apply Loctite #515.
Paint this machined surface. Apply Loctite #515.
Tightening torque
181 N .m (134 lbf .ft)
12 10 20 8 4 7 6 23 Apply Three Bond 1360K
OIL FILLING POR T P T3/4
A
2
LEVEL
POR T P T1/2
A
II
1 9 22 18 17 5 18 14 3 16 15 28 19
21 29 11
Be careful about
Insert 1mm(0.04") deep from installation direction
Lubricate grease.
the surface of Item 8 (spider). of retaining ring.
13 27 26 25
Wind seal tape around plug and
install it (tightening torque Wind seal tape around tube and install elbow to tube
10N .m (7 lbf .ft)) to item 26 elbow with tightening torque 30N .m (22 lbf .ft) and then make
until its surface becomes direction of elbow as shown in drawing by retightening.
the same surface of elbow end.
Wind the seal tape or
Install grease nipple apply the Locktite #577
as facing to motor side. 30 31 around the screw.
Tightening torque
10.8N .m (8.0 lbf .ft)
Leave installation angle as it is.
Punch here 2 portions to deform holes in order to
prevent spring pin (22) from coming out.
VIEW II
4 places
SECTION AA
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[14. UPPER SLEWING STRUCTURE]
Tightening Tightening
torque torque
No. Parts Q'ty No. Parts Q'ty
N·m N·m
(lbf·ft) (lbf·ft)
Tightening torque
Thread size Name Item No. of applicable part
N·m (lbf·ft)
When parts are different from the above-mentioned parts with item No., see the sectional assembly drawing.
14-165
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[14. UPPER SLEWING STRUCTURE]
Wrenches
Item No. of
Name Size Size Tool
applicable part
When plugs and bolts are different from the above-mentioned plugs and bolts, see the sectional assembly drawing.
Tool Size
Screw driver Middle-sized flat-head screwdriver, 2pcs.
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[14. UPPER SLEWING STRUCTURE]
14
(0.55”)
85 (3.35”)
75 (2.95”)
30 (1.18”)
15
(0.59”)
35 (1.38”)
2 .5 )
R1 49”
0 .
(
M16
Through
100 (3.94”)
30 (1.18”)
(0.55”)
44 (1.73”)
14
8 (0.31”)
M16
(0.16”)
BRAKE PISTON
4
DRAWING TOOL
o8
(0.31”) BRAKE PISTON
CASING
14
Tools
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[14. UPPER SLEWING STRUCTURE]
General precautions
• The hydraulic components are precise components and have small internal clearances between the parts, so
that perform disassembling and assembling works at a place where the amount of dust is small and clean. Use
each kind of tools and wash oil that are clean and be very careful about handling them.
• After removing the swing motor from the machine body, take sufficient care not to allow dust and water to enter
the inside, so clean the area around the ports carefully and plug them. In case of installing the swing motor to the
machine body, do not remove plugs until starting a piping work.
• Before starting work, consider the construction drawing and prepare required parts according to your objective
and a range of the work. Disassembled seals and O-rings are impossible to reuse.
Furthermore, some parts cannot be available as a single part, so that it needs to be replaced as a part of sub
assembly. Refer to the parts catalog and prepare the replacement part or sub assembly beforehand.
• The pistons and the cylinder block are already assembled in a new machine, so that if the pistons are to be
reused, make match marks when removing the pistons from the cylinder block.
Disassembling procedures
In case of disassembling the swing motor, disassemble it following the order below. The numbers inside the
parentheses ( ) following the part names show item numbers in the construction drawing of "Swing motor".
1. Wind a wire rope around the motor periphery, lift it by a crane, and wash it with kerosene. After washing it, dry it
with compressed air.
Mask each port by a tape, etc. to prevent foreign materials from entering inside the motor, and then wash adhered
soil and dust.
2. Drain the oil inside casing (301) from the drain port.
3. Place drive shaft (101) with the shaft end facing
downward on a workbench that is proper for easy
disassembling, and fix it to the workbench. At this
time, make match marks on the mating portions of
casing (301) and valve casing (303).
Select a clean place. Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
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[14. UPPER SLEWING STRUCTURE]
If necessary, remove anti-reaction valves (400) from casing of anti-reaction valve (100).
Be sure to replace the O-rings of the relief valves because they are damaged when loosening the relief valves.
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[14. UPPER SLEWING STRUCTURE]
Be careful not to allow the valve plate to fall off from the valve casing. (The valve plate may be attached to the
cylinder side.) When prying the mating surfaces with a screw driver, be careful not to damage the mating surfaces.
Hook the tip end of the jig to the groove of the brake piston and pull it up straight.
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[14. UPPER SLEWING STRUCTURE]
Be careful not to damage the sliding surfaces of the cylinder and the shoes. In case the shoe plate does not come
off, remove it in procedure 12.
11. Pull out friction plate (742) and separator plate (743)
from casing (301).
14
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[14. UPPER SLEWING STRUCTURE]
12. Pull out drive shaft (101) and shoe plate (124).
When pulling out the drive shaft, the spline will damage the oil seal, so that wind a vinyl tape, etc. around the spline
of the drive shaft.
Drive s ha ft
P la ce inne r ra ce
on pre s s s ta nd.
You can tap the inner race of the roller bearing by the hammer through the steel rod, but tap it evenly taking care
not to damage the bearing.
Do not reuse the removed bearing.
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[14. UPPER SLEWING STRUCTURE]
2) Tap the outer race of roller bearing (443) slightly from the housing side of oil seal (491) by the hammer
though the steel rod and then remove it from casing (301).
3) Remove roller bearing (444) from valve casing
(303) by using the slide hammer bearing puller.
That is all of the disassembling work. Inspect each part carefully for possible failure.
14
14-173
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[14. UPPER SLEWING STRUCTURE]
General precautions
Assembling is performed in the reverse order of the disassembling. Perform it taking care of the following items.
• Be sure to repair parts damaged during the disassembling work and prepare replacement parts beforehand.
• Wash each part by cleaning solvent sufficiently and dry it with compressed air.
• Be sure to apply clean hydraulic oil to the sliding portions and the bearings before assembling them.
• Always replace the sealing parts such as the O-ring and the oil seal, etc. in general.
• Tighten the mounting bolts and the plugs of each part using the torque wrench with the tightening torque shown
in the table.
Assembling procedures
Assembling procedures are described as follows. The numbers inside the parentheses ( ) following the part
names show item numbers in the construction drawing of "Swing motor".
1. Place casing (301) on a proper workbench with valve casing (303) side facing upward.
2. (This procedure is required only if the roller bearing is removed.)
Shrink-fit the inner race of roller bearing (443) onto drive shaft (101).
OUTP UT S IDE
Be careful about the orientation of the oil seal. (See the sectional assembly drawing.)
Apply a thin coat of grease to the lip of the oil seal. Tap the jig evenly, taking care not to damage the periphery
portion.
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[14. UPPER SLEWING STRUCTURE]
Be careful not to damage the lip of the oil seal when inserting the drive shaft. Protect the oil seal by winding a vinyl
tape, etc. around the spline portion of the drive shaft.
14
Install the shoe plate with its larger chamfer side facing the casing side. Apply a thin coat of grease to the mating
surfaces to prevent the shoe plate from falling off.
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[14. UPPER SLEWING STRUCTURE]
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[14. UPPER SLEWING STRUCTURE]
14
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[14. UPPER SLEWING STRUCTURE]
Tap the periphery of the outer race evenly until the outer race stops moving completely at the stepped portion of the
valve casing.
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[14. UPPER SLEWING STRUCTURE]
Apply a thin coat of grease to the mating surface of the valve plate. (falling off protection)
14
• Be careful about the orientation of the valve casing at installation. (See "ASSEMBLY DRAWING OF SWING
MOTOR UNIT")
• Be careful not to allow the valve plate to come off.
• Be careful not to allow the brake springs to fall down.
• Tighten the socket bolts evenly.
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[14. UPPER SLEWING STRUCTURE]
In case anti-reaction valves (400) are removed from casing of anti-reaction valve (100) at the time of
disassembling, install anti-reaction valves (400).
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[14. UPPER SLEWING STRUCTURE]
230 (9.1”)
a Stand
Material:
P.C.D 140
(5.5”) VIEW X
X
100 (4”)
removing jig (II)
SS400
Oil seal (15)
9
e 125 (4.9”)
installing jig
Material:
(0.35”)
132 (5.2”)
SS400
9
Material:
(2.4”)
(2.0”)
60
50
SS400
Spherical bearing (12) 91
h
press-fit jig (3.6”)
158
(6.2”)
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[14. UPPER SLEWING STRUCTURE]
Tools
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[14. UPPER SLEWING STRUCTURE]
13
13
14
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[14. UPPER SLEWING STRUCTURE]
13
11
29
21
J IG (a )
14-184
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[14. UPPER SLEWING STRUCTURE]
21
29
11
13
12
10 14
JIG (d)
14-185
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[14. UPPER SLEWING STRUCTURE]
14
• The shaft attached to spider assembly (7) is caulked. When replacing it, replace as the set of spider assembly.
• Pinions (3) cannot be replaced singly. Replace them it in a set of three.
29
21
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[14. UPPER SLEWING STRUCTURE]
2. Inserting sleeve
Insert sleeve (21) and oils seal (29) assembly in
pinion shaft (1).
29
21
11
14
Fitting spherical bearing (lower)
14-187
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[14. UPPER SLEWING STRUCTURE]
Applying grease
4. Fit oil seal (12) in housing (13) by using jig (g). JIG (g)
• Apply Three Bond #1211 to the periphery of the oil
seal.
• Fill one third (1/3) of the space of the groove-shaped
section on the oil seal lip with grease.
• Insert it horizontally taking care not to damage the oil 12
seal lip.
13
14-188
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[14. UPPER SLEWING STRUCTURE]
10
13
20
14-189
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[14. UPPER SLEWING STRUCTURE]
15
14
7
28 3
Attach the retaining ring with the sharp edge facing the motor side (upper side in the position of the figure
"Attaching retaining ring".
8 5
17
18
22
9
14-190
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[14. UPPER SLEWING STRUCTURE]
2) Fit thrust washer (18) and pinion (5) as in the figure, insert shaft (9) into spider (8), and then insert spring
pin (22).
Insert shaft (9) into spider (8) so that the holes for spring pin (22) are aligned with each other.
13
14-191
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[14. UPPER SLEWING STRUCTURE]
install it.
6
2. Engage #1 sun gear (2) with #1 pinion (3) to install
it. 3
Filling lubricant 13
Fill approx. 2.7 L (0.71 gal) of gear oil #90 (API Service
Classification GL-4 grade) in the swing reduction unit.
Installing #1 spider assembly
Installing swing motor assembly
1. Attach lifting eyes (M12) in the tapped holes for
lifting eye on the swing motor and put a wire sling to
them.
2. Apply sealant (Loctite #515) to the mating surfaces M14 130
of ring gear (6), insert the spline of the swing motor, 23
aligning the match marks.
3. Apply screw locking agent (Three Bond #1360K) to
socket bolts (23) and tighten them.
Tools: Allen wrench: 12 mm Match mark
Tightening torque: 181N·m (134 lbf·ft)
14-192
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[14. UPPER SLEWING STRUCTURE]
Recommended
Standard
Value for
Item Dimension Remedy
Replacement
mm (inch)
mm (inch)
0.027 0.052
Replace piston or cylinder.
(0.00160) (0.00205)
0.3
0 Replace piston and shoe assy.
(0.0112)
5.5 5.3
Replace piston and shoe assy.
(0.217) (0.209)
t
14
Thickness of friction plate (t)
2.0 1.8
Replace.
(0.0787) (0.0709)
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[14. UPPER SLEWING STRUCTURE]
• Lap each sliding surface to the level that the surface roughness is equal or lower than the standard of surface
roughness.
• If the sliding ball surfaces of the spring plate and the cylinder are rough, replace these parts together.
Inspection at disassembly
1. Spacers and thrust washers
1) Inspect that the parts are not seized or worn abnormally or unevenly.
2) Inspect and measure the parts to see that the wear does not exceed the allowable values.
2. Gears
1) Inspect that the gear tooth surfaces do not show pitting and seizure.
2) Inspect the bottom of the teeth that it does not show cracks by dye penetrant test.
3. Bearings
Turn the bearings and check that they do not generate abnormal sound, catching and other faults.
Do not reuse the removed spherical bearings.
4. Oil seals
Do not reuse the removed oil seals. Be sure to replace the O-rings with new ones at assembly.
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[14. UPPER SLEWING STRUCTURE]
Maintenance standard
A D
G
H Lubrica nt le ve l C
B
14
14-195
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[14. UPPER SLEWING STRUCTURE]
Unit: mm (inch)
0
2.0
E Thickness of thrust washer –0.2 1.7 (0.067) Replace
(0.08) (-0.0079)
Wear of shaft 0
95 dia.
F (Diameter of section contacting -0.089 94.9 dia. (3.736) Replace
(3.740) (-0.0035)
with oil seal)
Gear oil # 90
H Lubricant (API Service 2.7 L (0.71 gal) Refill or replace
Classification GL-4 grade)
Pressure does Safety valve in circuit is not correctly. Set valve to correct value.
not increase.
Relief valve does not function well.
1. Sticking of plunger 1. Repair or replace stuck section.
Seat of plunger does not function well. Check seat section and replace it if damaged.
Brake is not applied with release pressure. Check and repair circuit.
Friction plate is seized. Disassemble and check it. Replace seized one.
14-196
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[14. UPPER SLEWING STRUCTURE]
Motor rotates Motor is assembled to rotate reversely. Check Fig. "ASSEMBLY DRAWING OF SWING
reversely. MOTOR UNIT" and reassemble it correctly.
Speed does Oil flow rate is insufficient. Check pump delivery rate and circuit to motor.
not reach set
Oil temp. is high and oil leaks abnormally. Reduce oil temp.
value.
Sliding parts are worn or damaged. Replace damaged parts.
Brake torque is Friction plate is worn. Disassemble and check it. Replace it, if it is worn
insufficient. more than criterion.
Brake piston sticks. Disassemble and check it.
Spline of friction plate is damaged. Disassemble and check it. Replace it if damaged.
When external Relief valve does not function well. Replace it.
driving torque
Same as item "Hydraulic motor does not rotate.". Same as item "Hydraulic motor does not rotate.".
is applied to
motor, it slips Seat of plunger does not function well. Replace it.
too much.
Oil leakage 14
Oil leaks from oil seal.
Oil leaks from Lip catches foreign materials and is damaged. Replace oil seal.
oil seal.
Shaft is scratched or worn. Shift lip and shaft contact position or replace them.
Lip of oil seal is turned up due to abnormally If drain piping is clogged, repair it.
increased internal pressure of casing.
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[14. UPPER SLEWING STRUCTURE]
Oil leaks O-ring is unintentionally omitted. Install it correctly and carry out reassembling.
through mating
O-ring is scratched. Replace it.
surfaces.
Seal surface is scratched. Disassemble and repair it.
Bolts are loose or damaged. Tighten them with specified torque or replace them.
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[14. UPPER SLEWING STRUCTURE]
2) Oil leakage
Disassemble and apply
Oil leaks through mating surfaces. Liquid packing is not applied. liquid packing.
3) Temperature is high.
Check oil level and fill oil
Temperature of reduction unit casing is high. No gear oil or oil level is low. up to specified level.
14-199
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[14. UPPER SLEWING STRUCTURE]
VIEW Y
5
5 places
7 3 places
Tighte ning torque
3 30.4 N .m (22.4 lbf .ft)
10 Apply Loctite #242
4
11 2 places
Tighte ning torque
30.4 N .m (22.4 lbf .ft)
Apply Loctite #242
14-200
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[14. UPPER SLEWING STRUCTURE]
Tools
Item Part name Used for Remarks
Steel hammer
a Hammer
Wooden or plastic mallet
Spatula
Disassembly and Approx. 120 mm (4.72 inch)
f
assembly
Disassembly and
g Vise Vise with movable range of 150 mm (6 inch) or more
assembly
h Loctite - #242
i Lubricant - Hydraulic oil or vasaline
j Wash oil - -
Facility
1. Hoist or crane
Prepare lifting devices that are capable of lifting the swivel joint in an assembly condition.
2. Workbench
14
A workbench with the size of approx. 1.2 m X 1.5 m (4ft X 5ft) is required.
3. Others
Waste clothes, wooden blocks, and containers for drain oil are required.
14-201
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[14. UPPER SLEWING STRUCTURE]
ALLEN WRENCH
EXTENTION BAR
When removing thrust plate (3) by fixing body (1), support stem (2) to prevent it from falling off.
14-202
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[14. UPPER SLEWING STRUCTURE]
Be careful not to damage body (1) by the tip of the spatula. Also, do not hit the spatula.
O -R IN G
G R O O V E
S E A L (6 ) P IN (e ) S E A L G R O O V E
A S S Y
O IL G R O O V E
S E A L (5 ) S E A L G R O O V E
14-203
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[14. UPPER SLEWING STRUCTURE]
Enclose grease in the seal grooves of seal (6) and O-rings (8).
1. Installing sealing parts
1) Apply a thin coat of petroleum jelly (or hydraulic
oil) to O-rings (8) and then attach them in the O-
ring grooves.
After attaching them, check the O-rings for twist.
2) Attach the slipper ring of seal assembly (6) by
deforming it little bit as shown in the right figure
after inserting the backup ring. Then, after all
sealing parts are inserted, securely put them into
the seal grooves by using the spatula.
3) Assemble seal (5) by the same procedure above.
Remove petroleum jelly, hydraulic oil and grease from the seal groove completely before installing seal (5).
Seal (5) does not have a backup ring.
2. Assembling stem
Apply a thin coat of grease or petroleum jelly to the
Press in by applying your weight by your hands
periphery of stem (2) or the inside of body (1) and
then insert stem (2) slowly into body (1).
1
6
Work bench
• Insert stem (2) slowly because if it is pressed in too fast, the seal could be damaged.
• The clearance between body (1) and stem (2) is approx. 0.1 mm (0.0039 inch) so that push in the stem straight
along with the axial center.
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[14. UPPER SLEWING STRUCTURE]
4. Assembling cover
1) After installing O-ring (7) to cover (4), align the
1
match marks of cover (4) and body (1) with each MATCH MARK
other.
2) Apply Loctite #242 to socket bolts (10), and then 10
install and tighten them. That is all of the
assembling work. 4
Tools: Allen wrench: 6 mm
Tightening torque: 30.4N·m (22.4 lbf·ft)
ALLEN WRENCH
EXTENTION BAR
Protection seal
Replace O-ring if any oil leakage is
14
2,000hr for oil leakage Check oil leakage outside
found.
outside
Replace all sealing parts.
4,000hr Seal assembly
In principle, All sealing parts - (slipper ring, and backup ring)
disassemble and Seal
check swivel joint O-ring
regardless of
occurrence of oil Check abnormal wear, scoring, or
Repair or replace according to service
leakage All sliding parts corrosion caused by foreign materials or
limit.
seizure.
When
Check seizure, foreign materials, Repair or replace according to service
disassembly is
All parts abnormal wear, and deformation or limit. All O-rings and seals should be
performed due to
damage of seals. replaced.
failure
14-205
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[14. UPPER SLEWING STRUCTURE]
Protrusion
Replace
(with backup ring)
Backup ring
Slipper ring
Replace
(with backup ring)
1.5 mm(0.06 inch)
(Ma x.)
Backup ring
14-206
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[14. UPPER SLEWING STRUCTURE]
3 Stop valve
6 Stop valve
Set pressure:
High pressure relief
7 (Working pressure X
valve
1.5)
8 Selector valve
9 Pipe, etc.
14-207
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[14. UPPER SLEWING STRUCTURE]
TROUBLESHOOTING
External leakage of hydraulic oil Defective O-ring & seal Replace all sealing parts.
Internal leakage of hydraulic oil Defective slipper ring Replace all sealing parts.
Seizure of swivel stem Seizure of stem and body Perform grinding and honing.
Replace assembly, if stem and body
are too loose and causing oil
leakage.
Looseness of swivel stem and cover Insufficient tightening of socket bolt Retighten bolt with specified torque.
14-208
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[15. TRAVEL SYSTEM]
15
15-1
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[15. TRAVEL SYSTEM]
15-2
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[15. TRAVEL SYSTEM]
15
15-3
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[15. TRAVEL SYSTEM]
15.2 FOREWORD
1. This Manual describes all the procedures from removing to attaching, arranging them by item.
2. This Manual consists of the first half, "REMOVING AND INSTALLING ASSEMBLY", and the second half,
"REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT".
3. The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
4. The removing and attaching procedure does not completely cover all possible situations because of
differences of field condition and defective section.
5. Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
15-4
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[15. TRAVEL SYSTEM]
10
6 9
8
7 3
2
5
4
15
15-5
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[15. TRAVEL SYSTEM]
• When loosening the grease nipple of the adjuster, do not loosen it more than one turn.
• Where grease does not come out well, move the machine back and forth. The over loosening of grease nipple
may cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple.
R e m o v in g / fix in g
p o s itio n o f m a s te r p in
When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure yourself by
flying objects.
15-6
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[15. TRAVEL SYSTEM]
4) Removing crawler R e m o v in g
Put attachment on ground so that weight is not m a s te r p in
loaded to the lower frame, and remove track link
assy rotating sprocket.
Removing crawler
Crawler end section may fall on the ground just before extending it on the ground incurring danger of injury.
Please keep well away from the equipment.
15
15-7
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[15. TRAVEL SYSTEM]
2. Installing crawler
• Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
1) Winding crawler
Insert a crowbar into the master pin hole, lift the
lower frame 1 to 2cm (0.39 to 0.79 inch) above
the ground level by holding it by hand so the
machine body weight is not exerted on the shoe.
Retract the sprocket to help push the back
winding of the crawler.
3. Preparation for press fitting master pin
Winding crawler
1) Put square wood under the shoe plate.
(Refer to the figure "Removing/fixing position of master pin").
• When using a big hammer, exercise care so you are not injured by flying objects the same way as when pushing
out the master pin.
• Coat the master pin with molybdenum disulfide grease, before pressing it in.
15-8
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[15. TRAVEL SYSTEM]
15
15-9
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[15. TRAVEL SYSTEM]
1-6
1-1
1-8
1-4
1-3 2
1-8
1-7
3
1-1
4
1-7 1-5
1-2 1-2
LC Spec.
YN60D00055FA
Shoe assy
YN60D00055F1
No. Name Q'ty
15-10
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[15. TRAVEL SYSTEM]
MAINTENANCE STANDARD
F E
D D G
B
Unit : mm (inch)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Link pitch 190 ±0.1 (7.4803 ± 0.0039) 194 (7.64) 198 (7.80)
Replace the
+ 0.11 (+0.0043) link assy if the
B O.D. of bushing 58.78 dia. (2.3142) 55 dia. (2.17) 54 dia. (2.13)
– 0.05 (–0.0020) service limit is
exceeded
C Height of link 106 ±0.3 (4.1732 ± 0.0118) 100 (3.94) 98 (3.86)
Basic
Tolerance Fit Fit
dimension
Interference
D between bushing + 0.11
Interference
and link 58.78 dia. (+0.0043) Interference
Shaft 0.05
(2.3142) – 0.05 0
(0.0020) Replace
(–0.0020)
+ 0.1
Interference Interference
36.63 dia. (+0.0039) Interference
E between track pin Shaft 0.05
(1.4421) – 0.05 0
and link (0.0020)
(–0.0020)
– 0.03
Interference Interference
36.50 dia. (–0.00118) Interference
F between master Shaft 0.05 Replace Link
(1.4370) – 0.068 0
pin and link (0.0020)
(–0.0027)
G
Clearance
1.5 (0.06) (both side)
8 (0.32) 10 (0.39)
Replace
15
between links (both side) (both side)
Tightening torque
H 853 N·m (629 lbf·ft) Retightening
of shoe bolt
TIGHTENING TOOLS
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 30
15-11
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[15. TRAVEL SYSTEM]
JIGS
NAME SHAPE
15-12
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[15. TRAVEL SYSTEM]
3 NUT 4
4 WASHER 8
Preparation
Remove the crawler (by the above-mentioned procedures).
• Removing upper roller (1)
15
15-13
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[15. TRAVEL SYSTEM]
Inspection
Before reassembling, check it that it rotates smoothly by hand and for leak.
1. Install cap screws (2) by installing the nuts on the
position shown in VIEW I and II. MACHINE FRONT MACHINE FRONT
S TAMP
2. Insert the roller until the collar comes in contact with 2 3
the support. 4 4 4 4
3. Fit it directing the stamp on the shaft end upward. 3 2
S TAMP
4. Apply Loctite #262 on capscrew M20X120, and
tighten it to the specified torque. VIEWéé (LEFT SIDE) VIEWèè (RIGHT SIDE)
Tools: Socket: 30 mm
Tightening torque: 539 N·m (398 lbf·ft)
1
è è
é é
15-14
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[15. TRAVEL SYSTEM]
15
15-15
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[15. TRAVEL SYSTEM]
Collar (3) is press-fitted into shaft (2). Therefore do not disassemble it.
15-16
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[15. TRAVEL SYSTEM]
15
15-17
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[15. TRAVEL SYSTEM]
Pushing in bushing
If you fail in this operation by press-fitting the bushing unevenly, the bushing is distorted and gets unserviceable. In
that case, do not re-use the bushing as it may develop malfunctioning after assembly.
3 1
Inserting shaft
15-18
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[15. TRAVEL SYSTEM]
9. Refilling oil
Refill 62 to 68cc (3.78 to 4.15 cu·in) of engine oil
API grade CD #30 through the plug hole of cover 10
(4). 5
1
10. Installing plug (10) 4
Wind seal tape around plug (10) and screw it into
9
the plug hole of cover (5).
Tools: Allen wrench: 6mm
Tightening torque: 21.6 to 24.5 N·m (15.9 to 18.1
lbf·ft)
• After assembling the upper roller, confirm that oil f
is not leaking from the upper roller unit and that it
rotates smoothly by hand.
Refilling oil
15
15-19
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[15. TRAVEL SYSTEM]
E
F
D D
B
G
Unit : mm (inch)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. 140 dia. (5.51) - -
Basic
Tolerance Fit Fit
dimension
Clearance between + 0.086
E
shaft and bushing 45 dia. (+0.0034) Clearance Clearance
Shaft
(1.772) - 0.066 0.7 (0.028) 1.0 (0.039)
Replace bushing
(-0.0026)
+ 0.210
Interference between 49 dia. (+0.0083) Interference Clearance
F Hole
roller and bushing (1.929) - 0.186 0 0.01 (0.0004)
(-0.0073)
Tightening torque of
G 115 N・m (85 lbf・ft)
socket bolt
Oil Engine oil API grade CD #30, 62 to 68 cc (3.78 to 4.15 cu・in) Refill
TIGHTENING TOOLS
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 30
Allen wrench 10
15-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
JIGS
Unit : mm (inch)
120 (4.72)
90 (3.54)
160 (6.30)
f Cradle jig
52.5(2.07)
Shaft
g
(0 .7 0 9 )
push-out jig
18
48(1.89)
Shaft
h
(1 .1 8 )
push-out jig
6 0 (2 . 3 6 )
+0 . 1
+0 . 1
0
0
4 4 .6
4 8 .5
Bushing
i
1 . 7 5 6 +00 .0 0 4
1 . 9 0 9 +00 .0 0 4
15
15-21
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[15. TRAVEL SYSTEM]
2 1 B2
Apply Loctite #262
T=455N .m (336 lbf .ft)
ROLLER
LC LQ64D00066F1
ASSEMBLY
ITEM NAME Q'TY REMARKS
1 LOW ROLLER 16 LQ64D00063F1
2 CAPSCREW 64 M18X80(P=1.5)
15-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
LOWER HD YN01F00048F1
ROLLER STD YN01F00047F1
ITEM NAME Q'TY
TRACK GUIDE :
B2 2 4
YN63D00006P2
B5 CAPSCREW : M18X40(P=1.5) 8 16
15
15-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
6 9 1 2 4 53 7
15-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
JIG M
The shaft (2) pushing-out operation may cause the remaining lube oil to flow out. Prepare an oil container
beforehand.
1
15
15-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
JIG M
Strike the inside surface of the roller lightly with a mallet so as not to damage the surface. Put push-out jig (N)
securely over the circumference of bushing (4) and push-out it perpendicularly little by little.
15-26
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[15. TRAVEL SYSTEM]
9
7
15-27
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[15. TRAVEL SYSTEM]
2
9
7
After assembling the lower roller, confirm that oil is not leaking from the lower roller unit and that the roller rotates
smoothly by hand.
15-28
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
D
E
A
Lower roller
Unit : mm (inch)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A O.D. of flange 185 dia. (7.28) - -
Build up repair or
B Tread dia. 150 dia.(5.91) 134 dia.(5.28) 128 dia.(5.04)
replacement
C Flange width 33.5 (1.32) 18 (0.71) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
D shaft and bushing -0.060
(Wrapped bushing) 65 dia. (-0.0024) Clearance Clearance
Shaft
(2.56) - 0.090 0.7 (0.28) 1.0 (0.39) Replacement of
(-0.0035) bushing
+ 0.030
Interference between 69 dia. (+0.0012) Interference Clearance
E Hole
roller and bushing (2.71) - 0.020 0 0.01 (0.0004)
(-0.0008)
F Oil Engine oil API grade CD #30, 150 to 170cc (9.2 to 10.4cu·in) Refilling
H Plug (8) Execute air leak test at 0.245MPa (35.5psi) before tightening the plug.
TIGHTENING TOOLS
Unit : mm
15
NAME WIDTH ACROSS FLATS
Socket 19 and 27
Allen wrench 6
15-29
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[15. TRAVEL SYSTEM]
JIGS
Unit : mm (inch)
K V-block
100(3.94)
Pin (5)
(0 .5 5 1 )
L
14
push-out rod
1 6 (0 .6 3 0 )
200(7.87)
Bushing
N
push-out rod
290(11.4)
1 6 0 (6 . 3 0 )
M Cradle jig
(4 .9 2 )
125
270(10.6)
Shaft
P
(2 .5 2 )
push-out jig
64
(1 .1 8 )
30
86(3.39)
9 4 . 5 (3 . 7 2 )
6 4 . 5 (2 . 5 4 )
Bushing
Q
press-fitting jig
+0.1
64.6 0
(2.543 +0.004
0 )
15-30
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[15. TRAVEL SYSTEM]
BAR
15
15-31
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[15. TRAVEL SYSTEM]
3
4
15-32
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[15. TRAVEL SYSTEM]
1
2
3
7
8
6
5
4
Idler assembly
15
Removing pin (5)
15-33
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
U
3
15-34
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
15-35
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Preparation
• Spring set special jig
Before disassembling and assembling the idler
M30
adjuster assembly, prepare track spring set jig (V). HOLDING-DOWN NUT
(See "TRACK SPRING SET JIG" in Chapter
"TOOLS".) RETAINER PLATE
Capacity of hydraulic jack : 20 tons (44,000 lbs) or
more
Tools: Spanner: 46 mm
S TAND
HYDRAULIC JACK
BASE
Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.
1. Place a hydraulic jack between the jig base and the stand.
15-36
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[15. TRAVEL SYSTEM]
Loosen the holding-down nuts of the jig and draw out the retainer plate upward.
Tools: Spanner: 46 mm
2. Drawing out piston (6)
(See Fig. "Idler adjuster assembly".)
Draw out piston (6) from grease cylinder (1) of the idler adjuster assembly.
3. Removing U-packing (9), and O-ring (8)
(See Fig. "Idler adjuster assembly".)
Remove U-packing (9) and O-ring (8) from grease cylinder (1).
4. Slinging idler adjuster
Set the idler adjuster assembly with the above-
2
mentioned parts removed on the stand of the jig,
with its bracket side facing up.
S TAND
RETAINER PLATE
4
15-37
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[15. TRAVEL SYSTEM]
15-38
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
15
15-39
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[15. TRAVEL SYSTEM]
F
D
E
A
Idler assembly
15-40
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Unit : mm (inch)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. of idler projection 535 dia.(21.1) - -
Basic
Tolerance Fit Fit
dimension
Clearance between - 0.03
D
shaft and bushing 75 dia. (–0.0012) Clearance Clearance
Shaft Replacement of
(2.9528) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(–0.0024)
+ 0.035
Interference between 83 dia. Interference Clearance
E Hole (+0.0014)
idler and bushing (3.2677) 0 0.01 (0.0004)
0
F Oil Engine oil API grade CD #30, 200cc (12.2cu・in) Refilling
15
15-41
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
X aa
A, B
INSTALLA HELICAL S P LING, WHOS E S TARTING P OINT
D AT ITEM 2 BRACKET S IDE TO BE 35 DEGREES
EES
5 DEGR
3
DETAIL aa
SECTION XX
Approx. 524 mm
B Free length of spring
(20.6 inch)
Tightening torque of
F 59 N·m (43 lbf·ft)
grease nipple
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 24
Allen wrench 5
15-42
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[15. TRAVEL SYSTEM]
Unit : mm (inch)
(0 .5 9 1 )
(1 . 1 8 )
15
30
Pin
R
push-out jig
(0.591)
105(4.13) 15
340 (13.4)
Shaft
(2 . 9 1 )
S
74
push-out jig
(0 .6 3 0 )
16
300(11.8)
Bushing
T
push-out rod
U Cradle jig
(0 .7 8 7 )
105(4.13)
20
9 0 (3 . 5 4 )
Bushing
7 0 (2 . 7 6 )
V
press-fitting jig
+0. 1
74.6 0
(2.937 +0.
0
004
)
103(4.06)
Collar
W
press-fitting jig
(1 .1 8 )
30
15
15-43
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
• Removing sprocket
Loosen 30 sprocket mounting capscrews (5)
M16X55, and remove sprocket (4).
Weight of sprocket: 48 kg (106 lbs)
Tools: Socket: 24 mm
Removing sprocket
15-44
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[15. TRAVEL SYSTEM]
UNIT: mm (inch)
B
190 (7.480")
C
Sprocket
Unit : mm (inch)
Build up repair or
C I.D. of sprocket bottom 586 dia. (23.1) 578 dia. (22.8) 576 dia. (22.7)
replacement.
TIGHTENING TOOLS
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 24
15
15-45
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[15. TRAVEL SYSTEM]
15-46
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
2
APPLY LOCTITE #262
OR EQUIVALENT
TIGHTENING TORQUE:
279 N .m(206 lbf .ft)
6
1
15-47
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
3. Removing sprocket
Remove 30 (one side) capscrews (5) M16X55.
Tools: Socket: 24 mm
4. Loosening travel motor mounting bolts (2) REMOVE PIPES (CUT OIL COMMUNICATION)
Apply match marks on the travel motor and the
crawler frame, and remove 27 (one side) capscrews
(2) M16X55.
Tools: Socket: 24 mm
15-48
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Tightening torque
TIGHTENING
TOOLS
NAME SIZE NO. TORQUE REMARKS
HEX
N·m (lbf·ft)
15
15-49
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
FRONT
A A
2 SECTION AA
Matchmarks
15-50
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
GREASE BATH
temporarily.
Tools: Socket: 30 mm A A
15-51
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
2
4
3
15-52
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
1
PUSH-OUT ROD 6
2
3
5
WOOD BLOCK
EYE BOLT
HOOK ROD
WOOD BLOCK
To insert ball (3) and retainer (4), use a push rod or hook rod etc., to protect persons from injury from inserting
fingers into the plug hole.
15
4. Install plug (8) to outer race (1) while checking the orientation and position of the taper pin hole.
5. Apply the adhesive (Cyano Bond PX-3000 or equivalent) to the groove for seal (6) and attach the seal to the
groove of outer race (1) all the way around. And connect both ends of seal (6) with the adhesive (Cyano Bond
PO-X or equivalent).
6. After completion of assembly, caulk the hole portion of taper pin (7) by punching.
7. Check that grease nipple (9) is in proper condition, and fill it with the grease (extreme pressure heavy duty).
Then, check the swing bearing for smooth rotation and the seal lip portion for flaws.
• Shell Albania EP#2; 160 cc (9.8 cu·in)
15-53
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Z3 Z3
17 22 23 19,20 21 24 26 23 25 17
X1 X1
28
S ECTION Z6-Z6
(1P LACE)
29
11 13 12 7 6 5 4 3 67 30 8 9 10 S ECTION Z5-Z5
(3P LACES )
65 66
Z6
Z4 Z4
Z6
33 34 15 14 14 15 34 33
18
S ECTION Z4-Z4 S ECTION X1-X1
15-54
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
18 18 18
Z5 Z5
Z5
Z5
Z5 Z5
41 44 43 42 37 45 38 40 39 48 61 73 72 75 76 74 85 86 96
52 87
60 90
51 91
69 92
62 88
89
93
32
31
50
68 94
95
59
56 97
98
64
83
60
84
57 63 58 55 54 1 36 46 70 47 49 53 71 99 77 78 79 80 81 82
15-55
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
9.8 PLUG;
2.5 18 8 68 PLUG; PT1/2 1
(7.2) METALPLUG M5
SPOOL A :
19 2-SPEED 1 69 PLUG; PT1/4 1
CHANGE OVER
20 SPOOL C 1 70 FLOATING SEAL 2
ANGULAR
21 SPRING 1 71 2
BEARING
118 HOUSING
10 22 PLUG; PF1/2 1 72 1
(87) (RING GEAR)
539* Torques
26 WASHER 1 76 BOLT; M20X70 8
(398) T90
2.45
2.5 28 ORIFICE; M5X5 1 77 THRUST PLATE 4
(1.81)
2.45
2.5 29 ORIFICE; M5X5 3 78 INNER RACE 4
(1.81)
2.45 NEEDLE
2.5 30 ORIFICE; M5X5 2 79 4
(1.81) BEARING
15-56
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
47 BALL 2 95 COVER 1
73.4
48 PISTON ASSY 2 8 96 BOLT; M10X16 16
(54.1)
157
49 BALL BEARING 1 12 97 PLUG; PF3/4 3
(116)
15
15-57
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
15.4.1.2 TOOLS
Standard tools
Application Application
Tools name Type・・size Tools name Type・・size
Item (No.) Item (No.)
Hex bit for Opposing flats 8 96 Minus driver 6X100 2, 62, 68, 70
socket wrench Opposing flats 10 13, 22 Plastic hammer Nominal #3
Opposing flats 12 52, 97 For M20
Eye bolt
Opposing flats 14 6,15 For M12 2
Materials
Application Application
Materials name Description Materials name Description
Item (No.) Item (No.)
15-58
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[15. TRAVEL SYSTEM]
Special tools
Application Application
Special tools name Description Special tools name Description
Item (No.) Item (No.)
Measuring instrument
Measuring Application
Description
instrument name Item (No.)
15
15-59
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Cap (11) is pressed out by spring(9). Therefore, do the work, taking care of the following.
• Loosen socket bolts (13) evenly all round.
• Loosen socket bolts (13), holding down cap (11).
Plunger (3) and base plate (2) have a very tight fit. Therefore, do the work, paying attention to the following.
• In case plunger (3) gets stuck halfway and does not come out, do not try to force it out. If it is pulled out by force,
the bore surface of base plate (2) and the outer surface of plunger (3) are scored.
In case the plunger gets stuck halfway, do as follows:
Put plunger (3) back into base plate (2) by lightly tapping the end face of it with a plastic mallet. Then make sure
that the plunger (3) moves smoothly and draw out the plunger (3) once again, turning it by hand.
• Do not disassemble plunger (3) unless it is necessary; the outer surface of it may be scored at disassembly.
15-60
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
17-6 2
17-16
17-15
17
Relief valve assy (17) is set at certain pressure. The set pressure of it determines the starting power and the
braking power of the motor.
For this reason, do not do the following.
• Do not loosen nut (17-16) and tamper with set screw (17-15). If the set screw is turned, the set pressure of the
relief valve changes, making the motor unable to attain required performances.
• Do not disassemble the relief valve assy. Otherwise, the set pressure changes and the motor is unable to attain
required performances.
17-3
15-61
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
2
19
22
Spool (19) and base plate (2) are combined to a very small fit. For this reason, execute the work, paying attention to
the following.
• Do not disassemble spool (19) unless necessary.
• In case the spool gets stuck halfway, do not force it out. If the spool is forced out, the bore surface of base plate
(2) and the outer surface of spool (19) are scored.
If it gets stuck, do as below.
Put spool (19) into base plate (2) once again by lightly tapping the end face of spool (19) with a plastic mallet.
Then, make certain that spool (19) moves smoothly and draw it out, turning spool (19) by hand.
52
2
59
15-62
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
60
When removing base plate (2), do the work, taking care of the following.
• Base plate (2) is pushed up by the action of spring (59). Therefore, loosen the cap screws evenly all round.
• A positioning knock pin (60) is placed between base plate (2) and the main body. When removing base plate (2),
do it upright toward the motor shaft center so knock pin (60) is not wrenched. In case it is wrenched, bring knock
pin (60) back in place by lightly tapping base plate (2) with a plastic mallet and remove the knock pin.
• When removing base plate (2), valve plate (62) comes with base plate (2). Since the moving surface of valve
plate (62) tends to be scored, use care so valve plate (62) does not fall.
15
When removing valve plate (62), take care of the following.
• The moving surface of valve plate (62) tends to be scored. If the surface is scored, desired performances are not
available; use care so as not to score it.
15-63
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
60
63
64
56
56
57
58
54
55
54
55
54
15-64
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
37
When drawing out cylinder block (37), use care of the following :
• Hold cylinder block (37) by both hands and take it out slowly, while turning it both ways lightly.
• Exercise care so as not to score the moving surface of cylinder block (37) in contact with valve plate (62). If the
surface is scored, desired performances will not be attained.
• Exercise care so as not to score the moving surface of the shoe of piston assy (38). Desired performances will
not be attained if the surface is scored.
37 15
38
39
15-65
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
39
38
45
37
40
37
When removing snap ring (41), take care as below, so as not to injure yourself.
• If snap ring (41) is tight to remove with snap ring pliers, you may injure yourself when the snap ring comes off
from the pliers. Always use the removing jig to remove the snap ring and make certain that the claw of the pliers
is set in the hole of the snap ring.
15-66
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
43
42
37
46
15-67
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
36
49
97 97
15-68
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
72
95
91
94
15
93
15-69
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
1 s t s ta g e h o ld e r a s s y
Use care of the following when removing the 1st stage holder assy :
• Take care so you do not pinch your fingers at removing.
15-70
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
83
78
80 77
81
82
76
99
15-71
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
99
72
72
70
15-72
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
15
15-73
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
1
70
Make certain that there is no dust on the surface of flange (1) in contact with floating seal (70).
• Thoroughly degrease the surface where floating seal (70) of flange (1) is located.
• Make sure that no dust is there on the O-ring of floating seal (70).
• Thoroughly degrease the surface of the O-ring in floating seal (70).
71
72
71
Angular bearing fixing jig
15-74
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Floa ting s e a l
fixing jig
70
72
Make certain that there is no dust and foreign matter on the surface on which floating seal (70) in housing (72) is
located.
• Thoroughly degrease the surface where floating seal (70) in housing (72) is located.
• Make sure that there is no dust and foreign matter on the O-ring of floating seal (70).
• Thoroughly degrease the surface of the O-ring in floating seal (70).
72
Make certain that there is no foreign matter on the moving surface of the seal ring located in floating seal (70).
• Apply lubricating oil for the reduction unit or hydraulic oil to all sliding surface of seal ring located in floating seal 15
(70).
• When assembling housing (72) into flange (1), make sure that the shaft centers are aligned with each other.
15-75
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
h
Press load : 3,000kgf (6,600 lbf)
J IG
H
71
2) In that case, measure the step H between the end face of the inner race of angular bearing (71) and the end
face of flange (1).
3) Measure the step h at holder (74).
4) Select and combine the repair kit [T=0.05mm (0.002inch), 0.1mm (0.004inch), 0.3mm (0.012inch), 0.5mm
(0.020inch), 1.0mm (0.039inch)] of shims (73) so as to attain shim thickness that matches (H-h).
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[15. TRAVEL SYSTEM]
73
74
99
75
76
75
Be wa re of the a s s e mbling
dire ction of wa s he r (75).
Look a t the dire ction on
the figure on the right.
80 77 79 78
Place the draft on
the holder (74) side.
74 Assembling direction of
15
thrust plate (77)
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Assemble thrust plate (77) to planetary gear C (80) so the draft of the thrust plate (77) is located on holder C (74)
side.
• When the planetary gears C (80) are installed finally to the holder C (74), mesh the inner gear of housing (72)
with gear of planetary gear C (80).
• Use care of the assembling direction of planetary gear C (80).
81
Use care of the attaching direction of thrust plate (81). If the neck of the bolt is damaged, it breaks down.
• Clean the screw threads of bolt (82) thoroughly, degrease it and coat it with Locktite.
• Clean the screw threads in the tapped hole of holder C (74) thoroughly and degrease it thoroughly.
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[15. TRAVEL SYSTEM]
84 83
Engage the teeth of planetary gear C (80) with those of sun gear C (83) and assemble them together.
83
85
15
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[15. TRAVEL SYSTEM]
89
85
87
88
P la ce the dra ft on 89 86 88 87
the holde r (85) s ide .
85
Attach thrust plate (86) to planetary gear B (89) so the draft side (by press) of thrust plate (86) is located on the
holder B side (85).
• Finally, when assembling planetary gear B (89) to holder B (85), engage the inner gear teeth of housing (72) with
the teeth of planetary gear B (89)
• Be careful of the assembling direction of planetary gear B (89).
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[15. TRAVEL SYSTEM]
72
Measure the step T.
91
94
Unit : mm (inch)
Step Shim
Thrust plate code
dimension (T) thickness (t)
1.20 to 0.67
20941 - 62306 2.3 (0.09)
(0.0472 to 0.0264)
0.66 to 0.04
20941 - 62307 2.8 (0.11)
(0.0260 to 0.0016)
0.03 to -0.16
20941 - 62308 3.0 (0.12)
(0.00122 to -0.0063)
-0.174 to -0.41
20941 - 62309 3.2 (0.13)
(-0.00685 to -0.0161)
-0.42 to -0.80
B0841 - 23017 3.6 (0.14)
(-0.0165 to -0.0315)
15
Align the hole in the center of thrust plate (94) with the convex part of drive gear (93) and assemble them together.
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[15. TRAVEL SYSTEM]
Motor
1. Fitting oil seal (53)
Make sure that flange (1) is equipped with oil seal
(53). If not, press oil seal (53) into flange (1), using
the oil seal fixing jig.
Oil s e a l
fixing jig
53
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[15. TRAVEL SYSTEM]
Before attaching oil seal (53), apply grease to the bore surface of flange (1) and outer diameter surface of oil seal
(53).
• Coat the lip of the bore of oil seal (53) with grease and put it in.
• Push the oil seal upright. If it is tilted, the outer diameter of oil seal (53) will be scored.
• Be careful so as not to score the lip of the bore of oil seal (53) when fixing it. If the lip is scored, oil leakage may
occur and break the inside of the reduction gear while the motor is running.
47 15
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[15. TRAVEL SYSTEM]
Before fixing steel balls (47), apply hydraulic oil to the bore surface in the spherical part of flange (1) and steel balls
(47).
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[15. TRAVEL SYSTEM]
Assemble swash plate (46) by matching the holes in the rear spherical surface of the swash plate (46) to steel balls
(47).
• After coating steel balls (47) with hydraulic oil and assemble swash plate (46).
• After assembling swash plate (46), make sure that the swash plate moves smoothly.
37
J IG
15
If snap ring (41) is tight, the snap ring pliers come off from the snap ring and you are injured by it, in some cases.
When fixing the snap ring, always use a jig and make sure that the claw of the snap ring pliers is engaged in the
hole of the snap ring
• If it is difficult to narrow the snap ring, use snap ring pliers one size larger.
• To press in collar (44), align the center of the cylinder block with that of the press.
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[15. TRAVEL SYSTEM]
37
Before placing cylinder block (37) on a work bench, make certain that there is nothing on the work bench.
• Use care so as not to score the sliding surface of valve plate (62) in cylinder block (37). If the surface is scored,
the motor performances are deteriorated which leads to a failure of the motor in an early stage.
• Before fixing pins (45), coat the pin holes with grease.
37
40
39
38
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[15. TRAVEL SYSTEM]
37
38
Coat the piston holes (9pcs.) in cylinder block (37) with hydraulic oil, before installing piston assy (38)
• Coat the spherical surface of retainer holder (40) with hydraulic oil, before assembling it.
At assy, use care so piston assy (38), retainer plate (39) and retainer holder (40) do not come off from cylinder block
(37).
• Before assy, coat the surface of swash plate (46) and the sliding surface of piston assy (38) with hydraulic oil.
15
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[15. TRAVEL SYSTEM]
57
58
Positioning jig
56
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[15. TRAVEL SYSTEM]
59
Place valve plate (62) with the copper alloy side facing upward.
• Coat the matching face between base plate (2) and valve plate (62) with grease to prevent the valve plate from
falling off.
• Use care so as not to score the copper alloy surface of valve plate (62).
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[15. TRAVEL SYSTEM]
Assemble spool A (19) into base plate (2) so that the pipe port surface of base plate (2) comes toward yourself and
that the side of spool A (19) on which spring (21) is placed comes on the right. If the spool is assembled inversely,
spool change may get out of order and other trouble may occur in some cases.
• Coat the outer surface of spool (19) with hydraulic oil, before assembling it.
• After spool (19) is placed, make certain that it moves smoothly.
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[15. TRAVEL SYSTEM]
17-17,18 2
17-3
17-7
17
15
Assemble the plunger (3) to the base plate, while turning the plunger.
• Install plunger (3) straight.
• In case plunger (3) gets stuck, do not force it in, but tap it lightly with a plastic mallet.
• Coat the outer surface of plunger (3) with hydraulic oil before assmble.
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[15. TRAVEL SYSTEM]
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Piston assy (38) Sliding surface of shoe The roughness is 0.8a or the Lap the moving surface of shoe
surface is roughened or the (#1000).
scratch is deeper than 0.02mm If the scratch does not
(0.0008inch). disappear, replace cylinder
block assy.
O.D. of piston The roughness is 1.2a or the Replace cylinder block assy.
surface is roughened or the
scratch is deeper than 0.02mm
(0.0008inch).
Cylinder block (37) Sliding surface of The roughness is 0.8a or the Lap the sliding surface (#1000).
valve plate surface is roughened or the If the scratch does not
scratch is deeper than 0.02mm disappear, replace cylinder
(0.0008inch). block assy.
Bore diameter The roughness is 1.6a or the Replace cylinder block assy.
surface is roughened or the
scratch is deeper than 0.02mm
(0.0008inch).
Spline at the joint of The pin that measures the Replace cylinder block assy.
shaft (36) between dia. 38.749mm
(1.52732inch) measures 3.333
dia.mm (0.13122inch) (V1=2.80)
or is broken.
Valve plate (62) Sliding surface A scratch deeper than 0.02mm Lap the moving surface.
(0.0008inch) is there on the 0.8a (#1000) If the scratch does not
roughness moving surface or a disappear, replace the valve
seizure is seen on the surface. plate.
The moving surface shows
abnormal wear.
Retainer plate (39) Sliding surface The sliding surface of 0.8a Replace retainer plate and
Retainer holder (40) roughness shows a scratch retainer holder.
deeper than 0.02mm
(0.0008inch) or shows a seizure.
Swash plate (46) Sliding surface The sliding surface of 0.8a Lap the sliding surface. (#1000)
roughness shows abnormal If the scratch does not
wear or a scratch deeper than disappear, replace the valve
0.02mm (0.0008inch). plate. 15
Spherical hole in which a The spherical surface of 1.6a Replace swash plate.
steel ball is placed roughness shows a scratch
deeper than 0.02mm
(0.0008inch) or is roughened.
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Shaft (36) O.D. of oil seal sliding surface The sliding surface shows a Replace shaft.
scratch deeper than 0.02mm
(0.0008inch) or is roughened,
except the oil seal lip moving
marks on the 1.6a roughness.
Spline at the joint of cylinder The pin that measures the over-
block (37) pin dia. 47.380mm
(1.86535inch) measures 3.00
dia.mm (0.11811inch) or is
broken.
Spline at the joint of drive The pin that measures the
gear between dia. 30.498mm
(1.20071inch) measures 3.33
dia.mm (0.13122inch) or is
broken.
Brake piston (56) Appearance and dimension Height : Replace brake piston.
38.2mm (1.504inch)
Disk plate (54) Appearance and dimension Thickness : Replace disk plate.
3.2mm (0.126inch)
Ball bearing (49) Rolling surface Flaking or impressed marks are Replace ball bearing.
Ball bearing (50) seen.
Function Rotation is abnormal.
(abnormal sound and uneven
rotation)
Piston assy (48) Sliding surface of shoe The roughness is 1.6a or the Lap the sliding surface of shoe.
surface is roughened or the (#1000)
scratch is deeper than 0.02mm In case the scratch does not
(0.0008inch). disappear, replace the flange
holder kit.
O.D. of piston The roughness is 1.2a or the Replace flange holder kit.
surface is roughened or the
scratch is deeper than 0.02mm
(0.0008inch).
Plunger (3) O.D. of plunger The roughness is 0.8a or the Replace base plate kit.
surface shows a scratch deeper
than 0.02mm (0.0008inch) or is
roughened.
15-94
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Base plate (2) Hole in which plunger (3) is The surface has a roughness Replace base plate kit.
placed more than 0.8a or shows a
scratch deeper than 0.02mm
(0.0008inch) or is roughened.
Spool A (19) O.D. of spool The surface has a roughness Replace base plate kit.
more than 0.8a or a scratch
deeper than 0.02mm
(0.0008inch) or is roughened.
Free piston (17-9) Sliding surface and seat The surface has a scratch Replace relief valve assy.
surface of base plate deeper than 0.02mm
(0.0008inch) or is roughened.
Housing (17-1) Moving surface (O.D.) of free The surface has a scratch
piston deeper than 0.02mm
(0.0008inch) or is roughened.
O-rings and oil seals At disassy Replace O-rings and oil seals.
15-95
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Planetary gear A (89) Tooth thickness Bridged dimension of 6 teeth : Replace planetary gear.
66.649mm (2.62397inch)
Inner race (87) Outer diameter surface Flaking is seen on the surface.
Drive gear (93) Tooth thickness Bridged dimension of 3 teeth: Replace drive gear.
29.908mm (1.17748inch)
Inner race (78) Outer diameter surface Flaking is seen on the surface.
Housing (72) Tooth thickness The pin that measures the Replace housing.
between dia. 330.449mm
(13.00978inch) measures 7.00
dia.mm (0.27559inch).
Flange (1) Bore dia. of the hole in 2- Clearance : Replace flange kit.
speed piston and the O.D. of 0.040 mm (0.00157inch)
piston assy
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Thrust plate (94) Thickness The plate thickness is either Replace thrust plate.
3.3mm (0.130inch), 2.5mm
(0.098inch), 2.9mm (0.114inch),
2.0mm (0.079inch), 2.7mm
(0.106inch) or the moving
surface has a deep scratch.
Angular bearing (71) Rolling surface of ball Flaking is seen. Replace angular bearing
Floating seal (70) Sliding surface A deep scratch that develops oil Replace floating seal.
leaks is on the surface.
O-ring The surface has developed Do not disassemble any further
cracks. as oil leakage may occur if the
sliding marks on the seal ring
do not match the surface at
disassembly.
15
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Motor does not turn. Devices other than piston motor and Check that pressure is at the inlet of the
reduction gear have trouble. motor. Then check for the cause, inspect
and repair.
The motor itself has a problem; the Disassemble, clean, eliminate foreign
operating part is stuck with dirt. matter and reassemble. In case parts are
scored by foreign matter, replace parts.
Motor inlet pressure is low. Increase the set pressure by operating the
main relief valve of the circuit.
The moving surface of piston motor is Disassemble and replace such parts that
abnormally worn and oil pressure is are worn abnormally.
escaping. Eliminate scratches and burrs from the
surface, clean parts and reassemble.
The main parts of piston motor are broken. Disassemble and replace those parts that
In that case, piston motor makes an are broken.
abnormal sound. After cleaning, reassemble parts.
Relief valve is operating as piston motor is Check the loaded condition and adjust the
loaded too much. load to a level that matches the set pressure
of relief valve.
Rotating speed of motor is low. Because of some trouble of hydraulic Check that a required flow is supplied to the
pump, pressure regulating valve, flow inlet of piston motor.
control valve and the like, the piston motor Then check for the cause of the trouble,
does not receive a required flow. This is the inspect and repair.
cause of low revolution.
Since the moving surface of piston motor is Disassemble, check the worn condition of
worn, hydraulic pressure escapes from the the moving surface of piston motor, and
high to low sides. (Volumetric efficiency is repair or replace according the maintenance
low.) manual.
This is why the revolution is deficient.
Motor revolution varies much Since the moving surface of piston motor is Disassemble and check the worn condition
and motor makes a big sound. worn, high pressure oil runs out of the drain of the moving surface.
port. Then repair or replace according to the
This causes the revolution to decrease maintenance procedure.
extremely and changes the revolution.
When machine goes downhill, double Disassemble and check the worn condition
counterbalance valve develops hunting of double counterbalance valve.
and causes the motor revolution to vary. Then repair or replace according to the
maintenance procedure.
Operating sound is large. Poor alignment causes the driven part to Align the centers correctly.
interfere with other part and make a sound.
Piston motor bearing is worn or broken, or Disassemble and replace broken parts such
spring is broken. as bearing and spring.
This causes the motor to make a sound. Clean parts and reassemble.
15-98
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Oil leak Bolts in matching surface get slack. Retighten fastening bolts to a specified
This developed oil leakage. torque.
Oil is leaking as oil seal, O-ring and Disassemble and replace seals.
packing are broken. Confirm the temperature of hydraulic oil. In
case the operating oil temperature has risen
above 80C degrees (176F degrees),
examine the cooler and hold down the
hydraulic oil temperature below 80C
degrees (176F degrees).
Since the sliding surface of piston motor is Disassemble and check the worn condition
worn, the drain rate increased. of sliding surface.
This caused the oil seal to break and Repair or replace according to the shop
developed an oil leak. manual. Review oil seals.
Clean parts and reassemble.
Drain pressure rose as drain pipe was Disassemble and replace oil seals.
stuck with foreign matter or drain pipe is too Clean drain pipe and eliminate foreign
small or long. This caused oil seal to break matter. Review piping system so as to
and developed an oil leak. decrease the line resistance.
Abnormal sound and revolution Hydraulic oil level in hydraulic tank fell, Confirm the hydraulic oil level in hydraulic
and pressure fluctuations occur entrapped air and developed aeration. oil tank and resupply hydraulic oil according
due to cavitation. to the instructions of the machine proper.
Motor is installed improperly or the location Confirm the motor orientation and if it is
of hydraulic oil tank is improper. wrong, correct it to the correct orientation.
Therefore, hydraulic oil is discharged from Check that the oil level in the hydraulic oil
motor piping and motor circuits while the tank is above the motor level and if not,
hydraulic device is not running. change it higher than the motor level.
The motor developed aeration immediately Before running, place a self supply circuit so
after motor was driven. hydraulic oil is filled up in motor circuit and
piping.
When motor makes pumping action, motor Disassemble and repair or replace double
inlet pressure becomes negative due to counterbalance valve according to the shop
malfunctioning double counterbalance manual.
valve. This causes the motor to develop
cavitation.
Motor stopped while running Engine stalled because of too much load. Review load condition and change it to a
suitable level.
Motor stalled as the sliding surface of Check the spec (flow and motor revolution
piston motor was seized. in particular). if the motor revolution
exceeds a limit value, decrease the flow.
Replace motor as insides of motor are
broken beyond reuse.
15
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Parking brake
Trouble Probable cause Remedy
If motor is rested under external Parking brake torque is low as disk is worn. Disassemble and replace parking brake
load, motor rotates. disk. Clean parts and reassemble.
Disk face deteriorated due to poor contact. Disassemble and replace disk.
This decreased the parking brake torque. Correct the surface in contact with the disk
and reassemble.
Spring is distorted or broken. Disassemble and replace spring.
This decreased the parking brake torque. Clean parts and reassemble.
Since external load is too large, power of Review the external load and change it to a
the parking brake is deficient. suitable level.
Motor does not produce Since O-ring is broken and pressure Disassemble and replace O-ring.
required drive force. escapes, the parking brake is not released. Clean parts and reassemble.
Motor generates abnormal heat.
Orifice in parking brake release oil passage Disassemble and remove foreign matter
is stuck with foreign matter. Therefore, from orifice. Then clean parts and
pressure does not reach parking brake reassemble. Flush the inside of pipes.
cylinder chamber. Thus parking brake is
not released.
Since drain pipe is stuck with foreign Clean drain pipe.
matter, drain pipe is small or long, drain Also, review piping system to decrease the
pressure rises. line resistance.
This prevents parking brake from being
released.
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Relief valve
Trouble Probable cause Remedy
Motor does not turn or revolution Foreign matter is included between poppet Disassemble and remove foreign matter.
is low. seat and poppet of relief valve. Clean parts and reassemble.
This developed poor seating, and high
pressure oil is leaking toward the low
pressure side.
Spring of relief valve is broken and the high Replace relief valve.
pressure oil is leaking toward the low Disassemble motor, clean parts and
pressure side. reassemble.
Foreign matter is included between free Remove relief valve and eliminate foreign
piston of relief valve and seat in contact matter.
with base plate.
This causes the set pressure to fall.
Foreign matter gets stuck in orifice located Remove relief valve and eliminate foreign
in poppet of relief valve. This causes set matter.
pressure to fall. Remove relief valve and
eliminate foreign matter.
Motor does not stop or motor Since foreign matter is included between Disassemble and eliminate foreign matter.
stops late. poppet seat and poppet of relief valve, poor Clean parts and reassemble.
seating occurs.
Relief valve does not close.
Spring of relief valve is broken, and relief Replace relief valve.
valve does not close. Disassemble motor, clean parts and
reassemble.
Since spring of relief valve is fatigued, set Replace relief valve.
pressure falls and the braking power drops.
Since foreign matter is included between Remove relief valve and eliminate foreign
free piston of relief valve and seat in matter.
contact with base plate, set pressure falls
and the braking force decreases.
Since foreign matter is included in orifice Remove relief valve and eliminate foreign
located in poppet of relief valve, set matter.
pressure falls and the braking power falls.
Shocks are large at stop. Since foreign matter is included in the Replace relief valve.
moving surface of poppet, poppet does not
operate.
Free piston does not operate as it is stuck Remove relief valve and remove foreign
with foreign matter. matter. Then reassemble.
15-101
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Counterbalance valve
Trouble Probable cause Remedy
If motor makes pumping action Plunger does not operate smoothly as Disassemble and remove the
as external load acts on it, motor foreign matter is included in plunger. contamination.
revolution changes. Then clean the plunger and reassemble it.
Wrong orifice size is used in pilot oil Replace with a correct orifice.
passage.
If motor makes pumping action Foreign matter is included in plunger. Disassemble and eliminate foreign matter.
as external load acts on motor , Plunger movement is bad and motor does Check the extent of damage according to
motor develops cavitation and not display counterbalance functions. the shop manual and reassemble if it is still
makes an abnormal sound. serviceable.
In case plunger is not serviceable, replace
base plate kit.
15-102
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
High-speed rotation can not be Pilot pressure is not at Ps port. Check that pilot pressure is at Ps port,
selected check for the cause, inspect and repair.
Foreign matter is included between spool Disassemble, remove foreign matter, and
and base plate, and spool does not change check the extent of scratch according to the
over. maintenance manual.
If spool is reusable, reassemble.
If it can not be reused, replace base plate
kit.
2-speed control piston develops abnormal Disassemble and replace flange holder kit.
wear and pressure is leaking into casing.
Orifice in 2-speed oil passage is clogged Disassemble, eliminate foreign matter and
with foreign matter. Therefore, pressure reassemble.
does not reach 2-speed control piston.
Motor changes over to high 2-speed control piston is worn abnormally, Disassemble and replace flange holder kit.
speed, but changes to low and pressure is leaking into casing.
speed as the temperature of
hydraulic oil rises.
Motor does not select low Pressure at Ps port does not go down even Check that pressure at Ps port is below
speed. if speed control switch is set at low speed. 0.5MPa (72.5psi) and review piping system.
Spring in 2-speed control valve is broken. Disassemble, remove foreign matter and
replace spring.
Motor does not change over to Orifice in 2-speed passage is clogged with Disassemble, remove foreign matter and
low speed. foreign matter, and pressure does not go reassemble.
out of 2-speed control piston chamber.
Motor changes to low speed, but Pilot piping is clogged with foreign matter Clean the inside of piping and remove
changes to high speed while and oil leaks from 2-speed control valve. foreign matter.
running. As the result, pilot pressure rises to a Also review the piping system.
changeover level.
15
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Reduction unit
Trouble Probable cause Remedy
Reduction unit does not rotate. Devices other than piston motor and Check that pressure is there at the motor
reduction unit have trouble. inlet, check for the cause, inspect and
repair.
Load exceeding motor output torque is Check load condition and get rid of load
acting on it. acting upon motor.
Parts are interfering with each other Disassemble and confirm the broken
because the sliding surface in reduction condition. If something broken is
unit is broken. discovered, replace reduction unit.
If no part is broken, replace worn parts,
clean them and reassemble.
Reduction unit is generating Lube oil in reduction unit is deficient. Confirm that there is no oil leakage.
abnormal heat. Disassemble and make sure of the
damaged condition in reduction unit.
If something is found broken, replace
reduction unit.
Fill lube oil to a specified level.
Too much lube oil is filled in reduction unit. Adjust lube oil volume to a specified level.
Abnormal thrust load is acting in reduction Disassemble and confirm the damaged
unit because of wrong selection of thrust condition of the inside.
plate. If something broken is confirmed, replace
reduction unit.
If not, replace thrust place with one of
proper thickness.
15-104
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[15. TRAVEL SYSTEM]
Oil leakage occurs. Reduction unit cover is slack and oil is Remove cover, reapply liquid packing and
leaking. tighten cover to a specified torque. Then fill
in lube oil to a specified level.
Oil is leaking from leaked plugs in oil inlet, Retighten plugs to specified torque. After
outlet, and check ports of reduction unit tightening, fill in lube oil to a specified level.
cover.
Oil is leaking as O-rings in oil inlet, outlet Replace O-rings in plugs. After
and check ports of reduction unit cover are replacement, fasten plugs to a specified
aged. torque and fill in lube oil to a specified level.
Oil is leaking as foreign matter is included Disassemble reduction unit, remove foreign
in the sliding surface of floating seal. matter from floating seal and reassemble.
Oil is leaking as the sliding surface of Disassemble reduction unit and replace
floating seal is corroded. floating seal.
15
15-105
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[15. TRAVEL SYSTEM]
15-106
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16
16-1
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16-2
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16
16-3
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
16.2 PREFACE
Troubleshooting provides process locating for the cause
of trouble in the order that trouble occurred. This manual
describes how to solve the specific phenomenon
systematically as early as possible. For troubleshooting
concerning the inside of equipment, refer to
troubleshooting for each manual of equipment.
16-4
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16-5
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
When error code of self diagnosis is displayed on gauge Carry out troubleshooting according to the error code.
A
cluster.
When no failure is detected currently but error code after When it is hard to recreate the failure situation, cancel the
self diagnosis is remained in trouble history. data in the history and reproduce the failed situation or
B
suppose the cause according to the troubleshooting by
error code, and then repair it.
When error code of self diagnosis is not displayed or is Carry out troubleshooting according to instructions in
C
not remained in history. "TROUBLESHOOTING (BY TROUBLE)".
16-6
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16
16-7
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
B114 Power short circuit of option selector position detect pressure sensor
F011 Failure of output transistor OFF and GND short circuit of power boost SOL valve
F013 Failure of output transistor ON and disconnection of power boost SOL valve 16
F021 Failure of output transistor OFF and GND short circuit of swing parking SOL valve
F023 Failure of output transistor ON and disconnection of swing parking SOL valve
F031 Failure of output transistor OFF and GND short circuit of travel 1-2 speed SOL valve
16-9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
F041 Failure of output transistor OFF and GND short circuit of option selector SOL valve
F043 Failure of output transistor ON and disconnection of option selector SOL valve
F071 Failure of output transistor OFF and GND short circuit of boom M/I cut SOL valve
F073 Failure of output transistor ON and disconnection of boom M/I cut SOL valve
F081 Failure of output transistor OFF and GND short circuit of quick coupler SOL valve
F083 Failure of output transistor ON and disconnection of quick coupler SOL valve
G042 Overrun of received data from Mechatro-controller direct input speed sensor and engine controller
G043 Disconnection of received data from Mechatro-controller direct input speed sensor and engine controller
16-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The pump is not adjusted yet or the value cannot be set in the adjustment range during adjustment.
condition
Symptom Deviated from the pump output, but no problem in normal operations.
Control in the
Works with the default data.
event of failure
Return in normal
The pump adjustment is completed normally.
condition
Symptom Deviated from the unload valve output, but no problem in normal operations.
Control in the
Works with the default data.
event of failure
Return in normal
The adjustment of unload valve is completed normally.
condition
Screen No. 7 D-1 P1 UN-LOAD (BP-CUT)
Service
diagnosis Screen No. 7 D-2 P2 UN-LOAD (BP-CUT)
checking screen
Screen No.
Checking object Checking contents and remedy
16
16-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom Becomes not normal output, but no problem in normal operation.
Control in the
Controlled by the default value.
event of failure
Return in normal
Does not return. Replacement of the controller is required.
condition
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom No effect
Control in the
Controlled by the correct memory data.
event of failure
Return in normal
Does not return. Replacement of the controller is required.
condition
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
16-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
Judging
Check adjustment data, and judge the content of memory is correct or not.
condition
Symptom The hour meter reading can become 0.
Control in the
The machine works normally.
event of failure
Return in normal
Does not return. Replacement of the controller is required.
condition
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
16
16-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
Check adjustment data, and judge the content of memory is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation.
Control in the
Controlled by the default value.
event of failure
Return in normal
Does not return. Replacement of the controller is required.
condition
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
Judging During the period after the starter switch ON until start of the engine, the input voltage from the boom up
condition pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • Boom up pressure sensor When B012 is cancelled and another error occurs by turning the starter switch
SE-3 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between boom up When B012 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-126F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom up pressure sensor When B013 is cancelled and another error occurs by turning the starter switch
SE-3 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between boom up When B013 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-126F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom up pressure sensor When B014 is cancelled and another error occurs by turning the starter switch
SE-3 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between boom up When B014 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-126F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the boom
condition down pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • Boom down pressure sensor When B022 is cancelled and another error occurs by turning the starter switch
SE-4 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between boom down When B022 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-127F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from boom down pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom down pressure sensor When B023 is cancelled and another error occurs by turning the starter switch
SE-4 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between boom down When B023 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-127F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom down pressure sensor When B024 is cancelled and another error occurs by turning the starter switch
SE-4 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between boom down When B024 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-127F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the arm-out
condition pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • Arm-out pressure sensor When B032 is cancelled and another error occurs by turning the starter switch
SE-8 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between arm-out pressure When B032 is displayed by turning the starter switch on after replacing the
sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-131F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from arm-out pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Arm-out pressure sensor When B033 is cancelled and another error occurs by turning the starter switch
SE-8 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between arm-out pressure When B033 is displayed by turning the starter switch on after replacing the
sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-131F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Arm-out pressure sensor When B034 is cancelled and another error occurs by turning starter switch on
SE-8 after replacing the connector with that of another sensor, check sensor unit for
possible failure. If failure found, replace it.
2 • Wiring between arm-out pressure When B034 is displayed after turning the starter switch on after replacing the
sensor and controller connector with that of another sensor, check wiring for possible failure according
CN-131F to the wiring checking procedure and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the arm-in
condition pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • Arm-in pressure sensor When B042 is cancelled and another error occurs by turning the starter switch
SE-7 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between arm-in pressure When B042 is displayed by turning the starter switch on after replacing the
sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-130F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from arm-in pressure sensor is less than 0.1V.
condition
Symptom Cavitation occurs during independent arm-in operation. Speed of all operations slows down.
Return in normal
It returns automatically in normal condition.
condition
1 • Arm-in pressure sensor When B043 is cancelled and another error occurs by turning the starter switch
SE-7 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between arm-in pressure When B043 is displayed by turning the starter switch on after replacing the
sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-130F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Symptom Cavitation occurs during independent arm-in operation. Speed of all operations slows down.
Return in normal
It returns automatically in normal condition.
condition
1 • Arm-in pressure sensor When B044 is cancelled and another error occurs by turning the starter switch
SE-7 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between arm-in pressure When B044 is displayed by turning the starter switch on after replacing the
sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-130F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the bucket
condition digging pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • Bucket digging pressure sensor When B052 is cancelled and another error occurs by turning the starter switch
SE-1 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between bucket digging When B052 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-124F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from bucket digging pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Bucket digging pressure sensor When B053 is cancelled and another error occurs by turning the starter switch
SE-1 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between bucket digging When B053 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-124F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Bucket digging pressure sensor When B054 is cancelled and another error occurs by turning the starter switch
SE-1 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between bucket digging When B054 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-124F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the bucket
condition dump pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • Bucket dump pressure sensor When B062 is cancelled and another error occurs by turning the starter switch
SE-2 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between bucket dump When B062 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-125F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from bucket dump pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Bucket dump pressure sensor When B063 is cancelled and another error occurs by turning the starter switch
SE-2 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between bucket dump When B063 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-125F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-22
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Bucket dump pressure sensor When B064 is cancelled and another error occurs by turning the starter switch
SE-2 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between bucket dump When B064 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-125F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the swing
condition right pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • Swing right pressure sensor When B072 is cancelled and another error occurs by turning the starter switch
SE-40 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between swing right When B072 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-315F according to the wiring checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-23
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from swing right pressure sensor is less than 0.1V.
condition
Symptom The swing operability becomes poor.
Control in the
The swing parking solenoid is demagnetized (release condition).
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Swing right pressure sensor When B073 is cancelled and another error occurs by turning the starter switch
SE-40 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between swing right When B073 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-315F according to the wiring checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from swing right pressure sensor is 4.7V or more.
condition
Symptom The swing operability becomes poor.
Control in the
The swing parking solenoid is demagnetized (release condition).
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Swing right pressure sensor When B074 is cancelled and another error occurs by turning the starter switch
SE-40 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between swing right When B074 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-315F according to the wiring checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-24
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the swing left
condition pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • Swing left pressure sensor When B082 is cancelled and another error occurs by turning the starter switch
SE-41 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between swing left When B082 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-316F according to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from swing left pressure sensor is less than 0.1V.
condition
Symptom The swing operability becomes poor.
Control in the
The swing parking solenoid is demagnetized (release condition).
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Swing left pressure sensor When B083 is cancelled and another error occurs by turning the starter switch
SE-41 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between swing left When B083 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-316F according to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-25
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from swing left pressure sensor is 4.7V or more.
condition
Symptom The swing operability becomes poor.
Control in the
The swing parking solenoid is demagnetized.
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • Swing left pressure sensor When B084 is cancelled and another error occurs by turning the starter switch
SE-41 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between swing left When B084 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-316F according to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the swing
condition right pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
Screen No. 5 B-9 TRAVEL (R)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B092 is cancelled and another error occurs by turning the starter switch
SE-9 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between travel right When B092 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-301F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-26
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from travel right pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 5 B-9 TRAVEL (R)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B093 is cancelled and another error occurs by turning the starter switch
SE-9 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between travel right When B093 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-301F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from travel right pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 5 B-9 TRAVEL (R)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B094 is cancelled and another error occurs by turning the starter switch
SE-9 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between travel right When B094 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-301F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-27
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the travel left
condition pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
Screen No. 5 B-10 TRAVEL (L)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B102 is cancelled and another error occurs by turning starter switch on
SE-10 after replacing the connector with that of another sensor, check sensor unit for
possible failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-302F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from travel left pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 5 B-10 TRAVEL (L)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B103 is cancelled and another error occurs by turning the starter switch
SE-10 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between travel left When B103 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-302F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-28
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from travel left pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 5 B-10 TRAVEL (L)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B104 is cancelled and another error occurs by turning the starter switch
SE-10 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between travel left When B104 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-302F according to the wiring checking procedures and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from option selector position detect pressure sensor is less than 0.1V.
condition
Symptom The switched position of the selector valve cannot be detected.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Option selector position detect When B113 is cancelled and another error occurs by turning the starter switch
pressure sensor on after replacing the connector with that of another sensor, check the sensor
SE-29 unit for possible failure and replace it if necessary.
2 • Wiring between option selector When B113 is displayed by turning the starter switch on after replacing the
position detect pressure sensor connector with that of another sensor, check the wiring for possible failure
and controller according to the wiring checking procedures and repair it if necessary.
CN-1031F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-29
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from option selector position detect pressure sensor is 4.7V or more.
condition
Symptom The switched position of the selector valve cannot be detected.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Option selector position detect When B114 is cancelled and another error occurs by turning the starter switch
pressure sensor on after replacing the connector with that of another sensor, check the sensor
SE-29 unit for possible failure and replace it if necessary.
2 • Wiring between option selector When B114 is displayed by turning the starter switch on after replacing the
position detect pressure sensor connector with that of another sensor, check the wiring for possible failure
and controller according to the wiring checking procedures and repair it if necessary.
CN-1031F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P1side
condition option pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • P1 side option pressure sensor When B162 is cancelled and another error occurs by turning the starter switch
SE-20 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P1 side option When B162 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-304F according to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-30
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from P1 side option pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current. But normal control is
event of failure done when the left control pedal selection is ON.
Return in normal
It returns automatically in normal condition.
condition
1 • P1 side option pressure sensor When B163 is cancelled and another error occurs by turning the starter switch
SE-20 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P1 side option When B163 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-304F according to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1and P2 pump proportional valves becomes a constant current.
event of failure But normal control is done when the left control pedal selection is ON.
Return in normal
It returns automatically in normal condition.
condition
1 • P1 side option pressure sensor When B164 is cancelled and another error occurs by turning the starter switch
SE-20 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P1 side option When B164 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-304F according to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-31
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P2 side
condition option pressure sensor is from 1.4V or more to less than 4.7V.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • P2 side option pressure sensor When B172 is cancelled and another error occurs by turning the starter switch
SE-11 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P2 side option When B172 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-303F according to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from P2 side option pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the
The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • P2 side option pressure sensor When B173 is cancelled and another error occurs by turning the starter switch
SE-11 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P2 side option When B173 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-303F according to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-32
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1and P2 pump proportional valves becomes a constant current.
event of failure But normal control is done when the left control pedal selection is ON.
Return in normal
It returns automatically in normal condition.
condition
1 • P2 side option pressure sensor When B174 is cancelled and another error occurs by turning the starter switch
SE-11 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P2 side option When B174 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-303F according to the wiring checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P1 pump
condition pressure sensor is from 1.4V or more to less than 4.7V.
Symptom Speed of all operations slows down. Engine speed goes down significantly.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • P1 pump pressure sensor When C012 is cancelled and another error occurs by turning the starter switch
SE-22 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P1 pump When C012 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-139F according to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-33
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from P1 pump pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down. Engine speed goes down significantly.
Control in the
P1 pump pressure is controlled as 25 MPa (3625 psi).
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • P1 pump pressure sensor When C013 is cancelled and another error occurs by turning the starter switch
SE-22 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P1 pump When C013 is displayed after replacing the connector with that of another
pressure sensor and controller sensor, check the wiring for possible failure according to the wiring checking
CN-139F procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down. Engine speed goes down significantly.
Control in the
P1 pump pressure is controlled as 25 MPa (3625 psi).
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • P1 pump pressure sensor When C014 is cancelled and another error occurs by turning the starter switch
SE-22 on after replacing the connector with that of another sensor, check sensor unit
for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C014 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-139F according to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-34
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P2 pump
condition pressure sensor is from 1.4V or more to less than 4.7V.
Symptom Speed of all operations slows down. Engine speed goes down significantly.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • P2 pump pressure sensor When C022 is cancelled and another error occurs by turning the starter switch
SE-23 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P2 pump When C022 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-140F according to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from P2 pump pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down. Engine speed goes down significantly.
Control in the
P2 pump pressure is controlled as 25 MPa (3625 psi).
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • P2 pump pressure sensor When C023 is cancelled and another error occurs by turning the starter switch
SE-23 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P2 pump When C023 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-140F according to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-35
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom Speed of all operations slows down. Engine speed goes down significantly.
Control in the
P2 pump pressure is controlled as 25 MPa (3625 psi).
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • P2 pump pressure sensor When C024 is cancelled and another error occurs by turning the starter switch
SE-23 on after replacing the connector with that of another sensor, check the sensor
unit for possible failure and replace it if necessary.
2 • Wiring between P2 pump When C024 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-140F according to the wiring checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from boom head pressure sensor is less than 0.1V.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom head pressure sensor When C033 is cancelled and another error occurs after replacing the connector
SE-24 with that of another sensor, check the sensor unit for possible failure and
replace it if necessary.
2 • Wiring between boom head When C033 is displayed after replacing the connector with that of another
pressure sensor and controller sensor, check the wiring for possible failure according to the wiring checking
CN-706F procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-36
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom head pressure sensor When C034 is cancelled and another error occurs after replacing the connector
SE-24 with that of another sensor, check the sensor unit for possible failure and
replace it if necessary.
2 • Wiring between boom head When C034 is displayed after replacing the connector with that of another
pressure sensor and controller sensor, check the wiring for possible failure according to the wiring checking
CN-706F procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from boom rod pressure sensor is less than 0.1V.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom rod pressure sensor When C043 is cancelled and another error occurs after replacing the connector
SE-25 with that of another sensor, check the sensor unit for possible failure and
replace it if necessary.
2 • Wiring between boom rod When C043 is displayed after replacing the connector with that of another
pressure sensor and controller sensor, check the wiring for possible failure according to the wiring checking
CN-705F procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-37
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom rod pressure sensor When C044 is cancelled and another error occurs after replacing the connector
SE-25 with that of another sensor, check the sensor unit for possible failure and
replace it if necessary.
2 • Wiring between boom rod When C044 is displayed after replacing the connector with that of another
pressure sensor and controller sensor, check the wiring for possible failure according to the wiring checking
CN-705F procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Arm out/option conflux operation is impossible. Travel right operation is impossible.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 7 D-1 P1 UN-LOAD (BP-CUT)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D012 is cancelled and another error occurs after replacing the connector
PSV-D with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between P1 unload When D012 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-120F checking procedures and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-38
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is 100mA or less. (If output is 150mA or less, judging is not
condition done.)
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 7 D-1 P1 UN-LOAD (BP-CUT)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D013 is cancelled and another error occurs after replacing the connector
PSV-D with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between P1 unload When D013 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-120F checking procedures and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up, bucket digging, and bucket dump become slow. Travel left operation
is impossible.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 7 D-2 P2 UN-LOAD (BP-CUT)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D022 is cancelled and another error occurs after replacing the connector
PSV-B with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between P2 unload When D022 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-118F checking procedures and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-39
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is 100mA or less. (If output is 150mA or less, judging is not
condition done.)
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 7 D-2 P2 UN-LOAD (BP-CUT)
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D023 is cancelled and another error occurs after replacing the connector
PSV-B with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between P2 unload When D023 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-118F checking procedures and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of traveling and attachment.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Travel straight proportional valve When D032 is cancelled and another error occurs after replacing the connector
PSV-C with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between Travel straight When D032 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-119F checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-40
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is 100mA or less. (If output is 150mA or less, judging is not
condition done.)
Symptom Travel deviation occurs by combined operation of traveling and attachment. Speed of a part of operations
slows down.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Travel straight proportional valve When D033 is cancelled and another error occurs after replacing the connector
PSV-C with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between Travel straight When D033 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-119F checking procedures and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Operability of combined operation including arm-in becomes poor.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Arm-in spool 2 proportional valve When D062 is cancelled and another error occurs after replacing the connector
PSV-A with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between Arm-in spool 2 When D062 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-121F checking procedures and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
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Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is 100mA or less. (If output is 150mA or less, judging is not
condition done.)
Symptom Cavitation occurs during independent arm-in operation. Operability of combined operation including arm-
in becomes poor.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Arm-in spool 2 proportional valve When D063 is cancelled and another error occurs after replacing the connector
PSV-A with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between Arm-in spool 2 When D063 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-121F checking procedures and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back value from the proportional valve is 1000mA or more.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom 2 proportional valve When D172 is cancelled and another error occurs after replacing the connector
PSV-23 with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between boom 2 When D172 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-799F checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-42
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than 150mA, judging is
condition not done.)
1 • Boom 2 proportional valve When D173 is cancelled and another error occurs after replacing the connector
PSV-23 with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between boom 2 When D173 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-799F checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back value from the proportional valve is 1000mA or more.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Boom 3 proportional valve When D182 is cancelled and another error occurs after replacing the connector
PSV-24 with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between boom 3 When D182 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-823F checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-43
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than 150mA, judging is
condition not done.)
1 • Boom 3 proportional valve When D183 is cancelled and another error occurs after replacing the connector
PSV-24 with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
2 • Wiring between boom 3 When D183 is displayed after replacing the connector with that of another
proportional valve and controller proportional valve, check the wiring for possible failure according to the wiring
CN-823F checking procedures and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The fine operability of the attachment becomes poor.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • KPSS release switch Check that the KPSS release switch is set at the "release" side or not.
SW-22
2 • P1 pump proportional valve When E012 is cancelled and another error occurs after replacing the connector
PSV-P1 with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
3 • Wiring between P1 pump When E012 is displayed after replacing the connector with that of another
proportional valve, KPSS release proportional valve, check the wiring for possible failure according to the wiring
switch, and controller checking procedures and repair it if necessary.
CN-141F
CN-56F
CN-103F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-44
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than 150mA, judging is
condition not done.)
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • KPSS release switch Check that the KPSS release switch is set at the "release" side or not.
SW-22
2 • P1 pump proportional valve When E013 is cancelled and another error occurs after replacing the connector
PSV-P1 with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
3 • Wiring between P1 pump When E013 is displayed after replacing the connector with that of another
proportional valve, KPSS release proportional valve, check the wiring for possible failure according to the wiring
switch, and controller checking procedures and repair it if necessary.
CN-141F
CN-56F
CN-103F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-45
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The fine operability of the attachment becomes poor.
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • KPSS release switch Check that the KPSS release switch is set at the "release" side or not.
SW-22
2 • P2 pump proportional valve When E022 is cancelled and another error occurs after replacing the connector
PSV-P2 with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
3 • Wiring between P2 pump When E022 is displayed after replacing the connector with that of another
proportional valve, KPSS release proportional valve, check the wiring for possible failure according to the wiring
switch, and controller checking procedures and repair it if necessary.
CN-142F
CN-56F
CN-103F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-46
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than 150mA, judging is
condition not done.)
Control in the
Normal control
event of failure
Return in normal
Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
1 • KPSS release switch Check that the KPSS release switch is set at the "release" side or not.
SW-22
2 • P2 pump proportional valve When E023 is cancelled and another error occurs after replacing the connector
PSV-P2 with that of another proportional valve, check the proportional valve unit for
possible failure and replace it if necessary.
3 • Wiring between P2 pump When E023 is displayed after replacing the connector with that of another
proportional valve, KPSS release proportional valve, check the wiring for possible failure according to the wiring
switch, and controller checking procedures and repair it if necessary.
CN-142F
CN-56F
CN-103F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Not switch to bower boost operation.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is 24V level while exciting command is output.
condition
1 • ATT boost solenoid valve When F011 is cancelled and another error occurs after replacing the connector
SV-2 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between ATT boost When F011 is displayed after replacing the connector with that of another
solenoid valve and controller solenoid valve, check the wiring for possible failure according to the wiring
CN-117F checking procedures and repair it if necessary.
CN-102F 16
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-47
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Not switch to bower boost operation. Or not switch from power boost operation.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is grounding level while exciting command is not output.
condition
1 • ATT boost solenoid valve When F013 is cancelled and another error occurs after replacing the connector
SV-2 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between ATT boost When F013 is displayed after replacing the connector with that of another
solenoid valve and controller solenoid valve, check the wiring for possible failure according to the wiring
CN-117F checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking brake does not change. (The brake does not work.)
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is 24V level while exciting command is output.
condition
1 • Swing parking solenoid valve When F021 is cancelled and another error occurs after replacing the connector
SV-1 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Swing PB release switch Set swing PB release switch to the release side and check that connector (CN-
SW-4 63F) is switched. If failure is found, replace it.
3 • Wiring between swing parking When F021 is displayed after replacing the connector with that of another
solenoid valve, swing PB release solenoid valve, check the wiring for possible failure according to the wiring
switch, and controller checking procedures and repair it if necessary.
CN-123F
CN-63F
CN-104F
CN-102F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-48
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom The swing parking brake does not change. (Stays in braking condition or the brake does not work.)
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is grounding level while exciting command is not output.
condition
1 • Swing parking solenoid valve When F023 is cancelled and another error occurs after replacing the connector
SV-1 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Swing PB release switch Set swing PB release switch to the release side and check that connector (CN-
SW-4 63F) is switched. If failure is found, replace it.
3 • Wiring between swing parking When F023 is displayed after replacing the connector with that of another
solenoid valve, swing PB release solenoid valve, check the wiring for possible failure according to the wiring
switch, and controller checking procedures and repair it if necessary.
CN-123F
CN-63F
CN-104F
CN-102F
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom The speed does not switch to the travel 2 speed.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is 24V level while exciting command is output.
condition
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and another error occurs after replacing the connector
SV-3 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between travel 1, 2speed When F031 is displayed after replacing the connector with that of another
solenoid valve and controller solenoid valve, check the wiring for possible failure according to the wiring
checking procedures and repair it if necessary.
CN-122F
CN-102F
16
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-49
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom The speed does not switch to the travel 2nd speed. Or it does not switch to the travel 1st speed from the
travel 2nd speed.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is grounding level while exciting command is not output.
condition
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and another error occurs after replacing the connector
SV-3 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between travel 1, 2speed When F033 is displayed after replacing the connector with that of another
solenoid valve and controller solenoid valve, check the wiring for possible failure according to the wiring
CN-122F checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom The option selector solenoid valve does not change.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is 24V level while exciting command is output.
condition
1 • Option selector solenoid valve When F041 is cancelled and another error occurs after replacing the connector
SV-13 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between option selector When F041 is displayed after replacing the connector with that of another
solenoid valve and controller solenoid valve, check the wiring for possible failure according to the wiring
CN-1031F checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-50
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom The option selector solenoid valve does not change. Or stays in the changed condition.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is ground level while exciting command is not output.
condition
1 • Option selector solenoid valve When F043 is cancelled and another error occurs after replacing the connector
SV-13 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between option selector When F043 is displayed after replacing the connector with that of another
solenoid valve and controller solenoid valve, check the wiring for possible failure according to the wiring
CN-1031F checking procedures and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is 24V level while exciting command is output.
condition
1 • Boom cut solenoid valve When F071 is cancelled and another error occurs after replacing the connector
SV-105 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between boom solenoid When F071 is displayed after replacing the connector with that of another
valve and controller solenoid valve, check the wiring for possible failure according to the wiring
CN-800F checking procedures and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-51
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is grounding level while exciting command is not output.
condition
1 • Boom cut solenoid valve When F073 is cancelled and another error occurs after replacing the connector
SV-105 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between boom solenoid When F073 is displayed after replacing the connector with that of another
valve and controller solenoid valve, check the wiring for possible failure according to the wiring
CN-800F checking procedures and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Quick coupler operation cannot be performed.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is 24V level while exciting command is output.
condition
1 • Quick coupler solenoid valve When F081 is cancelled and another error occurs after replacing the connector
SV-14 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between quick coupler When F081 is displayed after replacing the connector with that of another
solenoid valve and expansion solenoid valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-548F
P-80
CN-1103F
CN-996F
CN-550F
CN-547F
CN-1036F
CN-1037F
3 • Expansion controller Check that the error is corrected after replacement of the expansion controller.
16-52
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Quick coupler operation cannot be performed.
Control in the
Normal control
event of failure
Return in normal
The feed-back signal is grounding level while exciting command is not output.
condition
1 • Quick coupler solenoid valve When F083 is cancelled and another error occurs after replacing the connector
SV-14 with that of another solenoid valve, check the solenoid valve unit for possible
failure and replace it if necessary.
2 • Wiring between quick coupler When F083 is displayed after replacing the connector with that of another
solenoid valve and expansion solenoid valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-548F
P-80
CN-1103F
CN-996F
CN-550F
CN-547F
CN-1036F
CN-1037F
3 • Expansion controller Check that the error is corrected after replacement of the expansion controller.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operates without problem.
Control in the
Receives rpm from the engine controller to perform control.
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service
diagnosis Screen No. 2 G-3 MEAS 2 (receives from engine controller)
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor. Normal value:
SE-13 1.6 to 2.0 kΩ
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and
repair it if necessary. Especially check wiring for false disconnection and noise
sensor and controller
CN-136F included. 16
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
(The controller is broken only when power voltage is applied to the signal GND
side.)
16-53
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The voltage of the alternator is 12 V or more and the speed sensor indicates the extreme low speed or
condition less.
Symptom Operates without problem.
Control in the
Receives rpm from the engine controller to perform control.
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor. Normal value:
SE-13 1.6 to 2.0 kΩ
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-136F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
(The controller is broken only when power voltage is applied to the signal GND
side.)
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operates without problem.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service
diagnosis Screen No. 2 G-3 MEAS 2 (receives from engine controller)
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor. Normal value:
SE-13 1.6 to 2.0 kΩ
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-103F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and
speed sensor, pressure sensor repair it if necessary.
and controller Especially check wiring for false disconnection and noise included.
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
(The controller is broken only when power voltage is applied to the signal GND
side.)
5 • Engine controller Check that the error is corrected after replacement of the controller.
16-54
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The voltage of the alternator is 12 V or more and the received data from the speed sensor and the engine
condition controller is the extreme low speed or less.
Symptom Abrupt load application may cause the engine speed to go down significantly.
Control in the
Engine speed input becomes 0 rpm. And ESS horse power reduction command becomes 0.
event of failure
Return in normal
It returns automatically in normal condition.
condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service
diagnosis Screen No. 2 G-3 MEAS 2 (receives from engine controller)
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor. Normal value:
SE-13 1.6 to 2.0 kΩ
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-136F
CN-103F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and
speed sensor, pressure sensor repair it if necessary.
and controller
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
(The controller is broken only when power voltage is applied to the signal GND
side.)
5 • Engine controller Check that the error is corrected after replacement of the controller.
16
16-55
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from accel potentiometer is less than 0.1V.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Acceleration potentiometer Measure the resistance between terminals of the acceleration potentiometer.
SE-16 Normal value:
1.6 to 2.4 kΩ
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between acceleration Check wiring for possible failure according to the wiring checking procedure and
potentiometer and controller repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from acceleration potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Acceleration potentiometer Measure the resistance between terminals of the acceleration potentiometer.
SE-16 Normal value:
1.6 to 2.4 kΩ
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between acceleration Check wiring for possible failure according to the wiring checking procedure and
potentiometer and controller repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-56
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Control in the
The fuel level is regarded as 0 %.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 Ω to FULL 5 Ω
2 • Wiring between fuel sensor and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-152F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Control in the
The fuel level is regarded as 0 %.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 Ω to FULL 5 Ω
2 • Wiring between fuel sensor and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-152F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-57
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from the sensor is less than 0.1V.
condition
Symptom Not affect machine movement.
Control in the
Hydraulic oil temperature is regarded as 0C degrees.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Hydraulic oil temperature sensor Measure the resistance between terminals of the hydraulic oil temperature
SE-21 sensor by changing the temperature of the sensor. Reference:
At 0 to 50 C degrees C, the resistance is 1150 to 98.2 Ω respectively.
2 • Wiring between hydraulic oil Check wiring for possible failure according to the wiring checking procedure and
temperature sensor and controller repair it if necessary.
CN-59F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from the sensor is 4.7V or more.
condition
Symptom Not affect machine movement.
Control in the
Hydraulic oil temperature is regarded as 0C degrees.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Hydraulic oil temperature sensor Measure the resistance between terminals of the hydraulic oil temperature
SE-21 sensor by changing the temperature of the sensor. Reference:
At 0 to 50 C degrees C, the resistance is 1150 to 98.2 Ω respectively.
2 • Wiring between hydraulic oil Check wiring for possible failure according to the wiring checking procedure and
temperature sensor and controller repair it if necessary.
CN-59F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-58
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The input voltage from swing speed sensor is less than 0.1V.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Wiring between swing speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-798F
CN-105F
2 • Swing speed sensor Check that the error is corrected after replacement of the sensor.
SE-99
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The input voltage from swing speed sensor is 4.7V or more.
condition
Symptom Not affect machine movement.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Wiring between swing speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-798F
CN-105F
2 • Swing speed sensor Check that the error is corrected after replacement of the sensor.
SE-99
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-59
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
Data from the engine controller cannot be received correctly. (Only trouble history)
condition
Symptom Affects operation very little.
Control in the
Keeps the last receiving condition.
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Wiring between ECU and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-1F (There is a possibility of false disconnection.)
CN-3F
CN-5F
CN-104F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
Data from engine controller can not be received correctly.
condition
Symptom Speed of all operations slows down.
Control in the Operates as the coolant temperature is 20 C degrees. Output of the P1 and P2 pump proportional valves
event of failure becomes 350 mA.
Return in normal
It returns automatically in normal condition.
condition
1 • Wiring between ECU and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-1F (There is a possibility of false disconnection.)
CN-3F
CN-5F
CN-104F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-60
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
Transmission data of the mechatro controller cannot be transmitted correctly.
condition
Symptom Affects operation very little.
Control in the
Normal control
event of failure
Return in normal
Normal control
condition
1 • Wiring between ECU and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-1F (There is a possibility of false disconnection.)
CN-3F
CN-5F
CN-104F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
Data from the gauge cluster cannot be received correctly. (Only trouble history)
condition
Symptom Switches of gauge cluster can not be used.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-601F (There is a possibility of false disconnection.)
CN-102F
CN-33F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-61
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
Data from gauge cluster cannot be received correctly.
condition
Symptom Switches of gauge cluster can not be used.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-601F (There is a possibility of false disconnection.)
CN-102F
CN-33F
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
Transmission data of the mechatro controller cannot be transmitted correctly.
condition
Symptom Gauge cluster can not be used.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-601F (There is a possibility of false disconnection.)
CN-102F
CN-33F
2 Mechatro controller Check that the error is corrected after replacement of the controller.
16-62
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
Data from the expansion controller cannot be received correctly.
condition
Symptom Devices connected to the expansion controller become inoperable.
Control in the
Normal control
event of failure
Return in normal
It returns automatically in normal condition.
condition
1 • Wiring between expansion Check wiring for possible failure according to the wiring checking procedure and
controller and controller repair it if necessary.
CN-1036F
CN-996F
CN-102F
2 • Expansion controller Check that the error is corrected after replacement of the expansion controller.
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch ON
condition signal turned OFF
Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.
Control in the
Normal control with key switch OFF
event of failure
Return in normal
Turn key switch ON. Or when the power supply 24V to mechatro controller is stopped.
condition
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery relay
R-1 coil. If 24V power lives on battery relay secondary side, check on battery relay
CN-256F for failure and replace it if failed.
2 • Auto idle stop relay 2 Turn off the key switch, and remove the connector (CN-256F) on the battery
R-24 relay coil side. If power of battery relay on secondary side falls, remove either
auto idle stop relay 2 or alternator relay.
• Alternator relay
The failure may be occurred in case where the power falls after the relay was
R-28
removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop When K014 is left displayed with the relay removed, check that 24V is produced
relay/alternator relay and on relay (-) line according to the wiring checking procedure and repair it.
controller When no failure is found after checking on wiring and K014 is left displayed,
CN2-1,CN-102F, and CN-104F replace fuse/relay box.
• Fuse & relay box
16
E-1
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-63
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power
condition source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay, check
R-31 relay unit for failure, replace it with new one if falied.
When resistance between relay terminals (1) and (2) shown in the following
figure is 0 Ω, relay is failed.
2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed, check that 24V is produced
prevention relay and controller on relay (-) line according to the wiring checking procedure and repair it.
CN-101F,CN2-1 When no failure is found after checking on wiring and R014 is left displayed,
replace fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-64
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to wiper motor normal rotation relay is short-circuited with the power
condition source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Wiper motor normal rotation relay When error is cancelled after removing wiper motor normal rotation relay, check
R-29 relay unit for failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the following
figure is 0 Ω, relay is failed.
2 • Wiring between wiper motor When R024 is left displayed with the relay removed, check that 24V is produced
normal rotation relay and on relay (-) line according to the wiring checking procedure and repair it.
controler When no failure is found after checking on wiring and R024 is left displayed,
CN-101F,CN2-1 replace fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-65
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power
condition source.
Symptom Wiper does not move after forward rotation.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Wiper motor reverse rotation relay When error is cancelled after removing wiper motor reverse rotation relay, check
R-30 relay unit for failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the following
figure is 0 Ω, relay is failed.
2 • Wiring between wiper motor When R034 is left displayed with the relay removed, check that 24V is produced
forward rotation relay and on relay (-) line according to the wiring checking procedure and repair it.
controller When no failure is found after checking on wiring and R034 is left displayed,
CN-101F,CN2-1 replace fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-66
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit for
R-32 failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the following
figure is 0 Ω, relay is failed.
2 • Wiring between washer motor When R044 is left displayed with the relay removed, check that 24V is produced
relay and controller on relay (-) line according to the wiring checking procedure and repair it.
CN-105F,CN2-1 When no failure is found after checking on wiring and R044 is left displayed,
replace fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-67
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The mechatro controller output line to the swing flasher relay is short-circuited with the power source.
condition
Symptom Swing flasher right relay does not work.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Swing flasher relay When the error is cancelled after removing the swing flasher relay, check the
R-19 relay unit for failure, replace it with a new one if failed.
When the resistance between terminals H and D shown in the following figure is
0 Ω, the relay is failed.
2 • Wiring between flasher relay and When R134 is left displayed with the relay removed, check that 24V is produced
controller on relay (-) line (C, shown in the upper figure) according to the wiring checking
CN-104F procedure and repair it.
CN-74F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
Judging
The mechatro controller output line to the swing flasher relay is short-circuited with the power source.
condition
Symptom The swing flasher left relay does not work.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Swing flasher relay When the error is cancelled after removing the swing flasher relay, check the
R-19 relay unit for failure, replace it with a new one if failed.
When the resistance between terminals H and D shown in the following figure is
0 Ω, the relay is failed.
2 • Wiring between flasher relay and When R144 is left displayed with the relay removed, check that 24V is produced
controller on relay (-) line according to the wiring checking procedure and repair it.
CN-104F
CN-74F
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-68
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Travel alarm relay When error is cancelled after removing travel alarm relay, check relay unit for
R8 failure, replace it with new one if failed.
When resistance between relays (1) and (2) shown in the following figure is 0 Ω,
relay is failed.
2 • Travel alarm switch Remove connector (CN-521F) and check that if conduction/non-conduction is
SW-13 switched by switch ON/OFF or not. If failure is found, replace it.
3 • Wiring between travel alarm relay, When R154 is left displayed with the relay removed, check that 24V is produced
travel alarm switch, and controller on relay (-) line according to the wiring checking procedure and repair it.
CN-105F,CN2–1 When no failure is found after checking on wiring and R154 is left displayed,
CN-521F replace fuse/relay box.
• Fuse & relay box
E-1
4 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-69
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
condition
Power source for mechatro controller often turns off.
Symptom
Auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Auto idle stop relay 2 When error is cancelled after removing of auto idle stop relay 2, check relay unit
R-24 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) shown in the following figure is 0 Ω,
relay is failed.
2 • Wiring between auto idle stop When R164 is left displayed with the relay removed, check that 24V is produced
relay 2 and controller on relay (-) line according to the wiring checking procedure and repair it.
CN-102F,CN2-1 When no failure is found after checking on wiring and R164 is left displayed,
replace fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-70
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The mechatro controller output line to engine forcible stop is short-circuited with the power source.
condition
When key switch is turned off, engine does not stop.
Symptom
Auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Engine forcible stop relay When error is cancelled after removing of engine forcible stop relay, check relay
R-25 unit for failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the following
figure is 0 Ω, relay is failed.
2 • Wiring between engine forcible When R174 is left displayed with the relay removed, check that 24V is produced
stop relay and controller on relay (-) line according to the wiring checking procedure and repair it.
CN-102F,CN2-1 When no failure is found after checking on wiring and R174 is left displayed,
replace fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-71
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The mechatro controller output line to lever lock relay is short-cricuited with the power source.
condition
Symptom Lever lock timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Lever lock relay When error R184 is cancelled after removing of lever lock relay, check relay unit
R-26 for failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the following
figure is 0 Ω, relay is failed.
2 • Wiring between lever lock relay When R184 is left displayed with the relay removed, check that 24V is produced
and controller on relay (-) line according to the wiring checking procedure and repair it.
CN-102F,CN2-1 When no failure is found after checking on wiring and R184 is left displayed,
replace fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16-72
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
Judging
The mechatro controller output line to safty relay is short-cricuited with the power source.
condition
Symptom Safty relay does not actuate.
Control in the
Relay output is stopped.
event of failure
Return in normal
When the power is OFF
condition
1 • Safty relay When error R214 is cancelled after removing of safty relay, check relay unit for
R-4 failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the following
figure is 0 Ω, relay is failed.
2 • Wiring between safty relay and When R214 is left displayed with the relay removed, check that 24V is produced
controller on relay (-) line according to the wiring checking procedure and repair it.
CN-105F,CN2-1 When no failure is found after checking on wiring and R214 is left displayed,
replace fuse/relay box.
• Fuse & relay box
E-1
3 • Mechatro controller Check that the error is corrected after replacement of the controller.
16
16-73
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[16. TROUBLE SHOOTING(BY ERROR CODES)]
16-74
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[17. TROUBLESHOOTING(BY TROUBLE)]
17
17. TROUBLESHOOTING(BY
TROUBLE)
17.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.............................................................17-3
17.2 HYDRAULIC SYSTEM ..........................................................................................................17-4
17.3 ELECTRIC SYSTEMS......................................................................................................... 17-35
17.3.1 WIRING CHECKING PROCEDURE .................................................................................. 17-35
17.3.2 TROUBLE ....................................................................................................................... 17-37
17-1
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[17. TROUBLESHOOTING(BY TROUBLE)]
17-2
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[17. TROUBLESHOOTING(BY TROUBLE)]
17-3
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[17. TROUBLESHOOTING(BY TROUBLE)]
17-4
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[17. TROUBLESHOOTING(BY TROUBLE)]
5 Pilot pressure • Stop engine and turn on key. Check 5V power of controller
sensor All pilot low pressure sensors are for possible failure.
0MPa to 0.1MPa (0 to 15psi).
6 Solenoid valve for Measure pressure About 0MPa (0psi) by pushing lock lever Replace solenoid valve.
lever lock of A1 port of 8 up, and 4MPa (580psi) or more by
section solenoid pushing it down.
block
7 Pilot line filter Disassemble and Check filter for clogging. Clean filter.
check it visually
8 Pilot gear pump Measure pilot Check that it is 4MPa (580psi) or more at Check gear pump and its relief
primary pressure high idle. valve for possible failure.
at gear pump
9 Multi control valve Switched position Since all are blocked if switching is failed,
(in case that travel check that lever is set to proper select
is operable) pattern position.
10 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD(BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.3: Boom up in full lever
operation & relief.
11 Secondary Measure Check that both P1/P2 unload valve Replace proportional valve.
pressures of P1/P2 proportional valve secondary pressures are from 0.5 to
unload proportional secondary 1.2MPa (73 to 174psi) in boom up full
valves pressures directly lever operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
12 Actually measured Carry out service • No.6 E-1 P1 PUMP In case where command value
current values of diagnosis. E-2 P2 PUMP is largely differed from the
P1/P2 pump actually measured value,
• See Service Diagnosis Data List for
proportional valves check proportional valve and
Operation No.18: Travel right in full
controller for possible failure.
lever operation and travel idling, and
Operation No.19: Travel left in full
lever operation and travel idling.
17-5
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[17. TROUBLESHOOTING(BY TROUBLE)]
14 Main relief Carry out service • See Service Diagnosis Data List for Measure actual relief pressure
pressure diagnosis Operation No.3: Boom up in full lever
operation & relief.
15 Main relief Check set Check that P1/P2 pump pressures are Reset or replace
pressure pressure 32MPa (4640psi) in boom up full lever
operation at high idle and H mode.
16 Pump regulator Visual check When removing pump regulator, it is free Replace
from abnormal resistance against sliding.
External appearance is it is free from
abnormal damage.
Spring is free from breakage, or damage,
etc.
17 Pump body Visual check When removing pump body, inside parts Replace
(cylinder block, piston, valve plate, and
shaft, etc.) are free from abnormal
resistance against sliding, and abnormal
damage, etc.
Engine down/stalle
No. Sections Contents/normal value Corrective action, others
1 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.1: No.operation.
2 Secondary Measure the pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures
pump proportional secondary are from 0.5 to 1.0MPa (73 to 145psi) in
valves pressures directly control lever neutral position at high idle.
(a4 and a5 ports)
3 Pressure sensors Check pressure • See Service Diagnosis Data List for Check pressure sensor and
of P1/P2 pumps values Operation No.1: No operation, and replace it if necessary.
No.3: Boom up in full lever operation
& relief.
4 Pump regulator Visual check When removing pump regulator, it is free Replace
from abnormal resistance against sliding.
External appearance is it is free from
abnormal damage.
Spring is free from breakage.
5 Pump body Visual check When removing pump body, inside parts Replace
(cylinder block, piston, valve plate, and
shaft, etc.) are free from abnormal
resistance against sliding, and abnormal
damage.
17-6
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[17. TROUBLESHOOTING(BY TROUBLE)]
3 Main spool Check target spool Check that spool is free from abnormal Replace
visually damage and spring is free from
breakage.
4 Port relief valve Check target port Check that port relief valve is free from Replace
relief valve visually foreign materials caught in valve.
Seat is free from failure.
5 Lock valve poppet Check target Seat is it is free from abnormal damage. Replace
(for boom, boom 2 poppet visually
and arm)
6 Lock valve selector Exchange lock Check that the phenomenon is reversed. Replace
(for boom, boom 2 valve selector of
and arm) boom with that of
arm, and vice
versa.
7 Holding valve spool Check smooth Check that holding valve spool for boom Replace
for boom sliding of spool in is free from abnormal resistance against Do not pull spool out of sleeve
sleeve sliding. forcibly.
8 Relief valve in Check target relief Check that filter part is free from Replace
holding valve for valve visually abnormal contamination.
boom
9 Cylinder Check target Check that seals, etc. are normal at Replace cylinders or seals.
cylinder visually inspection after disassembly.
17-7
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.1: No operation.
3 Secondary Measure Check that both P1/P2 unload Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures
unload proportional secondary are from 2.7MPa (392psi) or more in
valves pressures directly control lever neutral position at high idle.
at A2 and A8 ports
of 8 section
solenoid block
4 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.1: No operation.
5 Secondary Measure pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures Check regulator.
pump proportional secondary are from 0.5 to 1.0MPa (73 to 145psi) in
valves pressures directly. control lever neutral position at high idle.
(a4 and a5 ports)
6 Slow return check Visual check Check that the slow return check valve Clean and replace
valve of pilot line installed on the pilot line is free from
(for boom up, or foreign materials caught in valve.
arm in or out)
17-8
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure remote control or more in boom up full lever operation at When equipped with multi
pressure of boom high idle. control valve, check it while
up changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.4: Boom up in full lever between P1/P2 pump
P2 pump operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current value of P1/ diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valve proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.3: Boom up in full lever
operaion & relief.
5 Secondary Measure Check that both P1/P2 unload valve Replace proportional valve.
pressures of P1/P2 proportional valve secondary pressures are from 0.5 to
unload proportional secondary 1.2MPa (73 to 174psi) in boom up full
valves pressures directly lever operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
6 Actually measured Carry out service • No.6 E-1 P1 PUMP In case where command value
current values of diagnosis E-2 P2 PUMP is largely differed from actually
P1/P2 pump measured value, check
• See Service Diagnosis Data List for
proportional valves proportional valve and
Operation No.4: Boom up in full lever
controller for possible failure.
operation & in operation.
7 Secondary Measure the pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valves pressures are from
pump proportional secondary 2.1 to 3.0MPa (305 to 435psi) in boom
valves pressures directly up full lever operation at high idle.
(a4 and a5 ports)
8 P2 by-pass cut Visual check Check that sliding ability of main poppet Clean and replace
valve is proper and orifice is not contaminated.
<Trouble> Check that sliding ability of internal
Only P2 pressure is piston is proper.
low.
9 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
10 Lock valve poppet Visual check When removing lock valve, it is free from Replace
<Trouble> abnormal resistance against sliding. (Check casing for damage.)
Both P1/P2 External appearance is free from
pressures are low. abnormal damage.
11 Conflux check Visual check When removing conflux check valve, it is Replace
valve free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
Only P2 pressure is External appearance is free from
high. abnormal damage.
17-9
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
13 Boom spool Visual check When removing boom spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
Only P1 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
14 Boom spool Inspection after Boom spool is free from abnormal Replace spool assembly.
<Trouble> disassembly resistance against sliding.
Only P1 pressure is Spring is free from breakage.
low.
15 Conflux spool Visual check When removing conflux spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
Only P2 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
16 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
17 Port relief valve Visual check Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> (Head side) boom up full lever operation at high idle. boom up is low, replace port
Relief pressure is Free from foreign material caught in port relief valve.
low. relief valve.
Seat is free from abnormality.
17-10
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure remote Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure control pressure of or more in boom down full lever When equipped with multi
boom down operation at high idle. control valve, check it while
directly changing lever pattern.
3 Actually measured Carry out service P1 unload valve In case where command value
current values of diagnosis • See Service Diagnosis Data List for is largely differed from actually
P1 unload Operation No.5: Boom down in full measured value, check
proportional valve lever operation & in operation. proportional valve and
controller for possible failure.
4 Secondary Measure Check that P1 unload valve secondary Replace proportional valve.
pressure of P1 proportional valve pressure is from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in boom down full lever operation
valve pressures directly at high idle.
at the A2 port of 8
section solenoid
block.
5 Actually measured Carry out service • No.6 E-1 P1 PUMP In case where command value
current values of diagnosis is largely differed from actually
• See Service Diagnosis Data List for
P1 pump measured value, check
Operation No.5: Boom down in full
proportional valve proportional valve and
lever operation & in operation.
controller for possible failure.
6 Secondary Measure pump Check that P1 pump proportional valve Replace proportional valve.
pressure of P1 proportional valve secondary pressure is from 2.0 to
pump proportional secondary 2.6MPa (290 to 377psi) in boom down
valve pressures directly full lever operation at high idle.
(a4 port)
7 Actually measured Carry out service Check that value is not changed • Check pressure sensor of
current values of diagnosis regardless of operation. travel
travel straight ] • See Service Diagnosis Data List for • In case where command
proportional valve Operation No.1: No operation, value is largely differed from
Operation No.18: Travel right in full actually measured value,
lever operation & travel idle, and check proportional valve
Operation No.19: Travel left in full and controller for possible
lever operation & travel idle. failure.
8 Travel straight Measure directly Secondary pressure is 0.8MPa (116psi) Replace proportional valve.
proportional valve travel straight or less at high idle regardless of in
secondary proportional valve neutral position / operation.
pressure secondary
pressure.
9 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
10 Lock valve Visual check When removing lock valve poppet, it is Replace
poppet boom 1 free from abnormal resistance against (Check casing for damage.)
and boom 2 sliding.
<Trouble> External appearance is free from
Boom down is abnormal damage.
slow.
17-11
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
13 Boom spool Inspection after Check that boom spool is free from Replace spool assembly
<Trouble> disassembly abnormal resistance against sliding.
Machine can not be Spring is free from breakage.
lifted by supporting
with boom.
14 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
15 Port relief valve Visual check Check that port relief valve is free from Replace
<Trouble> foreign materials caught in valve.
Machine can not be Seat is free from failure.
lifted by supporting
with boom.
16 Boom 3 Visual check Outside surface is free from abnormal Replace proportional valve.
proportional valve damage.
17 Boom 3 spool Visual check When removing boom 3 spool, it is free Replace
from abnormal resistance against sliding. (Check casing for damage)
Outside surface is free from abnormal
damage.
Spring is free from breakage.
18 Boom meter in cut Visual check Outside surface is free from abnormal Replace solenoid
solenoid damage.
19 Boom meter in cut Visual check Outside surface is free from abnormal Replace boom meter in cut
valve damage. valve
17-12
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure remote control or more in arm-in full lever operation at When equipped with multi
pressure of arm in high idle. control valve, check it while
changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.7: Arm-in in full lever between P1/P2 pump
P2 pump operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.6: Arm-in in full lever
operation & relief.
5 Secondary Measure the Check that both P1/P2 unload valve Replace proportional valve.
pressures of P1/P2 proportional valve secondary pressures are from 0.5 to
unload proportional secondary 1.2MPa (73 to 174psi) in arm-in full lever
valves pressures directly operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block.
6 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.7: Arm-in in full lever
operation & in operation.
7 Secondary Measure the pump Check that both P1/P2 pump proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures are 2.0MPa
pump proportional secondary (290psi) or more in arm-in full lever
valves pressures directly. operation at high idle. (Secondary
(a4 and a5 ports) pressure is affected by oil temperature
and attachment weight)
8 Actually measured Carry out service • See Service Diagnosis Data List for In case where command value
current value of diagnosis Operation No.1: No operation, is largely differed from actually
arm in 2-speed Operation No.6: Arm-in in full lever measured value, check
proportional valve operation & relief, and proportional valve and
Operation No.7: Arm-in in full lever controller for possible failure.
operation & in operation.
9 Secondary Measure directly Check that proportional valve secondary Replace proportional valve.
pressure of arm in proportional valve pressure at high idle is within the range of
2-speed secondary following.
proportional valve pressure at A8 Lever neutral: 0MPa (0psi)
port (arm 2-speed) Operation in the air: 1.7 to 2.2MPa (247
of 8 section to 319psi)
solenoid block. Arm in relief: 2.5MPa (363psi) or more
17-13
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
13 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
14 Port relief valve Visual check Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> (Head side) arm-in relief operation. arm in is low, replace valve.
P1/P2 pressures Check that port relief valve is free from
are low. foreign materials caught in valve.
Seat is free from abnormality.
15 Port relief valve Visual check (Rod Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> side) arm-out relief operation. arm out is low, replace valve.
P1/P2pressures Check that port relief valve is free from
are low. foreign materials caught in valve.
Seat is free from abnormality.
16 Arm 1 spool Visual check When removing arm 1 spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P1/P2 pressures External appearance is free from
are high. abnormal damage.
Spring is free from breakage.
17 Arm 2 spool Visual check When removing arm 2 spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P1/P2 pressures External appearance is free from
are high or low. abnormal damage.
Spring is free from breakage.
18 Recirculation check Inspection after Check that check valve is free from Replace spool assembly
valve of arm 2 disassembly. abnormal resistance against sliding.
spool Spring is free from breakage.
<Trouble>
Arm in speed is
slow.
19 Check lock valve Visual check When removing lock valve poppet, it is Replace
poppet free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
Both P1/P2 External appearance is free from
pressures are high. abnormal damage.
17-14
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure remote control or more in arm out full lever operation at When equipped with multi
pressure of arm high idle. control valve, check it while
out changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.9: Arm-out in full lever between P1/P2 pump
P2 pump operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.8: Arm-out in full lever
operation & relief.
5 Secondary Measure Check that P1/P2 unload secondary Replace proportional valve.
pressures of P1/P2 proportional valve pressures are from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in arm out full lever operation
valves pressures directly and high idle.
at A2 and A5 ports
of 8 section
solenoid block
6 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.9: Arm-out in full lever
operation & in operation.
7 Secondary Measure pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures
pump proportional secondary are from 1.7 to 2.9MPa (247 to 421psi) in
valves pressures directly arm out full lever operation at high idle.
(a4 and a5 ports) (Secondary pressure is affected by oil
temperature and attachment weight.)
8 Actually measured Carry out service Check that value is not changed • Check pressure sensor of
current value of diagnosis regardless of operation. travel.
travel straight • See Service Diagnosis Data List for • In case where command
proportional valve Operation No.1: No operation, value is largely differed from
Operation No.18: Travel right in full actually measured value,
lever operation & travel idling, and check proportional valve
Operation No.19: Travel left in full and controller for possible
lever operation & travel idling failure.
9 Secondary Measure directly 0.8MPa (116psi) or less at high idle Replace proportional valve.
pressure of travel proportional valve regardless of in neutral lever position/
straight secondary operation.
proportional valve pressure at A4
port (travel
straight) of 8
section solenoid
block
17-15
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
11 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
12 Port relief valve Visual check (Rod Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> side) arm out relief operation. arm out is low, replace valve.
P1/P2 pressures Free from dust entered in port relief
are low. valve.
Seat is free from failure.
13 Arm 1 spool Visual check When removing arm 1 spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P2 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
14 Arm 2 spool Visual check When removing arm 2 spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P1 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
15 Recirculation check Inspection after Check that check valve is free from Replace spool assembly.
valve of arm 2 disassembly. abnormal resistance against sliding.
spool (spring side) Spring is free from breakage.
<Trouble>
Both P1/P2
pressures are low.
16 Check lock valve Visual check When removing lock valve poppet, it is Replace
poppet free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
Both P1/P2 External appearance is free from
pressures are high. abnormal damage.
17-16
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure remote control or more in bucket digging full lever When equipped with multi
pressure of bucket operation at high idle. control valve, check it while
digging changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.13: Bucket digging in between P1/P2 pump
P2 pump full lever operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.12: Bucket digging in
full lever operaion & relief.
5 Secondary Measure Check that both P1/P2 unload secondary Replace proportional valve.
pressures of P1/P2 proportional valve pressures are from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in bucket digging full lever
valves pressures directly operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
6 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.13: Bucket digging in
full lever operation & in operation.
7 Secondary Measure pump Check that secondary pressure of P1/P2 Replace proportional valve.
pressures of P1/P2 proportional valve pump proportional valve in bucket
pump proportional secondary digging full lever operation at high idle is
valves pressures directly as follows.
(a4 and a5 ports) P1 pump proportional valve: 2.5MPa
(363psi) or more
P2 pump proportional valve: 1.5 to 2.1
Mpa (218 to 305psi)
8 Power boost Carry out service No.3 F-1 POWER BOOST Check harness.
solenoid command diagnosis In bucket digging operation, COMP. Replace solenoid valve.
OFF, and MEAS. OFF.
9 Power boost Measure switching Check that pressure is 0MPa (0psi) in Replace solenoid valve.
solenoid secondary valve secondary bucket digging full lever operation at high
pressure pressure at A3 idle.
port of 3 section
solenoid block
10 Actually measured Carry out service • See Service Diagnosis Data List for In case where command value
current values of diagnosis Operation No.12: Bucket digging in is largely differed from actually
travel straight full lever operation & relief. measured value, check
proportional valve proportional valve and
controller for possible failure.
17-17
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
12 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
13 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
pressure Operation No.3: Boom up in full lever
operation & relief.
14 Bucket spool Visual check When removing bucket spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
Both P1/P2 External appearance is free from
pressures are high. abnormal damage.
Spring is free from breakage.
15 Port relief valve Check target port Check that port relief valve is free from Replace
relief valve visually foreign materials caught in valve.
Seat is free from failure.
17-18
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 3.0MPa Check remote control valve.
pressure remote control (435psi) or more in bucket dump full When equipped with multi
pressure of bucket lever operation at high idle. control valve, check it while
dump changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.15: Bucket dump in full between P1/P2 pump
P2 pump lever operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
4 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.14: Bucket dump in full
lever operation & relief.
5 Secondary Measure Check that both P1/P2 unload secondary Replace proportional valve.
pressures of P1/P2 proportional valve pressures are from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in bucket dump full lever
valves pressures directly operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
6 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves. proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.15: Bucket dump in full
lever operation & in operation.
7 Secondary Measure pump Check that the secondary pressures of Replace proportional valve.
pressures of P1/P2 proportional valve P1/P2 pump proportional valves in
pump proportional secondary bucket dump full lever operation and high
valves pressures directly idle is as follows.
(a3 port) P1 pump proportional valve: 2.7MPa
(392psi) or more
P2 pump proportional valve: 1.0MPa
(145psi) or more
8 Actually measured Carry out service • See Service Diagnosis Data List for In case where command value
current value of diagnosis Operation No.14: Bucket dump in full is largely differed from actually
travel straight lever operation & relief. measured value, check
proportional valve proportional valve and
controller for possible failure.
9 Secondary Measure directly Check that travel straight proportional Replace proportional valve.
pressure of travel proportional valve valve secondary pressure is 2.7MPa
straight secondary (392psi) or more in bucket dump full
proportional valve pressure at A4 lever operation at high idle.
port (travel
straight) of 8
section solenoid
block
17-19
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
12 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
13 Bucket spool Visual check When removing bucket spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
Both P1/P2 External appearance is free from
pressures are high. abnormal damage.
Spring is free from breakage.
14 Port relief valve Check target port Check that port relief valve is free from Replace
relief valve visually foreign materials caught in valve.
Seat is free from failure.
17-20
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressures are 3.0MPa Check remote control valve.
pressures remote control (435psi) or more in boom up full lever When equipped with multi
pressures of left operation at high idle. control valve, check it while
and right swing changing lever pattern.
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor.
brake solenoid diagnosis Swing parking lever neutral: COMP. ON, Check harness.
and MEAS. ON
Swing: COMP. OFF, and MEAS. OFF
4 Swing parking Measure pressure Lever neutral: 0MPa (0psi) Replace solenoid valve.
brake solenoid at A3 port of 8 In operation: 4MPa (580psi) or more
section solenoid
block
5 Pump pressure Carry out service • See Service Diagnosis Data List for Check high pressure sensor.
sensor diagnosis for P2 Operation No.11: Swing in full lever
pump pressures in operation & in operation.
operation
6 Actually measured Carry out service • No.7 D-2 P2 UN-LOAD (BP-CUT) In case where command value
current value of P2 diagnosis is largely differed from actually
• See Service Diagnosis Data List for
unload proportional measured value, check
Operation No.11: Swing in full lever
valve proportional valve and
operation & in operation.
controller for possible failure.
9 Secondary Measure pump Check that P2 pump proportional valve Replace proportional valve.
pressure of P2 proportional valve secondary pressure is 2.7MPa (392psi)
pump proportional secondary or more in swing full lever operation at
valve pressure directly high idle.
(a5 port)
10 Actually measured Carry out service Check that value is not changed • Check pressure sensor of
current value of diagnosis regardless of operation. travel.
travel straight • See Service Diagnosis Data List for • In case where command
proportional valve Operation No.1: No operation, value is largely differed from
(Check this by only Operation No.18: Travel right in full actually measured value,
swing operation) lever operation & travel idling, and check proportional valve
Operation No.19: Travel left in full and controller for possible
lever operation & travel idling. failure.
17-21
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
13 Travel straight Visual check When removing travel straight spool, it is Replace
spool free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
P2 pressure is low. External appearance is free from
abnormal damage.
Spring is free from breakage.
14 Swing spool Visual check When removing swing spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
P2 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
15 Swing relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.10: Swing in full lever
Relief pressure is operation & relief.
low.
16 Swing motor Visual check When removing swing motor, inner parts Replace
(cylinder block, piston, and valve plate,
etc.) are free from abnormal resistance
against sliding.
External appearance (brake disk, etc.) is
free from abnormal damage.
17 Swing reduction Take sample oil Sample oil does not include a lot of metal Disassemble and inspect
unit oil from swing powder. reduction unit.
reduction unit
drain
18 Swing reduction Visual check Tooth surfaces are not worn abnormally Replace
unit and not chipped.
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[17. TROUBLESHOOTING(BY TROUBLE)]
4 By-pass check Visual check When removing by-pass check valve, it is Replace
valve free from abnormal resistance against
(Sound of sliding.
cavitation at Spring is free from breakage.
stopping)
5 Swing motor Visual check Disassemble and inspect swing motor for Replace
(Brake disk/friction abnormal wear and scuffing.
plate)
6 Swing motor piston Visual check When removing swing motor piston, it is Replace
free from abnormal resistance against
sliding.
Spring is free from breakage.
7 Swing reduction Take sample oil Sample oil does not include a lot of metal Disassemble and inspect
unit oil from swing powder. reduction unit.
reduction unit
drain.
8 Swing reduction Visual check Tooth surfaces are not worn abnormally Replace
unit and not chipped.
17-23
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[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check and replace pressure
brake solenoid diagnosis Lever neutral: COMP. ON, and MEAS. sensor.
ON Check harness.
Swing: COMP. OFF, and MEAS. OFF Check parking brake release
switch.
4 Measure pressure Lever neutral: 0MPa (0psi) Replace solenoid valve.
at A3 port of 8 In operation: 4MPa (580psi) or more
section solenoid
block
5 Swing motor Visual check Disassemble and inspect swing motor for Replace
(Brake disk/friction abnormal wear and scuffing
plate)
6 Parking brake Visual check When removing parking brake, piston Replace
and friction plate are free from abnormal
resistance against sliding. Spring is free
from abnormal breakage.
2 Swing relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.10: Swing in full lever
Relief pressure is operation & relief.
low.
3 Anti-reaction valve Visual check Check that anti-reaction valve is free Clean or replace
from foreign materials caught in valve.
Sliding part should be free from foreign
materials caught in there, abnormal
damage, and wear.
4 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
5 Swing motor Visual check When removing swing motor, inner parts Replace
(cylinder block, piston, and valve plate,
etc.) are free from abnormal resistance
against sliding.
External appearance (brake disk, etc.) is
free from abnormal damage.
17-24
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[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure directly Check that pressure is 2.1MPa (305psi) Check remote control valve.
valve remote control or more in travel right (left), forward
pressures of travel (reverse) full lever operation at high idle.
right and left
3 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.18: Travel right in full
lever operation & travel idling, and
Operation No.19: Travel left in full
lever operation & travel idling.
4 Secondary Measure Check that P1/P2 unload proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures in travel
unload proportional secondary idling, travel right (left), and forward
valves pressures directly (reverse) full lever operation at high idle
at A2 and A5 ports are as follows.
of 8 section Travel right (P1 unload): 0.5 to 1.2MPa
solenoid block (73 to 174psi)
Travel left (P2 unload): 0.5 to 1.2MPa
(73 to 174psi)
5 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.18: Travel right in full
lever operation & travel idling, and
Operation No.19: Travel left in full
lever operation & travel idling.
6 Secondary Measure pump Check that P1/P2 pump proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures in travel
pump proportional secondary idling, travel right (left), and forward
valves pressures directly (reverse) full lever operation at high idle
(a4 and a5 ports) are as follows.
Travel right (P1 pump): 2.7MPa (392psi)
or more
Travel left (P2 pump): 2.7MPa (392psi)
or more
7 Actually measured Carry out service Check that value is not changed • Check voltage of low
current value of diagnosis regardless of operation. pressure sensor other than
travel straight • See Service Diagnosis Data List for sensor for travel.
proportional valve Operation No.1: No operation, • In case where command
Operation No.18: Travel right in full value is largely differed from
lever operation & travel idling, and actually measured value,
Operation No.19: Travel left in full check proportional valve
lever operation & travel idling. and controller for possible
failure.
17-25
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[17. TROUBLESHOOTING(BY TROUBLE)]
9 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
Check shuttle valve for sealing ability
and orifice for foreign materials caught in
it.
10 Travel straight Visual check When removing travel straight spool, it is Replace
spool free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
P1 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
11 Travel spool Visual check of When removing travel spool, it is free Replace
<Trouble> target spool from abnormal resistance against sliding. (Check casing for damage.)
Pump pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
12 Travel motor relief Check set Check P1/P2 pump pressures are When P1 pressure or P2 relief
valve pressure 32MPa (4640psi) or more in right and left valve pressure of right travel
travel levers full lever operation (relief motor is low, check and
operation at locked crawler belt) at high replace relief valve of left travel
idle. motor.
13 Travel motor Visual check When removing travel motor, inner parts Replace
(piston, cylinder block, valve plate, and
brake valve spool, etc.) are free from
abnormal resistance against sliding.
External appearance is free from
abnormal damage.
14 Parking brake in Visual check When removing parking brake, it is free Replace
travel motor from abnormal resistance against sliding.
No sticking on friction plate and
separator.
15 Travel reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
unit oil from travel metal powder. reduction unit.
reduction unit
drain
16 Travel reduction Visual check Tooth surfaces are not worn abnormally Replace
unit and not chipped.
17-26
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[17. TROUBLESHOOTING(BY TROUBLE)]
Travel deviation
No. Sections Contents/normal value Corrective action, others
1 Travel right and left Carry out service Check and replace pressure
pressure sensor diagnosis
• See Service Diagnosis Data List for
Operation No.18: Travel right in full sensor. 17
lever operation and travel idling, and Check remote control valve.
Operation No.19: Travel left in full
lever operation and travel idling.
2 Remote control Measure directly Check that pressure in travel idling, Check remote control valve.
valve remote control travel right (left), and forward (reverse)
pressure of travel full lever operation at high idle is 2.1 MPa
right and left (305psi) or more.
3 Actually measured Carry out service Check that value is not changed • Check voltage of low
current value of diagnosis regardless of operation. pressure sensor other than
travel straight • See Service Diagnosis Data List for sensor for travel
proportional valve Operation No.1: No operation, • In case where command
Operation No.18: Travel right in full value is largely differed from
lever operation & travel idling, and actually measured value,
Operation No.19: Travel left in full check proportional valve
lever operation & travel idling. and controller for possible
failure.
4 Secondary Measure directly 0.8MPa (116psi) or less at high idle Replace proportional valve.
pressure of travel travel straight regardless of in neutral lever position/
straight proportional valve operation.
proportional valve secondary
pressure
5 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.18: Travel right in full
lever operation & travel idling, and
Operation No.19: Travel left in full
lever operation & travel idling.
6 Secondary Measure Check that P1/P2 unload proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures in travel
unload proportional secondary idling, travel right (left), and forward
valves pressures directly (reverse) full lever operation at high idle
at A2 and A5 ports are as follows.
of 8 section Travel right (P1 unload): 0.5 to 1.2MPa
solenoid block (73 to 174psi)
Travel left (P2 unload): 0.5 to 1.2MPa
(73 to 174psi)
7 Actually measured Carry out service • No.6 In case where command value
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.18: Travel right in full
lever operation & travel idling, and
Operation No.19: Travel left in full
lever operation & travel idling.
17-27
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[17. TROUBLESHOOTING(BY TROUBLE)]
11 Travel straight Visual check When removing travel straight spool, it is Replace
spool free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
P1 pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
12 Travel spool Visual check of When removing travel spool, it is free Replace
<Trouble> targeted spool from abnormal resistance against sliding. (Check casing for damage.)
Pump pressure is External appearance is free from
high. abnormal damage.
Spring is free from breakage.
13 Travel motor relief Check set Check P1/P2 pump pressures are When P1 pressure or P2 relief
valve pressure 32MPa (4640psi) or more in right and left valve pressure of right travel
travel levers full lever operation (relief motor is low, check and
operation at locked crawler belt) at high replace relief valve of left travel
idle. motor.
14 Travel motor Visual check When removing travel motor, inner parts Replace
(piston, cylinder block, valve plate, and
brake valve spool, etc.) are free from
abnormal resistance against sliding.
External appearance is free from
abnormal damage.
15 Travel reduction Take sample oil Sample oil does not include a lot of metal Disassemble and inspect
unit oil from travel powder. reduction unit.
reduction unit
drain
16 Travel reduction Visual check Tooth surfaces are not worn abnormally Replace
unit and not chipped.
17 Pump regulator Visual check When removing pump regulator, it is free Replace
from abnormal resistance against sliding.
External appearance is free from
abnormal damage.
Spring is free from breakage.
18 Pump body Visual check When removing pump body, inside parts Replace
(cylinder block, piston, valve plate, and
shaft, etc.) are free from abnormal
resistance against sliding, and abnormal
damage.
17-28
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[17. TROUBLESHOOTING(BY TROUBLE)]
4 1/2 speed Visual check Check that orifice is free from foreign Remove dust or replace
switching orifice in materials caught in it.
travel motor
5 Tilting piston in Visual check Check that tilting piston and seal are free Replace
travel motor from abnormal wear. (Check casing for damage.)
2 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
3 Parking brake in Visual check When removing parking brake, it is free Replace
travel motor from abnormal resistance against sliding.
Spring is free from breakage.
4 Orifice of passage Visual check Check that orifice is free from foreign Remove dust or replace
for parking brake in materials caught in it.
travel motor
17-29
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[17. TROUBLESHOOTING(BY TROUBLE)]
Machine does not travel straight in simultaneous operation of traveling left and right and attachment
No. Sections Contents/normal value Corrective action, others
1 Actually measured Carry out service Check that current value in travelling left • Check voltage of low
current values of diagnosis and right and boom up full lever pressure sensor other than
travel straight operation at high idle is as follows. travel sensor.
proportional valve No.7 D-3 S-TRAVEL
• In case where command
COMP. 590 mA and MEAS. 590 mA
value is largely differed
from actually measured
value, check proportional
valve and controller for
possible failure.
2 Secondary Measure travel Check secondary pressure is from 2.0 to Replace proportional valve.
pressure of travel straight 2.4 MPa (290 to 348psi) in travelling left
straight proportional valve and right and boom up full lever
proportional valve secondary operation at high idle.
pressure directly
at A4 port of 8
section solenoid
block
3 Travel straight Visual check When removing travel straight spool, it is Replace
spool free from abnormal resistance against (Check casing for damage.)
sliding.
External appearance is free from
abnormal damage.
Spring is free from breakage.
17-30
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[17. TROUBLESHOOTING(BY TROUBLE)]
2 Remote control Measure remote Check that pressure is 2.1MPa (305psi) Check remote control valve.
pressure control pressure of or more in optional attachment full lever
bucket digging operation at high idle.
directly
3 Actually measured Carry out service • See Service Diagnosis Data List for • In case where command
current values of diagnosis Operation No.16: P2 side option in full value is largely differed from
P1/P2 unload lever operation & relief. actually measured value,
proportional valves check proportional valve
and controller for possible
failure.
4 Secondary Measure Check that both P1/P2 unload Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures
unload proportional secondary are from 0.5 to 1.2MPa (73 to 174psi) in
valves pressures directly optional attachment full lever operation at
at A2 and A5 ports high idle.
of 8 section
solenoid block
5 Actually measured Carry out service • See Service Diagnosis Data List for • Check voltage of low
current value of diagnosis Operation No.16: P2 side option in full pressure sensor other than
travel straight lever operation & relief. sensor for optional
proportional valve attachment.
• In case where command
value is largely differed from
actually measured value,
check proportional valve
and controller for possible
failure.
6 Secondary Measure Check that travel straight proportional Replace proportional valve.
pressure of travel proportional valve valve secondary pressure is 2.7MPa
straight secondary (392psi) or more in optional attachment
proportional valve pressure at A4 full lever operation at high idle.
port (travel
straight) of 8
section solenoid
block
7 P1 by-pass cut Visual check Check main poppet for sliding ability and Clean or replace
valve orifice for contamination.
<Trouble> Check internal piston for sliding ability.
Only P1 pressure is
low at conflux.
8 Relief pressure Check set • See Service Diagnosis Data List for Reset or replace
pressure Operation No.16: P2 side option in full
lever operation & relief.
(Set value of factory shipment is
24.5MPa (3553psi).)
9 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
Check shuttle valve for sealing ability
and orifice for foreign materials caught in
it.
17-31
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[17. TROUBLESHOOTING(BY TROUBLE)]
11 Spool for optional Visual check When removing spool, it is free from Replace
attachment abnormal resistance against sliding. (Check casing for damage.)
<Trouble> External appearance is free from
P1/P2 pressures abnormal damage.
are high. Spring is free from breakage.
12 Port relief valve Check target port Check that port relief valve is free from Replace
relief valve visually foreign materials caught in valve.
Seat is free from failure.
17-32
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[17. TROUBLESHOOTING(BY TROUBLE)]
2 N&B selector Emergency Check that the error indication is Replace solenoid valve
solenoid manual screw disappeared by loosening emergency
manual screw.
3 N&B selector Carry out service • No.9 F-4 OPT SELECT Check and replace solenoid
solenoid diagnosis Breaker mode: valve.
COMP. ON, and MEAS. ON Check harness.
SPOOL POS. BRK
SELECT SWITCH BRK
4 N&B selector Carry out service • No.13 B-11 Check pressure sensor.
pressure sensor diagnosis Breaker mode: 3.0 MPa (435psi) Check harness.
Nibbler mode: 0.0 Mpa (0psi)
2 N&B selector Carry out service • No.9 F-4 OPT SELECT Check solenoid valve.
solenoid diagnosis Nibbler mode: Check harness.
COMP. OFF, and MEAS. OFF
SPOOL POS. NIB
SELECT SWITCH NIB
17-33
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[17. TROUBLESHOOTING(BY TROUBLE)]
Option Selector
Lock Lock
selector valve Failure
Engine lever lever Work Spool Warning
No. valve detection diagnosis
condition SW's relay's mode position display
COMP. pressure display
input output
MEAS. sensor
1 Running ON OFF Nibbler OFF Nibbler Normal - -
"NIBBLER AND
BREAKER
[F041]
SWITCHING
2 Running ON OFF Nibbler ON Breaker Normal displayed
FAILURE PARK
simultaneously
AND REPAIR
MACHINE"
"NIBBLER AND
BREAKER
SWITCHING
3 Running ON OFF Nibbler OFF Breaker Normal -
FAILURE PARK
AND REPAIR
MACHINE"
[F041]
4 Running ON OFF Nibbler ON Nibbler Normal -
displayed
"NIBBLER AND
BREAKER
[F043]
SWITCHING
6 Running ON OFF Breaker OFF Nibbler Normal displayed
FAILURE PARK
simultaneously
AND REPAIR
MACHINE"
"NIBBLER AND
BREAKER
SWITCHING
7 Running ON OFF Breaker ON Nibbler Normal -
FAILURE PARK
AND REPAIR
MACHINE"
[F043]
8 Running ON OFF Breaker OFF Breaker Normal -
displayed
"NIBBLER AND
BREAKER
[B113]
SWITCHING
9 Running ON OFF - - - Failure displayed
FAILURE PARK
simultaneously
AND REPAIR
MACHINE"
10 Stopping - - - - - - - -
11 - OFF - - - - - - -
12 - - ON - - - - - -
17-34
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[17. TROUBLESHOOTING(BY TROUBLE)]
Do not insert the male terminal the thickness differs. It may cause loose connection.
17-35
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[17. TROUBLESHOOTING(BY TROUBLE)]
Since the voltage may vary between with connector connected and with connector not connected. Measure the
voltage with each connector connected whenever possible.
Checking the general view of connector CRIMPED
PART
• Check the terminal crimped condition
Pull one electric cable with the about 3kg force, and
RUBBER
make sure that the cable does not come out of the PLUG
RECEPTACLE.
terminal. CONTACT
When came out, replace the terminal and crimp it PLUG
again. SEALING
(is housed in plug)
• Check connector for imperfect insertion DOUBLE LOCK
Check that all top ends form a line on the same PLATE FOR PLUG
DETAIL aa
17-36
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[17. TROUBLESHOOTING(BY TROUBLE)]
17.3.2 TROUBLE
• Engine does not stop.
• "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
17
• Auto accel does not actuate. (The engine speed does not automatically slow down.)
• Auto accel does not actuate. (The engine speed does not automatically speed up.)
• Wiper does not function.
2 Key ON holding Measure voltage of When starter switch is OFF, voltage is Check key ON holding relay for
relay wire between 62E OFF. possible failure.
wire, which is
between key ON
holding relay and
engine controller, and
machine ground
2 Wiring 770A and 582A wires See "WIRING CHECKING Repair wiring
in transceiver circuit PROCEDURE".
of mechatro controller
and gauge cluster
3 Mechatro controller Check control of Engine speed varies according to Check mechatro controller and
mechatro controller accel potentiometer operation. replace as necessary.
such as acceleration (Perform remote control lever
control operation because auto accel function
can be working.)
17-37
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[17. TROUBLESHOOTING(BY TROUBLE)]
Auto acceleration does not actuate (engine speed does not automatically slow down).
No. Sections Contents/normal value Corrective action, others
1 Gauge cluster Indication of auto Auto acceleration mark appears/ Replace gauge cluster.
acceleration disappears according to operation of
auto acceleration switch on gauge
cluster.
2 Engine coolant Check engine coolant When “No.2 G-5 WATER TEMP” Replace engine coolant
temperature temperature by shows temperature of less than -15 sensor.
carrying out service degrees C (5 degrees F), auto
diagnosis. acceleration does not work. Perform
warming-up operation to raise water
temperature to -15 degrees C (5
degrees F) or more.
3 Low pressure Carry out service When remote control lever operation Check low pressure sensor.
sensor diagnosis is performed, each control pressure of
No.5 and 6 rises and does not fall.
Auto acceleration does not actuat (engine speed does not automatically rise).
No. Sections Contents/normal value Corrective action, others
1 Low pressure Carry out service When control lever is in neutral Check low pressure sensor.
sensor diagnosis position, each control pressure of No.
5 and 6 is from 0 to 0.1 (0 to 15psi)
MPa.
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position
17-38
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[17. TROUBLESHOOTING(BY TROUBLE)]
No. S e ctions Conte nts /norma l va lue Corre ctive a ction, othe rs
1 Fus e Che ck fus e No.20 Re pla ce fus e .
2 S W-19: S e rvice dia gnos is No.14 DI4 Che ck wipe r inte rlock s witch
Wiper interlock switch Wipe r s witch dis pla y (DI4) is OFF with front window clos e d. a nd re pa ir it if ne ce s s a ry. 17
Che ck it a ccording to "WIRING
CHECKING P ROCEDURE" a nd
re pa ir it if ne ce ssa ry.
3 Ris e up limit s witch built- Service diagnosis No.19 Wiper sys te m Che ck a nd re pa ir s witch
in wipe r motor a ccording to "WIRING
Re ve rs e limit s witch CHECKING P ROCEDURE" .
S witch a ction in ope ra tion
Norma l condition
Rise up limit switch
Wiper motor (RIS EUP S W) ON OFF OFF
Re ve rs e limit s witch
Wiper motor (REVERSE SW ) ON ON OFF
Che ck tha t the re la y is worke d a s s hown in the ta ble . Che ck tha t the re la y is e xcite d.
* Whe n the limit s witch doe s not cha nge in OFF a fte r 4 s e conds Che ck re la y & fus e box a nd re pla ce it
from the wipe r s ta rtup, turn OFF a ll re la y's outputs . if ne ce s s a ry.
17-39
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[17. TROUBLESHOOTING(BY TROUBLE)]
17-40
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18. ENGINE
18.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.............................................................18-5
18.2 GENERAL ............................................................................................................................18-6
18
18.2.1 Warning ............................................................................................................................18-6
18.2.2 How to read this manual ...................................................................................................18-7
18.2.3 Precautions for work ...................................................................................................... 18-11
18.2.4 Tightening of engine bolts and nuts ............................................................................... 18-14
18.2.5 Tightening of flare nuts and hoses ................................................................................. 18-16
18.2.6 Taper thread sealant for piping ....................................................................................... 18-17
18.2.7 Assembly of joints and gaskets for piping ...................................................................... 18-18
18.2.8 Handling of liquid gasket ................................................................................................ 18-20
18.2.9 Failure diagnosis table for each problem........................................................................ 18-21
18.2.10 Failure diagnosis procedures ....................................................................................... 18-22
18.2.11 Failure diagnosis using HinoDX.................................................................................... 18-24
18.2.12 Connection method of HinoDX...................................................................................... 18-29
18.2.13 Engine number ............................................................................................................. 18-30
18.3 STANDARD VALUE ............................................................................................................ 18-31
18.3.1 Engine Mounting/Dismounting ....................................................................................... 18-31
18.3.2 Fuel system .................................................................................................................... 18-31
18.3.3 Emission control ............................................................................................................ 18-31
18.3.4 Electrical......................................................................................................................... 18-32
18.3.5 Intake.............................................................................................................................. 18-32
18.3.6 Engine Mechanical ......................................................................................................... 18-33
18.3.7 Exhaust .......................................................................................................................... 18-39
18.3.8 Cooling ........................................................................................................................... 18-40
18.3.9 Lubrication ..................................................................................................................... 18-41
18.3.10 Starting and Charging................................................................................................... 18-43
18.3.11 Turbocharger ................................................................................................................ 18-46
18.4 PARTS TO BE PREPARED ................................................................................................. 18-47
18.4.1 Engine Mounting/Dismounting ....................................................................................... 18-47
18.4.2 Fuel System .................................................................................................................... 18-47
18.4.3 Emission control ............................................................................................................ 18-47
18.4.4 Electrical......................................................................................................................... 18-47
18.4.5 Engine Mechanical ......................................................................................................... 18-48
18.4.6 Exhaust .......................................................................................................................... 18-51
18.4.7 Lubrication ..................................................................................................................... 18-51
18.4.8 Starting and Charging..................................................................................................... 18-52
18.4.9 Turbocharger .................................................................................................................. 18-53
18.4.10 Engine Failure Diagnosis .............................................................................................. 18-54
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18
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[18. ENGINE]
PREFACE
This manual describes the engine unit. Please note that this shop manual uses the service manual of Hino Motors,
Ltd.
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18.2 GENERAL
18.2.1 Warning
Observe the following precautions to work safely and to prevent damage to customers' machine.
This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles
may be impaired. Never use a method or tool not recommended.
• This manual shows "Warning" and "Caution" for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with "Warning" or
"Caution" are not absolute for safety.
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Standard value
1. Standard value, limit, action and tightening torque described in the text are summarized in tables.
Items to be prepared
1. Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list section
of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually equipped in general
service shop are omitted.
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2. Pre-inspection
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Example
ENGINE MECHANICAL [J0 8E] 9–19
S AP H30ZBE0900047
It is the ID number for parts to prepare electronic data. It is not required for repair work.
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Definition of terms
Terms in this manual are defined as follows :
1. Direction (Individual unit)
Front/back direction
The power input side is front and the output side is back.
Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is left
rotation.
Vertical direction
With a unit mounted on the machine main unit, the upward direction is upper and the downward direction is
lower.
Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
2. Standard value⋅⋅⋅⋅⋅⋅⋅Basic dimension excluding tolerance and clearance generated by tolerances when two
parts are joined.
3. Repair limit⋅⋅⋅It is the value requiring repair. Symbol of + or - with the value means increase or decrease to the
standard value.
4. Operation limit⋅⋅⋅It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
5. Warning⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that may result in risk of human life or serious injury by incorrect handling.
6. Caution⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that should not be performed including inhibited work or an item that require
attention in working procedures.
7. Reference⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is supplementary explanation in work.
Unit
1. SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
2. This manual shows both the SI unit and conventional units. The conventional units are shown in { }.
Conversion value*1
Item SI unit Conventional unit
(1[Conventional unit] = X [SI unit])
1kgf/cm2=98.0665kPa
kgf/cm2
Pressure Pa =0.0980665MPa
mmHg 1mmHg=0.133322kPa
r/min 1rpm=1r/min
Rotational speed rpm
min-1 1rpm=1min-1
Volume L cc 1cc=1mL
Efficiency W PS 1PS=0.735499kW
Calorific value W・h cal 1kcal=1.13279W・h
Fuel consumption rate g/W・h g/PS・h 1g/PS・h=1.3596g/kW・h
*1 : X means the value when 1 [Conventional unit] is converted to the SI unit.
It is used as the conversion factor from the conventional unit to the SI unit.
*2 : The conversion value of the torque may vary depending on the unit.
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4. Handling of connector
1) When a connector is removed, hold the
connector (as shown by the arrow in the left) and
pull it out. Do not pull the wire harness.
2) Unlock the locking connector before pulling.
3) Insert the locking connector completely until it
clicks.
4) To insert a test lead into the connector, insert it
from the back of the connector.
5) If it is difficult to insert a test lead from the back of
the connector, prepare a harness for inspection.
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M12 x 1.25 (Fine thread) 108 {1100, 80} 136 {1390, 101}
M14 x 1.5 (Fine thread) 171.5 {1750, 127} 216 {2200, 160}
Remark Bolt with number “7” on the head Bolt with number “9” on the head
M10 x 1.25 (Fine thread) 29 {300, 22} 51 {520, 38} 64 {650, 47}
M10 x 1.5 (Coarse thread) 26 {270, 20} 47 {480, 35} 59 {600, 43}
M12 x 1.25 (Fine thread) 54 {550, 40} 93 {950, 69} 118 {1200, 88}
M12 x 1.75 (Coarse thread) 49 {500, 36} 83 {850, 61} 108 {1100, 80}
M14 x 1.5 (Fine thread) 83 {850, 61} 147 {1500, 108} 186 {1900, 137}
M14 x 2 (Coarse thread) 74 {750, 54} 132 {1350, 98} 172 {1750, 127}
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Precoated bolt
18
Precoated bolt is the bolt with application of seal lock agent at the thread.
Check torque with the lower limit of the tightening torque allowable value. If movement is found, tighten the bolt
according to the procedure below.
• Some engines are tightened with the plastic region tightening method.
• Since it is different from the conventional method, tighten it according to the instruction in the text.
Example
One turn by 90° One turn by 90° Two turn by 90° Tighte n it 90°
Tighte n it 45° (Second time)
One turn by 45° (Second time)
Tighte n it 90°
Tighte n it 90° Tighte n it 90°
(First time) (First time)
1. Parts tightened
Cylinder head bolt, crankshaft main bearing cap bolt, connecting rod bearing cap bolt, etc.
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Measure the overall length of the bolt before assembly and replace the bolt if the length exceeds the operation limit.
Apply engine oil to bolt seating and bolt thread in assembly.
Pipe outer
ø4.76 ø6.35 ø8 ø10 ø12 ø15
diameter
15±5 21±1 32±3 44±5 64±5 66±2.5
Tightening
{153±50, 11 {214±10, 15 {326±31, 24 {449±51, 32 {653±51, 47 {673±25, 47
torque
±3.6} ±0.7} ±2.2} ±3.6} ±3.6} ±1.8}
Packing
Brake hose 46±2.5 {469±25, 33±1.8} —
51.5±7.5 {525±75, 15±1}
Screw nominal
M14 M16 M20 M22 M24
size
Tightening 48±10 66±13 120±36 130±30 150±30
torque {489±102, 35±7} {673±204, 47±14} {1224±367, 89±26} {1326±306, 96±22} {1530±306, 110±22}
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The taper thread of the air pipe joint has application of sealant [Loctite # 575 (by Japan Loctite)]. Follow the
procedures below for connection or disconnection of pipes.
If your eye or skin comes in contact with sealant, wash it off immediately with water.
Screw diameter
Material
1/4 3/8 1/2
49±10 64±15
Steel
{500±100, 36±7} {650±150, 47±10}
2) When a sealing tape is replaced with sealant, remove the tape completely first as in (1).
3) If air leak is found after assembly with application of sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and (2).
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Sealing method
M8 13 {130, 9}
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Sealing surface
: 4 places
18
Gasket Flare connector
One piece eye joint Gasket
with sleeve Gasket Sealing surface
: 5 places Sealing surface: 5 places
Gasket
Nut
Joint bolt Lock washer Bracket
Nut
Sealing surface
: 8 places
Connector nipple
Bracket
Sealing surface
: 3 places
Joint bolt
Joint bolt
Joint pipe
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For a tube, desired application width may be obtained from the cut position at the nozzle end.
Nozzle of tube
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S ta tu s Ca u s e Ac tio n
En g in e ove rh e a t (c o o la n t) Ins ufficie nt coola nt Re ple nis h coola nt
Fa ulty the rmos ta t Re pla ce the rmos ta t
Wa te r le a k from cooling s ys te m Corre ction
Fa ulty coola nt pump Re pa ir or re pla ce
En g in e ove rh e a t
Fa ulty he a d ga s ke t
Clogging of ra dia tor
Re pla ce he a d ga s ke t
Cle a ning of ra dia tor
18
(ra d ia to r) Corros ion of cooling s ys te m Cle a n a nd re pa ir cooling s ys te m
Clogging of ra dia tor core front pa rt Cle a n ra dia tor
Fa ulty ra dia tor ca p Re pla ce ra dia tor ca p
En g in e o ve rh e a t Non-s ynchronous inje ction timing Adjus t inje ction timing.
(c o m p re s s io n p re s s u re ) Fa ulty fue l inje ction pre s s ure Adjus t inje ction pre s s ure
Fa ulty fue l Re pla ce with corre ct fue l
Fa ulty inje ctor Re pla ce inje ctor
En g in e o ve rh e a t De te riora tion of e ngine oil Re pla ce e ngine oil
(lu b ric a tio n u n it) Fa ulty oil pump Re pla ce oil pump
Ins ufficie nt e ngine oil Re ple nis h e ngine oil
La rg e e n g in e o il c o n s u m p tio n We a r of pis ton ring a nd cylinde r Re pla ce pis ton ring a nd cylinde r
(p is to n , c ylin d e r lin e r a n d p is to n line r line r
rin g ) Da ma ge to pis ton ring Re pla ce pis ton ring a nd cylinde r
line r
Fa ulty fixing of pis ton ring Re pla ce pis ton ring a nd cylinde r
line r
Fa ulty a s s e mbly of pis ton ring Re pla ce pis ton ring a nd cylinde r
line r
Fa ulty e ngine oil Re pla ce e ngine oil
Fa ulty pis ton ring joint Re a s s e mble pis ton ring
La rg e e n g in e o il c o n s u m p tio n We a r of va lve s te m Re pla ce va lve a nd va lve guide
(va lve a n d va lve g u id e ) We a r of vavle guide Re pla ce va lve guide
Fa ulty a s s e mbly of va lve s te m s e a l Re pla ce s te m s e a l
Exce s s ive oil lubrica tion to rocke r Ins pe ction of cle a ra nce be twe e n
a rm rocke r a rm a nd rocke r a rm s ha ft
La rg e e n g in e o il c o n s u m p tio n Fa ulty oil leve l ga uge Re pla ce with corre ct leve l ga uge
(o th e rs ) Exce s s ive filling of e ngine oil Fill with a ppropria te a mount of oil.
Le a k of e ngine oil Re pa ir or re pla ce the pa rt of oil
le a k.
P is to n s e izu re (in o p e ra tio n ) S udde n s top of e ngine Pe rform wa rm-up be fore s top of
e ngine
P is to n s e izu re (lu b ric a tio n u n it) Ins ufficie nt e ngine oil Re ple nis h e ngine oil
De te riora tion of e ngine oil Re pla ce e ngine oil
Incorre ct e ngine oil Re pla ce with corre ct e ngine oil.
Low oil pre s s ure Ins pe ction of lubrica tion unit
Fa ulty oil pump Re pla ce oil pump
P is to n s e izu re Abnorma l combus tion Re fe r to ove rhe a t s e ction.
P is to n s e izu re Cooling unit Re fe r to ove rhe a t s e ction.
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Multiple display
The information will be also cleared on past failures stored in the DCU.
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2. Re move the ECU s ide conne ctor of the s igna l che ck ha rne s s
a nd me a us re the re s is ta nce be twe e n te rmina l B6 a nd te rmina l 18
B7. Details of work
S ta n d a rd va lu e : Ap p rox. 125.5 17 (20 d C)
OK
1. Conne ct the ECU s ide conne ctor of the s igna l che ck ha rne s s.
Afte r de le ting the pa s t fa ilure, output the dia gnos is code a ga in.
S ta n d a rd : No rm a l
S AP H03Z010300011
OK
Norma l
NG Fa ilure of ma in e ngine s pe e d s e ns or
OK
Check the harness of the relevant circuit and repair the faulty area.
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HinoDX is used for inspection and adjustment of the system in addition to failure diagnosis.
Hino-DX
1. With HinoDX, failure of the common rail fuel
injection system can be diagnosed. The interface
box (Hino-Bowie or DST-i) and the special cable are
required for connection to the unit.
Hino Diagnostic
eXplorer — Install the software included in the
(Hino-DX) Hino Diagnostic eXplorer (Hino-DX)
into the computer. For the installation
method, refer to the instruction manual
included with the CD.
• Computer interface
09993 - E9070
Hino-Bowie
*1 • The cable between the personal
computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or USB.
Cable bundled
to the Hino-Bowie
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Part name Part No. External shape General description and function
*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the user’s manual in the
HinoDX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HinoDX CD-ROM. For details, refer to
the user’s manual in the HinoDX CD-ROM.
*2: HinoDX (Ver. 3.0.5 or later), only when use DST-i.
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DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
7
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i — — — — — —
1.0.9 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN OK OK OK OK OK OK
Bowie w/o CAN OK OK — — — —
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
XP
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
DST-i OK OK — — — —
1.0.9 Bowie w/ CAN OK OK — — — —
Bowie w/o CAN OK OK — — — —
18-26
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Engine ECU
18
Engine Machine
harness harness
Te s t le a d
2) Connect the signal check harness to the engine harness, machine harness and engine ECU.
Part No.
09843-E4050
Signal check harness (for engine control system)
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3) Terminal No.
For the signal check harness connector, the ECU terminal number in the text is treated as follows :
Engine ECU
Engine Machine
harness harness
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18
2. Connection of HinoDX
1) Connect the engine failure diagnosis connector to the PC which installed Hino-DX through the interface box
(HIino-Bowie or DST-i).
Special tool : 09993-E9070 Hino-Bowie (Interface box)
S0904-21220 (09042-1220)
Connecting cable
CD-ROM HinoDX
95171-010*0 DST-i set
CD-ROM Hino-DX
2) Set the starter key to "ON" and start HinoDX. Failure diagnosis connector
Interface box
(Hino-Bowie
or DST -i)
Connecting cable
Connect to the failure diagnosis
connector at the unit side.
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Stamp positio n
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18.3.4 Electrical
Standard value
Tightening torque
18.3.5 Intake
Tightening torque
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[18. ENGINE]
Unit : mm {in.}
IN 0.30 {0.0118} —
Valve clearance (cold)
EX 0.45 {0.0177} —
0.01-0.08
Cylinder liner protrusion —
{0.0004-0.0031}
18
Cylinder liner inner diameter 112 {4.4094} — Replace
0.053-0.077
Piston clearance — Replace
{0.0020-0.0030}
0.30-0.40
Top 1.5 {0.0591}
{0.0118-0.0157}
Top Taper —
0.035-0.056
Connecting rod bushing oil clearance 0.08 {0.0031} Replace
{0.0014-0.0022}
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[18. ENGINE]
0.031-0.082
Crank pin oil clearance 0.2 {0.0079} Replace*2
{0.0012-0.0032}
Repair limit
0.500 {0.0197}
Crankshaft end play 0.050 {0.0020} Replace
Service limit
1.270 {0.050}
0.20-0.52
Connecting rod end play 1.0 {0.03937} Replace
{0.0079-0.0204}
0.100-0.178
Camshaft end play — Replace
{0.0039-0.0070}
0.030-0.101
Rocker arm oil clearance 0.15 {0.0059} Replace
{0.0012-0.0040}
IN 7 {0.2755} —
Valve stem outer diameter Replace
EX 7 {0.2755} —
IN 7 {0.2755} —
Valve guide inner diameter Replace
EX 7 {0.2755} —
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[18. ENGINE]
0.55-0.85
IN 1.1 {0.0433}
{0.0217-0.0334}
Valve sink Replace
1.15-1.45
EX 1.7 {0.0669}
{0.0453-0.0571}
IN 30° 30°-30°35'
18
Valve seat angle
EX 45° 45°-45°30'
Replace
IN 30° 29°30'-30°
Valve face angle
EX 45° 44°30'-45°
Valve spring seat thickness — — Refer to the text.
Set length 44.8 {1.7638} —
128.5N 118.2N
Set load Replace
Inner {13.1kgf, 28.8 lbf} {12kgf, 26.5 lbf}
313.8N 288.7N
Set load Replace
Outer {32kgf, 70.5 lbf} {29.4kgf, 64.9 lbf}
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0.114-0.160
End play 0.30 {0.0118} Replace
{0.0045-0.0062}
0.040-0.120
End play 0.30 {0.0118} Replace
{0.0016-0.0047}
0.040-0.120
End play 0.30 {0.0118} Replace
{0.0016-0.0047}
0.016-0.22
End play —
{0.0007-0.0086}
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[18. ENGINE]
Repair limit
Surface runout of flywheel — Grind
0.15 {0.0059}
Main bearing cap bolt length 106.8 {4.2047} 108.0 {4.2520} Replace 18
Connecting rod bolt length 67.0 {2.6378} 68.0 {2.6772} Replace
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[18. ENGINE]
Tightening torque
36 {370, 27} M8
Flywheel housing stay - Flywheel housing 171.5 {1750, 127} M14
Rear end plate torx bolt 55 {560, 41}
18-38
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[18. ENGINE]
18.3.7 Exhaust
Tightening torque
DPR differential pressure sensor braket mounting nut 52±5.2 {530±53, 38±3.8}
18-39
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[18. ENGINE]
18.3.8 Cooling
Standard value
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[18. ENGINE]
18.3.9 Lubrication
Standard value
Unit : mm {in.}
54
Outer diameter of drive gear —
{2.1260} 18
Cylinder block side 54
—
Oil pump chamber inner diameter {2.1260}
28.5
Drive gear width —
{1.1220}
0.047-0.150
Drive gear end play 0.15 {0.0059} Replace oil pump
{0.0019-0.0059}
18
Outer diameter drive gear shaft —
{0.7087}
18
Inner diameter of cylinder block bushing —
{0.7087}
Oil Clearance between drive gear shaft outer
pump 0.040-0.099 Replace oil pump
diameter and bushing inner diameter at —
{0.0015-0.0038} or bushing
cylinder block side
18
Outer diameter of driven gear shaft —
{0.7087}
18
Cylinder block hole diameter —
{0.7087}
18
Outer diameter of driven gear shaft —
{0.7087}
18
Inner diameter of driven gear bushing —
{0.7087}
18-41
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Tightening torque
24.5±4.9
M14
{250±50, 18±3.6}
24.5±4.9
M20
{250±50, 18±3.6}
Oil circuit spring plug
29.4±4.9
Oil cooler M22
{300±50, 22±3.6}
34.3±4.9
M24
{350±50, 25±3.6}
44.1±4.9
Coolant drain plug
{450±50, 33±3.6}
18-42
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Unit : mm {in.}
Replace shaft
Metal bushing inner diameter of shaft assembly 9 {0.3543} 9.2 {0.3622}
assembly
18-43
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-44
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Unit : mm {in.}
Ball bearing
25mm {0.9843in.} 24.98mm {0.9835in.}
insertion area
Shaft outer diameter of rotor assembly Replace
Roller bearing
17mm {0.6693in.} 16.98mm {0.6685in.}
insertion area
Forward
Approx. 10Ω —
Resistance between diode and resistance value
Replace
rectifier holder Reverse
Infinite —
resistance value
Forward
Approx. 10Ω —
Resistance between regulator resistance value
Replace
terminals F - E Reverse
Infinite —
resistance value
B-E Approx. 20Ω —
Adjust
Resistance between terminals E-B Infinite —
B - E and P - E P-E Approx. 7Ω —
Adjust
E-P Infinite —
18-45
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[18. ENGINE]
127-157
Pulley mounting nut
{1300-1600, 94-115}
3.9-4.9
Field coil - End frame
{40-50, 2.9-3.5}
1.9-2.5
Rectifier mounting bolt
{20-25, 1.5-1.8}
1.6-2.3
For regulator fix
{16-23, 1.2-1.6}
Regulator 1.0-1.4
For coil lead
mounting bolt {10-14, 0.8-1.0}
1.0-1.4
For heat sink
{10-14, 0.8-1.0}
4.9-5.9
B terminal mounting nut (Inside)
{50-60, 3.7-4.3}
7.8-9.8
Driver end frame - End frame
{80-100, 5.8-7.2}
3.3-4.4
Cover mounting bolt
{34-44, 2.5-3.1}
18.3.11 Turbocharger
Standard value
Unit : mm {in.}
Tightening torque
18-46
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S0949-11010
Wire rope For engine lifting
(09491-1010)
18
S0955-21030 Compression gauge
(09552-1030) adapter (3/4-16 UNF)
Adjusting to screw size of air
gauge, the adapter which it
S0955-21060 Compression gauge selects
(09552-1060) adapter (W16 ridges 18)
18.4.4 Electrical
Special tool
Shape Part No. Name Remark
S0944-41210
Compression gauge For V-belt tension adjustment
(09444-1210)
18-47
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[18. ENGINE]
S0947-11520
Guide For valve guide press-fit
(09471-1520)
S0947-21210
Bar For nozzle seat clamping
(09472-1210)
S0943-11020
Valve lapping tool For valve adjustment
(09431-1020)
S0947-22100
Bar For valve stem seal mounting
(09472-2100)
18-48
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
For assembly/disassembly of
S0940-21530
Press sub-assembly connecting rod small end
(09402-1530)
bushing
For assembly/disassembly of
connecting rod small end
SL271-01036
Wing nut bushing (together with S0940-
(9233-10360)
21530
(09402-1530))
For assembly/disassembly of
connecting rod small end
S0948-11130
Guide bushing (together with S0940-
(09481-1130)
21530
(09402-1530))
For assembly/disassembly of
S0940-21540
Spindle connecting rod small end
(09402-1540)
bushing
S0944-11370
Piston ring holder For piston mounting
(09441-1370)
18-49
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[18. ENGINE]
S0947-11490
Guide For insertion of cylinder liner
(09471-1490)
Gauge
Name Remark
Micrometer For measurement of part outer diameter
18-50
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[18. ENGINE]
Lubricant, etc.
Name Remark
Liquid gasket
For sealing of parts
(Threebond TB1207B or equivalent : Black)
Liquid gasket
For sealing of parts
(Threebond TB1207D or equivalent : Silver)
Liquid gasket
For sealing of parts
(Threebond TB1211 or equivalent : White)
18.4.6 Exhaust
Lubricant, etc.
Name Remark
Anti-seize
(NEVER-SEEZ Nickel Special Grade, BOSTIC FINDLEY For installing DPR exhaust temperature sensor
(U.S.A.))
AbBlue/DEF analyzer
Refractometor
18.4.7 Lubrication
Special tool
Shape Part No. Name Remark
S0950-31110
Oil filter wrench
(09503-1110)
Lubricant, etc.
Name Remark
Liquid gasket
• Threebond TB1207B (Black) or equivalent
• Threebond TB1207D (Silver) or equivalent For sealing of parts
• Threebond TB1211 (White) or equivalent
• Threebond TB1217G (Gray) or equivalent
18-51
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[18. ENGINE]
Jig A (Rolle r be a ring ins e rtion jig) Jig B (Support jig) Unit : mm{in.}
23{20.827} 25{0.984}
1C{0.039}
35{1.378}
50{1.964}
70{2.756}
50{1.964}
1C{0.039}
10 - 20 50{1.969}
+0.5{0.0196} {0.394 - 0.787}
19{0.748}
0
30{1.181}
Jig C Jig D
34{1.339} 41{1.614}
20{0.787} 20{0.787}
40{1.575} 40{1.575}
10{0.394} 10{0.394}
54{2.126} 64{2.520}
60{2.362} 70{2.756}
18-52
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[18. ENGINE]
Gauge
Starter
Name Remark
Circuit tester For measurement of parts
Alternator
18
Name Remark
Circuit tester For measurement of parts
Regulator checker
For inspection of regulator
(G&M Machinery ICD-101D or equivalent)
Lubricant, etc.
Starter
Name Remark
Kyodo Yushi Multemp AC-N For lubrication of parts
Alternator
Name Remark
Soldering bit
For lead wire
Solder suction device
Screw lock (Threebond TB1344) For regulator mounting
18.4.9 Turbocharger
Special tool
Shape Part No. Name Remark
S0944-41800
Tool assembly
(09444-1800)
18-53
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Hino Diagnostic
eXplorer — Install the software included in the
(Hino-DX) Hino Diagnostic eXplorer (Hino-DX)
into the computer. For the installation
method, refer to the instruction manual
included with the CD.
• Computer interface
09993-E9070
Hino-Bowie
*1 • The cable between the personal
computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or USB.
Cable bundled
to the Hino-Bowie
18-54
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Part name Part No. External shape General description and function
Interrupting installation between unit side harness and DCU allows inspection
Signal check harness 09843-E9030
with a tester rod while the power is supplied.
18
09843-E9030
*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the user’s manual in the
HinoDX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HinoDX CD-ROM. For details, refer to
the user’s manual in the HinoDX CD-ROM.
*2: HinoDX (Ver. 3.0.5 or later), only when use DST-i.
18-55
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[18. ENGINE]
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
7
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i — — — — — —
1.0.9 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN OK OK OK OK OK OK
Bowie w/o CAN OK OK — — — —
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
XP
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
DST-i OK OK — — — —
1.0.9 Bowie w/ CAN OK OK — — — —
Bowie w/o CAN OK OK — — — —
18-56
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Measure the compression pressure before disassembly of the engine and record the result. Regular measurement
of the compression pressure can tell the engine status.
18
1. Preparation before measurement
1) Charge the battery completely.
2) Check the valve clearance and adjust it when exceeding the standard value.
3) Warm the engine and set the water temperature to 80°C{176°F}.
4) Remove the air cleaner.
5) Remove the head cover.
6) Remove all injectors.
7) To prevent spread of engine oil, attach a jig which cuts a head cover in half.
(Cut it so that the camshaft may be covered.)
2. Measurement
1) Attach a special tool to the nozzle sheet of the
cylinder where the compression pressure is
measured with nozzle clamp and clamp fixing
bolts.
Special
tool
Engine
S0955-21110
Insert in the injector mounting area
(09552-1110)
S0955-21030
(09552-1030)
(3/4-16 UNF) Adjusting to screw size of air gauge,
S0955-21060 the adapter which it selects
(09552-1060)
(W16 ridges 18)
18-57
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Compression pressure
Inspection item
Unit: MPa {kgf/cm2, lbf/in2}
4) If the compression pressure is the service limit or less or if the difference between cylinders is over the
standard value, overhaul the engine.
5) After measurement, reassemble the removed parts.
18-58
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[18. ENGINE]
2) Drain engine oil from the oil pan drain cock as required.
Cylinder head
Cover
Close the opening of the intake manifold with a packing tape to prevent entry of dirt inside the engine.
18-59
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[18. ENGINE]
18-60
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Work carefully so that the engine may not come in contact with the frame and others.
18
18-61
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18.5.2.2 Installation
1. Connection of fuel hose
1) Insert a fuel hose and fix it with a hose band.
Filler cap
Oil quality
JASO DH-2
API CJ-4
ACEA E-6, E-9
HINO recommends these oil to the Tier 4 regulation countries, and use ultralow sulfur fuel only.
Viscosity recommendations (SAE)
-40 -22 -4 14 32 50 66 88 104 °F
-40 -30 -20 -10 0 10 20 30 40 °C
SAE 5W-3 0
SAE 10W-3 0
SAE 15W-4 0
In order to maintain a trouble-free functioning of the DPR (exhaust gas after treatment system) for a long time, it is
recommended to use the specified (recommended) brand of engine oil.
2. Air bleeding of the fuel system Please use the machine side priming pump.
1) Loosen the air bleeding bolt of fuel filter, move
the priming pump to discharge the air from the
fuel system.
• Fuel filter (Type with water cup, but without harness)
Refer to the “Fuel filter (Type with water cup, but
without harness), Water draining“
Do not use this priming pump.
18-62
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Positive pressure
Negative pressure
Injector Return
Common rail 18
Supply pump
Suction
Feed pump
control valve
Engine mount
fuel filter
Engine side
Chassis side
Priming pump
Machine mount
fuel filter
Fuel filter
Fuel filter
18-63
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Tightening torque
A 63.7N・m{650kgf・cm} D 28.5N・m{290kgf・cm}
B 44.1N・m{450kgf・cm} E 28.5N・m{290kgf・cm}
C 28.5N・m{290kgf・cm} F 25N・m{250kgf・cm}
18-64
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
Tightening torque
A 44N・m{450kgf・cm}
18-65
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18.6.2 Fuel filter element (With water cup without harness, machine mount)
18.6.2.1 Parts layout
The maintenance method differs according to the fuel filter type. Carefully check the type, then perform the
maintenance work.
Type-1
Tightening torque
18-66
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[18. ENGINE]
Type-2
2
18
3 Water cup
18-67
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[18. ENGINE]
• As air enters into the fuel piping during the work, air bleeding must be performed after completion of the work.
• Take care that no dirt or water gets into the system during the work.
• Always use the machine side priming pump for air bleeding and water draining.
Since discharged water contains fuel, observe the local disposal procedure for disposal.
18-68
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
• Make sure that the fuel filter air bleeding bolt has been loosened.
• The air bleeding bolt has as a slit (groove) as shown in the figure. As air will bleed out even when the bolt is not
removed completely, perform priming work with the bolt loosened to an intermediate position in order to prevent
the entry of foreign matter to the fuel system.
After work, wipe off spilled water or fuel. After start of the engine, make sure that there is no fuel leak.
18-69
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
• The frequency for water draining and replacement of the fuel filter element differs according to the fuel situation
in the use region.
Replace the fuel filter element every 500 hours or when the engine output decreases, whichever occurs first.
• Inspection of the fuel filter element and draining of water should be performed before each start of operation.
• Always use HINO genuine parts filter element.
• Complete the work for removal and installation quickly to prevent entry of foreign matter to the fuel system.
• Take care that no dirt or water get into the system during the work.
• As air enters into the fuel piping during the work, air bleeding must be performed after completion of the work.
• Before assembly, make sure that there is no dirt the seating surface of the parts.
• Always do air bleeding after replacing an element.
• Completely remove any dust around the fuel filter head and especially around the air vent bolt.
• Since the filter contains diesel oil, prepare a tray.
1) The soiling and the foreign material of the clamp face are removed.
2) Install the fuel filter element to the fuel filter head and turn the element 7/8 of a turn after the gasket comes
into contact with the fuel filter head.
18-70
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[18. ENGINE]
Gasket
18
Element
7/8 turns
after the gasket comes
into contact.
3) Install the water cup to the fuel filter element and turn the cup 3/4 of a turn after the gasket comes into
contact with the fuel filter element.
Element
3/4 turns
after the gasket comes
into contact. Gasket
Water cup
18-71
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[18. ENGINE]
O-ring
Case
Element
Drain plug
18-72
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[18. ENGINE]
Water draining and air bleeding from the fuel filter case
1. Precautions
• As air enters into the fuel piping during the work, air bleeding must be performed after completion of the work.
• Take care that no dirt or water gets into the system during the work. 18
• Always use the machine side priming pump for air bleeding and water draining.
1) When you air bleeding and water draining, Please use the machine side priming pump.
always use the machine side priming pump.
Refer to the "Fuel filter (with water cup, without
harness, machine mount), Water draining"
2. Fuel discharging
1) Prepare a container under the drain pipe of the
machine side fuel filter.
Air bleeding bolt
2) Loosen the drain valve next loosen the air
bleeding valve at the machine side fuel filter.
Discharge fuel from the drain valve.
Confirm that fuel has stopped coming out from
the drain valve and tighten the drain valve.
Drain plug
18-73
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
• To dispose fuel, observe the specified method (waste disposal) or the method with attention to environment.
• Make sure that the drain plug is not damage or corrosion.
• When draining the fuel, drain all fuel from inside the filter. When the element is replaced without draining all fuel,
there is the possibility that unfiltered fuel remains in the filter and flows to the engine side.
• Prepare a container for catching dripped fuel from the filter that the fuel remains in the case.
When the element is replaced without draining all fuel from the fuel filter case, unfiltered fuel remains in the fuel
filter case; make sure that the filter case does not contain any remaining fuel.
4) Applying fuel to a new O-ring and install them to the fuel filter case groove.
18-74
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
5) Align the match mark and set the cap to the fuel Cap Center bolt
filter case and tighten the center bolt.
Tightening torque:
28±4.9 N・m {286±50 kgf・cm, 21±3.6 lbf・ft}
18
• Be careful to prevent twisted damage of the O-ring.
• Make sure the O-ring is fitted to the clamp face.
• Match the match mark of the fuel filter cap at the fuel filter case.
18-75
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-76
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18.6.4.2 Replacement
Take care that no dirt or water gets into the system during the work.
Always use the machine side priming pump for air bleeding and water draining.
Fuel temperature
sensor
18-77
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Prepare a reservoir and a waste cloth because fuel spills when removing the pressure feed pipe.
Flywheel housing
cover
2) Turn the clankshaft counter clockwise in the
engine direction (counter clockwise rotation as
seen from the flywheel side) and align the No.1 Flywheel
cylinder mark to the pointer in the flywheel
housing inspection opening.
1
Flywheel housing
Close
contact
With
gap
Remove
Contact surface
4) Mount the special tool in the hole from which the oil pipe connector of the bearing holder case was removed.
Make sure the base of the pin closely contacts the supply pump.
Special tool : S0904-81040 Guide pin
18-78
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
• If the special tool is not seated, it will contact parts other than the coupling flange stopper key; therefore, do not
push too hard.
• If the special tool is not touch the flange, No.1 cylinder is not setting to the Compression Top Dead Center.
Remove the special tool, and rotate the engine and then check again.
• When you rotate the crankshaft, always remove the special tool.
• Do not rotate the crankshaft with the special tool inserted.
18
7. Removal of the supply pump
Pipe??
• Take care that no dirt or water get into the system during the work.
• Do not remove pipes A.
• Do not apply any force to pipes of the supply pump.
• Example: Do not carry the supply pump by holding the pipe. (Twist of the pipe may cause fuel leakage.)
2) Remove the supply pump from the bearing holder case portion.
3) Remove the drive gear using the special tool.
Special tool : S0965-01101 (09650-1101) Bearing puller
18-79
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fuel temperature
sensor
Standard value
7.65-8.15Ω
(at 20°C {68°F})
• Take care that no dirt or water get into the system during the work.
• Before assembly, make sure that there is no dirt on the seating surface of the parts.
• Always do air bleeding after replacing an element.
18-80
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Bearing holder
case
2) Fix the supply pump and install the injection Injection pump drive gear
pump drive gear to the shaft. Tighten nuts while
fixing with a vice to prevent turning.
Tightening torque: Nut
63 N・m {650 kgf・cm, 47 lbf・ft}
Do not use the guide pin for stopper key of the shaft.
18-81
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
• Engage the gears not to change the setting of the compression stroke top dead center of no.1 cylinder.
• When you rotate the crankshaft, always remove the special tool.
Remove
Contact surface
• After all parts are assembled, do not fail to remove the special tool and mount the oil pipe connector.
• Before turning the crankshaft, do not fail to pull out the special tool.
• Do not perform cranking with the special tool inserted.
• Do not reuse the gasket of the oil pipe removed.
Flywheel housing
cover
18-82
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
Always replace the pressure feed pipe by a new one because the pipe is subjected to high pressure; reusing the
same pipe may result in a fuel leak.
2) Mount the clips (2 pcs.) with the nuts (2 pcs.) and fix the pressure feed pipe.
6. Connecting the harness
Suction control
1) Connect the connector to the fuel temperature
valve
sensor and suction control valve of the supply
pump.
Fuel temperature
sensor
Before connecting the connectors, make sure that the terminals are free of a spark mark.
18-83
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[18. ENGINE]
It is necessary to reset the ECU default value using the diagnosis tool at the time of supply pump service
replacement.
ECU has a function enabling it to learn the performance of the supply pump at the time of ECU service
replacement, so ensure sufficient time (several minutes) is available.
ECU default value can be reset by "Supply pump specification learning" in the "Check function" menu of the
diagnosis tool.
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[18. ENGINE]
18.6.5 Injector
18.6.5.1 Parts layout
18
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[18. ENGINE]
18.6.5.2 Replacement
1. Precautions
Take care that no dirt or water gets into the system during the work.
Leakage
pipe
Part of connector
Injector Cylinder
harness head
Removal becomes easier when the connector part of the camshaft housing is disconnected last.
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[18. ENGINE]
Injector clamp
18-87
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[18. ENGINE]
Unit inspection
1. Resistance check Megger tester
1) Measure the resistance between the one side
injector terminal (No polarity) and upper body of
the injector using 1,000V megger tester. Upper body
Do not measure between the terminal to terminal using a megger tester. That the injector will be damaged.
Upper body
Standard value
0.47±0.1Ω
(at 20°C {68°F})
3) If resistance of the step (1)(2) exceed standard value replace the injector.
2. Cleaning of the injector
1) Use a shop towel to remove any sludge sticking to the terminal part and its surroundings.
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[18. ENGINE]
• If the sludge has hardened, use a brush and cleaning fluid for cleaning.
• Red lead can be used to check for contact.
2) Confirm that the inside of the nozzle seat is free of sludge and foreign matter.
• Take care that no dirt or water gets into the system during the work.
• Before assembly, make sure that there is no dirt the seating surface of the parts.
• As air enters into the fuel piping during the work, air bleeding must be performed after completion of the work.
Injection pipe
Injector clamp
Injection pipe
oil seal
O-ring
• Apply the engine oil at a new O-ring and install it to the injector, install the injector clamp and the injector
temporarily.
• Please use care as a damaged O-ring can cause fuel leakage and starting the engine may become impossible.
• Do not tighten the injector clamp until the injection pipe has been installed provisionally.
Install the injection pipe oil seal so to the injection nozzle that no unreasonable force is applied. (When the positions
of the injection pipe oil seal and the injection nozzle are not matched, oil leakage or faulty installation of the injection
pipe may be caused.)
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• Always replace the pressure feed pipe by a new one because the injection pipe is subjected to high pressure;
reusing the same pipe may result in a fuel leak.
• Always follow the procedure exactly, because a fuel leakage can be the result when the injection pipe is not
installed correctly.
• Fuel leakage causes engine damage.
Install so that the markings of the tightening nuts for the flared parts of the injection pipes are arranged in the
indicated order.
Mark:1
Mark:4
Mark:2
Mark:3
Injector
Injector clamp
An insufficient tightening torque can cause gas leakage, nozzle seizure, etc.
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[18. ENGINE]
Injector
• When the injector is replaced, it is necessary to enter the injector correction value (QR code) described on the
new injector to the engine ECU.
• Incorrect entry of the correction value may result in faulty engine.
• Available entry methods of the injector correction value are the PC tool and the QR code reader.
• The work flow is described below. For detailed procedures, refer to the Hino DX operation manual.
1) Read the injector QR code with the scanner of the QR code reader and prepare the correction data file.
2) Enter the injector correction value directly from the Hino DX to the engine ECU.
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[18. ENGINE]
PC
QR code reader
Hino-Bowie
or
DST-i
Engine type code
(QR code)
Connector
New injector
ECU
Before connecting the connector, confirm that the terminal shows no signs of sparking.
Part of connector
Injector Cylinder
harness head
Installation becomes easier when the connector part of the camshaft housing is connected first.
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[18. ENGINE]
Leakage
pipe
A:Injector side (M8 x 1.0)
B:Camshaft housing side (M8 x 1.25) 18
B
A A
/ H D N D J H
S L S H
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[18. ENGINE]
18.6.6.2 Inspection
Union bolt
Pressure
limiter
Union bolt
Vinyl hose Container
1-2
1.05-3.55
5-6
2-3
6.7-18.7
4-5
18-95
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[18. ENGINE]
18.6.6.3 Replacement
Take care that no dirt or water get into the system during the work.
Common rail
Harness side
Female connector
Spring lock
Pull out the female connector from the male connector during pushing the spring lock at the female connector.
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[18. ENGINE]
Common rail
pressure sensor
Pressure
limiter
Flow damper
18
Bolt
Common rail
• Protect with clean vinyl to avoid entry of dirt into the common rail.
• Remove dirt from around each part, and detach the common rail.
• Remove the common rail together with the flow damper, the common rail pressure sensor, and the pressure
limiter.
• Take care that no dirt or water get into the system during the work.
• Before assembly, make sure that there is no dirt the seating surface of the parts.
• As air enters into the fuel piping during the work, air bleeding must be performed after completion of the work.
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[18. ENGINE]
Pressure
limiter
Flow damper
Bolt
Common rail
• Always replace the injection pipe by a new one because the injection pipe is subjected to high pressure; reusing
the same pipe may result in a fuel leak.
• Always follow the procedure exactly, because a fuel leakage can be the result when the injection pipe is not
installed correctly.
• Fuel leakage causes engine damage.
Install so that the markings of the tightening nuts for the flared parts of the injection pipes are arranged in the
indicated order.
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[18. ENGINE]
Mark:1
Mark:4
Mark:2
Mark:3
18
2) Fix the injection pipes with the clips (5pcs.) by
nuts (5pcs.).
Common rail
Male connector
Female connector
Common
rail side
Spring lock
Harness side
18-99
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[18. ENGINE]
• Engaging the female connector with the male connector until the spring lock "clicks" and returns.
• Before connecting the connectors, make sure that the terminals are free of a spark mark.
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[18. ENGINE]
18
3 Gasket* 8 O-ring*
Tightening torque
A 28.5N・m{291kgf・cm} D 55N・m{560kgf・cm}
B 55N・m{560kgf・cm} E 125N・m{1,280kgf・cm}
C 68.5N・m{700kgf・cm}
18.7.1.2 Inspection
1. Inspection before servicing
1) Using the Hino-DX for operation check of the air flow sensor.
2) Using the Hino-DX for operation check of the EGR valve on board.
(Refer to the Hino-DX user's manual.)
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[18. ENGINE]
18.7.1.3 Replacement
Perform replacement after cooling to prevent burns.(Turn the starter key to the "LOCK" position and leave it for
more than 30 minutes to cool.)
Do not touch the EGR pipe with bare hands while it is hot immediately after running.
& R R O D Q W S L S H 7 K H U P R V W D W F D V H
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[18. ENGINE]
• Do not hold the pipe and shell while working to avoid defects such as dent and water leakage.
• Do not touch the EGR cooler with bare hands while it is hot immediately after running.
Gasket
Non-reusable bolt
Non-reusable nut
Non-reusable snapring
Linkage
A Section A - A
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[18. ENGINE]
• This agent is alkali. Wear protective equipment (glasses, rubber gloves, and protective garment) to prevent it
from contacting eyes, skin, and cloth.
• If it contact the skin, wash it off with running water immediately. If it should get into eyes, rinse thoroughly with
running water and consult a physician.
• Making sure to check the "Material Safety Data Sheet" of Parker Corporation in the MSDS (Material Safety Data
Sheet) before use.
Remove the coolant hose in advance to avoid possible damage due to immersion in the detergent.
EGR cooler
• Immerse the whole EGR cooler into the detergent so that no air remains in the cooler.
• As a guide, replace the detergent after cleaning 5 EGR coolers or about 3 weeks.
Dissolved carbon
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[18. ENGINE]
Dissolved carbon inside the EGR cooler flows out. If carbon stain cannot be removed easily, use a nylon brush.
Gasket
Do not hold the pipe and shell while working to avoid defects such as dent and water leakage.
& R R O D Q W S L S H 7 K H U P R V W D W F D V H
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[18. ENGINE]
18-106
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[18. ENGINE]
18.8 ELECTRICAL
18.8.1 Electrical System
18.8.1.1 Part layout
18
Tightening torque
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[18. ENGINE]
Tightening torque
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[18. ENGINE]
18
1 Glow plug
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[18. ENGINE]
Tightening torque
A 28.5N・m{290kgf・cm, 21 lbf・ft}
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[18. ENGINE]
18
18-111
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[18. ENGINE]
Engine ECU
Left side view
18-112
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[18. ENGINE]
18
18-113
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[18. ENGINE]
Injector harness
Engine sub
revolution
sensor
Top view
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[18. ENGINE]
2
out. When the oil pressure is lower than the 4.7lbf/in }
specified pressure, conductivity is established, Within
which causes the warning lamp to light up. OFF Toward pressure increase
Characteristics
• The operating pressure of the oil pressure gauge is between 39.2 kPa and 58.8 kPa.
• Replace the oil pressure gauge when there is no conductivity below 39.2 kPa or when there is conductivity
above 58.8 kPa.
2. Inspection of coolant temperature sender gauge Coolant temperature sender gauge
(Installation on thermostat case)
1) Heat the coolant temperature sender gauge Connector color: Dark
using hot water.
2) Measure the resistance between terminals using A
a circuit tester. If it is faulty, replace the gauge.
C
B
Between A and C
75{167} 79 - 92
100{212} 35.5 - 42.5
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[18. ENGINE]
20{68} 2.59-3.29
6. Inspection of injector
1) For inspection and replacement of the injector, refer to the chapter of "5 FUEL SYSTEM".
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[18. ENGINE]
18
Engine sub revolution sensor
O-ring
18-117
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[18. ENGINE]
Alternator pully
Crankshaft pully
Measuring
New V-belt When inspection
item
Deflection
3-5 {0.1} 4-6 {0.2}
(mm {in.})
Special tool : S0944-41210 (09444-1210) Compression gauge (used at the time of measuring the deflection
amount)
[ Reference push force 98N {10kgf, 22lbf} ]
MITSUBOSHI BELTING LTD.; Belt Tension Meter (DOCTOR TENSION® TYPE-III)
(used at the time of measuring the tension force)
When the V-belt has been replaced by a new one, the V-belt will become loose because of initial run-in, so that the
V-belt tension should be adjusted again after running the engine for 3 to 5 minutes.
At the time of inspection, the new V-belt has reached the value after complete initial stretching. A new V-belt
completes initial stretching after running the engine for approximately two hours.
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[18. ENGINE]
Before replacement, wait until the engine cools down as you may get burned. (Turn the starter key to the "LOCK"
position and leave it for more than 30 minutes to cool.)
Connector
If it is much dirty, squirt water at the connector sliding portion and connector surface.
2. Blow air around the engine ECU connector and engine ECU surface to remove dirt and foreign matter.
4. Using a waste cloth, wipe off around the engine ECU connector and engine ECU surface.
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[18. ENGINE]
5. If you feel the movement of the lever unsmooth, repeat steps (1), (2), (3), (4) and (5).
6. Disconnect the engine ECU connector and check it
for deposition of dirt and foreign matter.
1) Set the hook of the connector in the direction of
the arrow to release the lock.
Hook
Primary latch
Lever
If it cannot be pulled out with a light force, check if the lever is fully open.
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[18. ENGINE]
Harness side
connector
18
• Use a thoroughly wrung waste cloth.
• Do not wipe off the terminal opening.
• Do not directly spray water.
Do not wipe
Engine ECU
side connector
9. Blow air on the terminal part inside the engine ECU side connector to remove dirt and foreign matter.
Engine ECU
18-121
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[18. ENGINE]
• Protect the connector of the engine ECU with a vinyl cover or similar to prevent the entry of dirt or foreign matter.
• Do not subject the ECU to impacts.
• Do not use an engine ECU which has been dropped.
• Do not touch the connector terminals with bare hands.
• The engine ECU cannot be disassembled.
• Do not apply paint, oil, or fat to the surface of the ECU and the connector part in order to maintain the functions
and the durability.
Engine ECU
Filter
(resin housing)
Boss
• Make sure that there are no dirt and foreign matter to the connector of the engine ECU.
• Do not subject the ECU to impacts.
• Do not use an engine ECU which has been dropped.
• Do not touch the connector terminals with bare hands.
• The engine ECU cannot be disassembled.
• Do not apply paint, oil, or fat to the surface of the ECU and the connector part in order to maintain the functions
and the durability.
• Check that there is no dirt on the bosses (4 locations) on the rear of the engine ECU.
• Confirm that the filter (resin housing) on the rear of the engine ECU is not broken or contaminated by oil.
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[18. ENGINE]
18
Lever
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[18. ENGINE]
If the lever cannot move smoothly, repeat steps (1) and (2). Also drop a few drops of water to the sliding portion to
make it smooth.
Hook
18-124
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[18. ENGINE]
18.9 INTAKE
18.9.1 Intake Manifold
18.9.1.1 Parts layout
18
Tightening torque
18-125
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[18. ENGINE]
18.9.1.2 Replacement
1. Removal of intake manifold
Gasket
1) Remove bolts and nuts and remove the intake
manifold.
Intake manifold
Intake manifold
Install the gasket so that the protrusion may come at the rear end stud bolt of the cylinder head.
3) Install the intake manifold and tighten it with bolts and nuts.
Tightening torque: 28.5 N・m {290 kgf・cm, 21 lbf・ft}
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[18. ENGINE]
18
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[18. ENGINE]
18.9.2.2 Replacement
Intake throttle
valve
Intake
throttle
Intake
throttle
Intake throttle
valve
• Take care to install so that the valve is not subjected to impact at the time of installation.
• Remove any remaining gasket traces from the intake throttle valve mounting surface of the intake pipe before
installation.
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[18. ENGINE]
18
18-129
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[18. ENGINE]
Tightening torque
B 28.5N・m{290kgf・cm, 21 lbf・ft}
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[18. ENGINE]
7 15 20 12 4
11 19 16 8
Eye-bolt
Underhead length
Bolt
Standard value (mm) Operation limit (mm)
length
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[18. ENGINE]
Before working, remove dirt, water or oil on the cylinder head and cylinder block.
3) Set the new head gasket to the dowel pin and place the gasket on the upper surface of cylinder block.
4. Installation of cylinder head gasket and liquid gasket
application procedure
1) Set the new head gasket to the dowel pin and
place the gasket on the upper surface of cylinder
block.
2) Install the cylinder head gasket on the cylinder
block and the flywheel housing.
• Remove dirt, water or oil from the mounting surfaces of the cylinder head and the cylinder block before work.
• Never reuse the gasket. Otherwise, it may damage the engine.
• The water hole seal ring of the cylinder head gasket is susceptible to damage. Avoid contact with hand or object.
• Before installation of the cylinder head gasket, make sure that there is no fall of or damage to the seal ring.
3) Apply liquid gasket (ThreeBond TB1211: White or equivalent) to the cylinder block upper surface rear end
and head gasket mating area of the flywheel housing (2 places).
Spreading part
? ? Space none
Propriety
Space
Too few
Spreading part
Liquid gasket
Cylinder Head gasket
head Space Space
Rear end plate Heap up liquid gasket over the top surface
? ? Section
18-132
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[18. ENGINE]
• When applying liquid gasket, use care not to allow the surface of liquid gasket to go over the upper surface of the
head gasket.
• Mount the case within 20 minutes after applying the liquid gasket.
Eye-bolt
• Before mounting the cylinder head, make sure that there is no foreign matter in the cylinder.
• When the cylinder head is mounted, be careful for engagement between the cam idle gear and the sub-idle gear.
(Contact of gear teeth with undue force may cause impact mark or chipping, resulting in abnormal noise or
missing tooth.)
Mounting of the cylinder head with guide bolt can prevent displacement of the liquid gasket.
15 7 2 10 18
11 3 6 14
M12 : No.1~18
M10 : No.19~21
5) Tighten the 18 head bolts (M12 only) again (cylinder head to cylinder block) in the order as shown in the
figure.
Tightening torque: 59 N・m {600 kgf・cm, 44 lbf・ft}
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[18. ENGINE]
Marking
8) Retighten the head bolts (M12 only) in the same order following the angles in the table.
135° 4, 5, 12, 13
Do not loosen the bolt even when it is over tightened during retightening.
9) Make sure the head bolts that have the same tightening angle markings have the same orientation.
10) Tighten the remaining head bolts No. 19, 20, 21
as shown in figure. 19
20
Tightening torque: 59 N・m {600 kgf・cm, 44 lbf・ft}
21
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[18. ENGINE]
18-135
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[18. ENGINE]
Mounting the case within 20 minutes after applying the liquid gasket.
0
4) Put the cylinder head cover on the cylinder head Cylinder Bolt
and tighten bolts. head cover Silent block
Tightening torque:
28.5 N・m {290 kgf・cm, 21 lbf・ft}
0
Cylinder
head cover
gasket
Cylinder head
undersurface
0
Cylinder head
0
18-136
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[18. ENGINE]
Injector harness
connector
18
2) Remove the O-ring from the injector harness O-ring
connector.
When removing carbon and other adherents, do not damage the bottom surface of the cylinder head.
• In press fit, be careful not to damage the valve stem at the upper/lower ends of the guide.
• In press fit, be sure to apply engine oil to the circumference of the valve guide.
18-137
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[18. ENGINE]
Electric weld
Valve
Cut three points
Replace the valve seat in the following procedure may damage the cylinder head. For secure replacement, we
recommend you to ask a machine processor.
1) Use the unnecessary valve to replace the valve seat. After cutting out three parts from the valve periphery,
weld to the valve seat.
Before welding, apply grease to the bottom surface of the cylinder head to protect from spatter.
2) Place the dolly block (such as a brass bar) to the valve stem head and pull off the valve seat by using the
press.
3) Remove welding spatter or dirt on the valve seat surface.
4) Heat the cylinder head in hot water to about 80°
C-100°C {176°F -212°F}. Tap in the cooled valve
seat to the cylinder head mounting area using the
dolly block and hammer.
6) Use the special tool to tap and lap the valve while rotating it.
Special tool : S0943-11020 (09431-1020) Valve wrapping tool
5. Removing nozzle seats
1) Tap nozzle seats from the lower side of the
cylinder head. Then, screw in appropriate bolts.
2) Use the hammer to tap the bolt head and pull up
the nozzle seat out of the cylinder head.
3) Remove the O-ring from the cylinder head.
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[18. ENGINE]
After pulling out the nozzle seats, remove all and any residual liquid gasket, dirt or other deposits.
4) After inserting the new O-ring into a nozzle seat Cylinder head
insertion hole in the cylinder head, apply liquid
gasket (ThreeBond TB1211 or equivalent: White) O-ring
to the bottom of a new nozzle seat before
installing it to the cylinder head.
Nozzle sheet 18
Liquid gasket
Make sure to replace with new O-rings. Reuse of O-rings may cause coolant or gas leakage, resulting in overheat
and/or cracks in the cylinder head.
5) To clinch the nozzle seat, using the special tool. Bar Nozzle sheet
Special tool : S0947-21210 (09472-1210) Bar
SN441-00610 (9800-06100)
Steel Ball
Cylinder
head
Steel ball
Thickness
gauge
Longitudinal Right angle
direction direction
Location of measurement
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[18. ENGINE]
Longitudinal direction
0.20 {0.0079}
0.06 {0.0024}
Do not adjust the bottom surface by grinding or the timing gear backlash will be changed.
2) Using the dye penetrant testing (red check) to inspect for crack and damage on the cylinder head. If found
defective, replace the cylinder head.
7. Mounting the injector harness connector O-ring
1) Replace with the new O-ring and fit it to the
injector harness connector.
Injector harness
connector
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[18. ENGINE]
18
2 Cooling jet
Tightening torque
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[18. ENGINE]
18.10.2.2 Overhaul
1. Removing the cylinder liner
1) Use the oil pen to put alignment marks on the
flange surface of the cylinder block and cylinder
liner.
• The removed cylinder liners must be identified and stored in order of cylinder No.
• Never using the punch to put alignment marks.
2) Hold the cylinder liner end with both hands and Cylinder liner
pull it off over the cylinder block at a stroke.
• Use the particular care in handling the cylinder liner. No dropped cylinder liners are reusable.
• The removed cylinder liners must be identified and stored in order of cylinder No.
Pull off the cylinder liner vertically at a stroke. Otherwise it gets caught with the cylinder block and will not be
removed easily.
Using care to avoid the special tool from contacting the cooling jet.
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[18. ENGINE]
5) Align the alignment mark indicated on the cylinder liner and the one indicated on the cylinder block and use
a special tool to insert the cylinder liner in the vertical posture. 18
Special tool : S0947-11490 (09471-1490) Guide
Liner identification mark
Front
side
of block
EXAMPLE
Engine model BACB
Front of engine
Cylinder
liner
When mounting new cylinder liners, select appropriate cylinder liners that have the same identification mark (A, B
or C) as the liner identification mark engraved on the cylinder block in the order of cylinders.
0.01-0.08
Standard value (mm {in.})
{0.0004-0.0032}
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[18. ENGINE]
Cooling jet
2) Connect the oil hose for injection test to the
special tool from under the cylinder block.
Bolt for
checking
Oil hose
4) Inject oil from the cooling jet nozzle at 196 kPa {2 OIL JET DEVICE (EXAMPLE)
Pressure
kgf/cm2, 28 lbf/in2}. regulator
Oil hose
Air tank
(Oil tank)
Compress
Air gauge air
Air hose
For
Cooling jet Valve
5) When the injection center hits within the specified Jet Gauge target
line of the gauge, it is considered normal.
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[18. ENGINE]
• Oil may splash and catch fire, causing fire. Keep from flame.
• Working in a well-ventilated area.
6) Make sure that the jet position check gauge hole at the tool assembly end may not interfere with the cooling
jet pipe.
7) If the injection does not hit the target circle, replace with a new cooling jet.
8) Unfasten the special tool (bolt for checking) and use a proper union bolt to secure the cooling jet on the
18
cylinder block.
Tightening torque: 22 N・m {230 kgf・cm, 16 lbf・ft}
9) After mounting the piston, check that the cooling jet does not interfere with the piston at the piston bottom
dead center.
4. Inspecting the cylinder block
1) Use the straightedge and thickness gauge to Straight edge
measure the strain of the upper surface of
cylinder block. If a measurement reading
exceeds the operation limit, replace it.
Thickness gauge
Longer Right-angled
direction direction
Location of measurement
Do not grind the surface. Otherwise, backlash in timing gears may change.
2) Use the dye penetrant testing (red check) to inspect the cylinder block for crack and damage. If found
defective, replace the cylinder block.
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[18. ENGINE]
C A
A
B
B
A B
B
A
A A
Tightening torque
B 55N・m{560kgf・cm, 41 lbf・ft}
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18
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18
• If there is no dedicated engine bench, the engine cannot be supported. In this case, turn over the engine and
place the cylinder block joint surface on the wooden workbench during work.
• If the flywheel housing does not come off smoothly, temporarily fasten one mounting nut in the center of the
flywheel housing and use a plastic hammer to tap the back face to remove the flywheel housing.
2) Use the scraper to remove dirt and fouling from Liquid gasket
the joint surfaces of the flywheel housing and
rear end plate. Liquid
gasket
3) Apply liquid gasket (ThreeBond TB1207D: Silver or equivalent or ThreeBond TB1217G: Gray or equivalent)
to the flywheel housing as shown in the figure.
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[18. ENGINE]
4) Fasten 2-4 guide bolts and align the flywheel housing with the cylinder block mounting position along the
guide bolts.
5) Tighten the bolts and nuts with the specified
C A
tightening torques to secure the flywheel A
B
housing.
Tightening torque: B
A B
196 N・m {2,000 kgf・cm, 145 lbf・ft} (Part A: M16)
B
55 N・m {560 kgf・cm, 41 lbf・ft} (Part B: M10)
36 N・m {367 kgf・cm, 27 lbf・ft} (Part C: M8) A
A A
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[18. ENGINE]
18
2. Mounting rear end plate
1) Install a new gasket and the rear end plate.
Check that no dirt, fouling or foreign matters remain in the threaded holes or on the mounting surface on the
cylinder block.
2) Apply the sealant (Thread Lock Super 5M or equivalent) to threads of the torx bolts.
3) Use the special tool, mount the torx bolts.
Special tool : S0941-11300 (09411-1300)
Socket wrench
Tightening torque: 55 N・m {560 kgf・cm, 41 lbf・ft}
4) Use the scraper to cut off excessive upper and Gasket
lower protruding portions of the gasket so that the Cylinder block
End plate
Cut with
gasket will be flush with the upper and lower scraper
Flywheel
housing
surfaces of the cylinder block.
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[18. ENGINE]
Plate
Bolt x 4
Plate
2) Hook the special tool hooks (2 pcs.) on the chuck Claw Plate
of the crankshaft front oil seal and fasten special
tool bolts to secure the hooks onto the special
tool plate.
Hook
3) From the crankshaft, remove 2 crankshaft pulley mounting bolts securing the special tool plate.
4) Fit and gradually tighten the special tool center
bolt to pull off the crankshaft front oil seal.
• Inspect the engagement of the special tool and oil seal half way through the work and pull off the seal without
removing the special tool.
• The crankshaft front oil seal is nonreusable.
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[18. ENGINE]
2. Mounting the crankshaft front oil seal Check that there are
no hit marks or
1) Check that there is no dent or dirt in the oil seal scratchings.
insertion part of the front oil seal retainer and
crankshaft.
Oil seal
guide
Bolt
3) Apply small amount of engine oil to the fitting Oil seal guide
area (crankshaft and oil seal retainer side) of a
new crankshaft front oil seal. Oil seal
4) Note the direction of the oil seal and insert it to the oil seal guide of the special tool.
• Note the front and rear direction of the crankshaft front oil seal. (The felt surface is the crankshaft pulley side)
• Mounting the oil seal so that is not inclined.
5) Remove the dirt from the joint surfaces of the Oil seal
crankshaft front oil seal and cylinder block.
6) After inserting the new crankshaft front oil seal into the oil seal guide, fasten special tool guide bolts to
secure the oil seal guide on the crankshaft.
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[18. ENGINE]
After tightening the guide bolts, check that a height difference or a step between the crankshaft and the oil seal
guide is consistent all around the circumference.
8) Fit the special tool center bolt into the oil seal press and tighten it until it stops. Then, press-fit the crankshaft
front oil seal.
9) Tighten the center bolt until the press comes in contact and check that the oil seal is press-fit evenly around
the circumference.
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[18. ENGINE]
18
Align the large hole of the plate with the collar knock of the crankshaft.
Bolt x4
Plate
Hook
3) From the crankshaft, remove the flywheel assembly mounting bolts (2 pcs.) securing the special tool plate.
4) Fit and gradually tighten the special tool center
bolt to pull off the crankshaft rear oil seal.
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[18. ENGINE]
• Inspect the engagement of the special tool and oil seal half way through the work and pull off the seal without
removing the special tool.
• The crankshaft rear oil seal is nonreusable.
Oil seal
guide Center
bolt
3) Apply small amount of engine oil to the fitting Oil seal guide
area (crankshaft and flywheel housing side) of a Oil seal
new crankshaft rear oil seal.
4) Note the direction of the oil seal and insert it to the oil seal guide of the special tool.
• Note the front and rear direction of the crankshaft rear oil seal. (The felt surface is the flywheel side)
• Mounting the oil seal so that is not inclined.
5) After inserting the new crankshaft rear oil seal Oil seal
into the oil seal guide, fasten special tool guide
bolts to secure the oil seal guide on the
crankshaft.
Oil seal
guide
Guide bolt
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[18. ENGINE]
• Align the large hole of the oil seal guide with the collar knock of the crankshaft.
• After tightening the guide bolts, check that a height difference or a step between the crankshaft and the oil seal
guide is consistent all around the circumference.
6) Align the holes in the oil seal press with the guide
bolts and insert the oil seal press.
18
Center bolt
8) Tighten the center bolt until the press comes in contact and check that the oil seal is press-fit evenly around
the circumference.
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[18. ENGINE]
Tightening torque
A 69N・m{700kgf・cm, 51 lbf・ft}+90°+45°
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18
Tightening torque
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[18. ENGINE]
Cylinder liner
disconnection
preventing jig
Make sure not to damage the lower part of the carbon adhered area.
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[18. ENGINE]
The connecting rod cap is connected with the dowel pin. However, the rod and the cap can be separated easily by
hammering the bolt head.
18
5) Remove the bolts on the connecting rod cap and Connecting rod
remove the connecting rod cap. cap
Not to change the combination of the connecting rod and connecting rod cap, the removed connecting rod caps
must be identified and stored in order of cylinder number.
When removing the piston, set the crankshaft to the top dead center in the applicable cylinder.
Cooling jet
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[18. ENGINE]
• When pulling out the piston, rotate the connecting rod and be careful not to bend the cooling jet.
• The removed pistons and connecting rods must be identified and stored in order of cylinder number.
Retainer ring
While working, wear safety glasses because the retainer ring may come out.
2) Put alignment marks on the back and side of the Piston pin
piston before pulling it out and separate the Piston
piston from the connecting rod.
Mark
Connecting rod
The removed pistons and connecting rods must be identified and stored in order of cylinder number.
White paint
White paint
When writing cylinder numbers on the piston and connecting rod, use white paint to place markings at the positions
indicated in the figure.
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[18. ENGINE]
18
• Handle the piston ring with care because it can be easily damaged.
• The piston rings must be identified and stored in order of cylinder No.
• Store the piston rings without mixing the upper surface and bottom surface.
Connecting rod
bearing
Concave portion
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[18. ENGINE]
• Measurement position is 17 mm {0.669 in.} above the lower end of the piston in right-angled direction to the pin
hole.
3) Calculate the difference between the cylinder liner inner diameter and the piston outer diameter. If a
measurement reading exceeds the standard value, replace the cylinder liner and piston.
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[18. ENGINE]
Thickness gauge
Second ring
2.0 {0.0787} 2.2 {0.0866}
groove
Piston ring
Thickness gauge
2) Using the thickness gauge to measure the closed gap clearance of the piston ring. If a measurement
reading exceeds the operation limit, replace the piston ring.
0.30-0.40
Top ring 1.5 {0.0590}
{0.0118-0.0157}
0.75-0.90
Second ring 1.5 {0.0590}
{0.0295-0.0354}
0.15-0.30
Oil ring 1.2 {0.0472}
{0.0059-0.0118}
5. Inspecting the piston pin outer diameter and piston boss inner diameter
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[18. ENGINE]
3) Calculate the gap between the outer diameter of the contact surface of the piston pin with the piston boss
and the piston boss inner diameter. If a calculated value exceeds the operation limit, replace the piston pin.
0.011-0.032
0.05 {0.0020}
{0.0005-0.0012}
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[18. ENGINE]
3) Calculate the difference between the inner diameter of the connecting rod small end and the outer diameter
of the piston pin, and if it is beyond the service limit, replace the connecting rod or the bush.
0.035-0.056
0.08 {0.0031}
{0.0014-0.0022}
Clogging in the oil hole may cause insufficient oiling, resulting in seizure.
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[18. ENGINE]
Imperfect
Small
curvature
curvature Stepped
radius Stepped
radius
P
GOOD BAD
When grinding the crankshaft, adjust a fillet radius dimension as indicated below.
Crankpins: 2.5-3.0 mm {0.0984-0.1181 in.}
Journals: 2.5-3.0 mm {0.0984-0.1181 in.}
2) Mount the bearing to the connecting rod large end. After mounting the cap, tighten the connecting rod bolt
with the specified torque.
3) Using the cylinder gauge to measure the bearing
inner diameter of the connecting rod large end.
4) Calculate the difference between the crankpin outer diameter of crankshaft and the connecting rod bearing
inner diameter. If a measurement reading exceeds the operation limit, replace the connecting rod bearing or
crankshaft.
0.031-0.082 0.2
{0.0012-0.0032} {0.0079}
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18
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[18. ENGINE]
• Orienting the "H" mark engraved on the guide to the top before assembly.
• Making sure that the lower ends of the guide and the press subassembly are level.
Press
sub assy
Align the groove in the special tool press subassembly with a groove in the special tool spindle before mounting.
4) Use the press to pull off the connecting rod bush. Press
Bush
5) Check the small end of the connecting rod with the bush removed, and see if there is deformation to the
inner diameter or scratches or dents on the inner surface.
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[18. ENGINE]
The presence of deformation, scratches or dents indicates that the bush was not properly installed.
18
• Aligning grooves in the special tools (guide and spindle) with each other before mounting.
• Making sure of tight fit between the end faces of the special tools (spindle and guide).
Using dry ice to cool the bush to -10°C (14°F) before assembling it will improve the quality of the assembled bush.
Also, work quickly so that the bush does not warm up during assembling work.
2) Align the oil hole in the bush assembled to the PRESS Chamfering
special tools with an oil hole in the connecting rod side
and check that a groove in the special tool
Groove
spindle is aligned with an groove in the special
tool press subassembly. Oil hole
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[18. ENGINE]
• Orient the connecting rod in the proper direction so that the chamfered inner diameter of the small end of the
connecting rod faces the bush.
• Apply engine oil to the inner diameter surfaces of the connecting rods.
3) Use the press to press-fit the bush into the connecting rod.
After press-fitting the bush, make sure there are no machine burrs on the bush.
Off-position of the oil hole may cause insufficient oiling, resulting in seizure.
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[18. ENGINE]
18
Connecting rod
bearing
Concave
part
• While working, wear safety glasses because the retainer ring may come out.
• Making sure that the retainer ring is correctly put in the groove.
• Checking the retainer ring for play or looseness.
2) Orient the "0" mark indicated on the piston to the “0” MARK Piston
opposite direction of the alignment mark position
indicated on the connecting rod when fitting the
Exhaust Intake
piston to the connecting rod. side side
Oil hole
MARK
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[18. ENGINE]
3) After applying engine oil to the piston pin, align Piston pin
Piston
the alignment mark on the piston with the one on
the piston pin before inserting the piston pin.
Mark
Connecting rod
Retainer ring
• While working, wear safety glasses because the retainer ring may come out.
• Making sure that the retainer ring is correctly put in the groove.
• Checking the retainer ring for play or looseness.
UPPER
Oil ring
Top ring 2nd ring
LOWER
The identification print is given only to the second ring while there is no vertical identification given to the top and oil
rings.
End
gap
Coil expander
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[18. ENGINE]
3) Position the piston rings with the ring ends 2nd ring
positioned at an equal interval away from one
another as shown in the figure.
If the crankshaft is not at the top dead center, the connecting rod touches the cooling jet.
2) Apply engine oil to the piston periphery, cylinder liner inner surface and connecting rod bearing. Add engine
oil into the connecting rod oil hole.
3) Use the special tool to compress the piston ring
and set it to the cylinder liner.
Special tool : S0944-11370 (09441-1370)
Piston ring holder
• Assembling the pistons and connecting rods in the order of cylinder numbers as identified before removal.
• Checking the special tool for deformation or scratches.
"0" mark
• Before insertion, orient a "0" mark indicated on the piston to the exhaust side.
• Be careful not to damage the cylinder liner, crankshaft and cooling jet during work.
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[18. ENGINE]
5) Make sure that "0" marks indicated on the pistons Exhaust side "0"mark
rest on the exhaust side.
Intake side
6) Apply engine oil to the threaded part and seat Connecting rod
surface of the bolts. Align with identification with cap
the connecting rod cap and connecting rod
removed before tightening the bolts temporarily.
Do not change the combination of the connecting rod and connecting rod cap.
The cap is provided with a mis assembly-preventing dowel pin. Mount with the pin.
8) Check that the engraved alignment mark directions and Nos. of the connecting rod cap and connecting rod
match.
9) Tightening the connecting rod bolt.
Tightening torque: 69 N・m {700 kgf・cm, 51 lbf・ft} Connecting rod
cap
45
90
Marking
10) Use the paint to mark the bolt heads in the same direction.
11) Tighten the bolts by 90° (1/4 turns) in the rotational direction and check that all the paint marks face to the
same direction.
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[18. ENGINE]
12) Retighten the bolt by 45° (1/8 turn) in the rotation direction and check that all the paint marks face in the
same direction.
Do not loosen the bolt even when it is over tightened during retightening.
18
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[18. ENGINE]
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[18. ENGINE]
3) Mount the thrust bearing to the main bearing cap Product number
stamping
with the groove side (front side) facing to the
Bearing cap
crank arm side and the part No. side (back side)
to the main bearing cap side before applying
engine oil.
Thrust
bearing
18
Groove
Apply engine oil or grease to the back side of the thrust bearing to prevent it from falling off during assembly.
Do not mount the thrust bearing on the cylinder block side now because it must be inserted after the crankshaft is
placed.
Product number
stamping side
Groove side
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[18. ENGINE]
6) Set the main bearing cap mounted with the thrust Stamp number
bearing and main bearing to the cylinder block.
Front of engine
Stamp number
• Make sure that the pentagon-shaped marks indicated on the main bearing caps face to the engine front side in
the order of 1-5 from front to back.
• Check the engraving No. on the main bearing cap against the engraving No. on the cylinder block.
Front of engine
45
90
15) Check that all the paint markings face the same direction.
Do not loosen the bolt even when it is over tightened during retightening.
16) After completion of tightening, tap the front and back ends of the crankshaft with the plastic hammer so that
crankshaft fits the assembly.
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[18. ENGINE]
Do not loosen the bolt even when it is over tightened during retightening.
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[18. ENGINE]
Wear is 0.2 mm
Regrind
{0.0079 in.} or larger
Wear is 0.7 mm
Replace crankshaft
{0.0276 in.} or larger
18-182
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[18. ENGINE]
Imperfect
Small
curvature
curvature Stepped
radius Stepped
radius
P
GOOD BAD
When grinding the crankshaft, adjust a fillet radius dimension as indicated below. 18
Crankpins: 2.5-3.0 mm {0.0984-0.1181 in.}
Journals: 2.5-3.0 mm {0.0984-0.1181 in.}
Standard value
80.0 {3.150}
(mm {in.})
3) Using the cylinder gauge to measure the inner diameter of the crankshaft bearing.
4) Calculate the difference between the outer diameter of the crankshaft journal and the crankshaft bearing
inner diameter. If a measurement reading exceeds the repair limit, regrind the crankshaft and use undersize
bearings.
0.051-0.102
0.2 {0.0079}
{0.0020-0.0040}
18-183
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[18. ENGINE]
Imperfect
Small
curvature
curvature Stepped
radius Stepped
radius
P
GOOD BAD
When grinding the crankshaft, adjust a fillet radius dimension as indicated below.
Crankpins: 2.5-3.0 mm {0.0984-0.1181 in.}
Journals: 2.5-3.0 mm {0.0984-0.1181 in.}
18-184
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[18. ENGINE]
Imperfect
Small
curvature
curvature Stepped
radius Stepped
radius
P
GOOD BAD
When grinding the crankshaft, adjust a fillet radius dimension as indicated below. 18
Crankpins: 2.5-3.0 mm {0.0984-0.1181 in.}
Journals: 2.5-3.0 mm {0.0984-0.1181 in.}
18-185
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[18. ENGINE]
To prevent the co-rotation of the crankshaft, insert a large flat-blade screwdriver into the flywheel gear from the
inspection hole of the flywheel housing and stop the rotation of the crankshaft.
To prevent the co-rotation of the crankshaft, insert a large flat-blade screwdriver into the flywheel gear from the
inspection hole of the flywheel housing and stop the rotation of the crankshaft.
18-186
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[18. ENGINE]
18
To prevent the co-rotation of the crankshaft, insert a large flat-blade screwdriver into the flywheel gear from the
inspection hole of the flywheel housing and stop the rotation of the crankshaft.
Do not touch with bare hands while the ring gear and flywheel are hot.
18-187
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[18. ENGINE]
Do not touch with bare hands while the ring gear and flywheel are hot.
Do not touch with bare hands while the ring gear and flywheel are hot.
Do not touch with bare hands while the ring gear and flywheel are hot.
18-188
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[18. ENGINE]
Install one special tool on the collar dowel and the other at the opposite side of the collar dowel.
3) Insert the flywheel until it comes in contact with the collar dowel of the crankshaft and adjust the position.
5) Apply engine oil to the bolt seat surface and bolt threaded part of the flywheel assembly mounting bolt.
6) Fit the six bolts into bolt holes not occupied by
the special tools and manually tighten them by a
couple of turns.
lbf・ft}
• To prevent the co-rotation of the crankshaft, insert a large flat-blade screwdriver into the flywheel gear from the
inspection hole of the flywheel housing and stop the rotation of the crankshaft.
18-189
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[18. ENGINE]
Tightening torque
18-190
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[18. ENGINE]
18
Tightening torque
A 108N・m{1,100kgf・cm, 80 lbf・ft}
18-191
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[18. ENGINE]
Remove the adjust screw without winding may cause the rocker arm shaft to bend.
Be careful that the gear is free from deformation, dent or damage during work.
18-192
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[18. ENGINE]
18
Standard Operation
Measured item value limit
(mm {in.}) (mm {in.})
50.067 49.987
Intake
{1.971} {1.968}
Cam height
52.104 52.024
Exhaust
{2.051} {2.048}
8.067 (7.987
Intake
{0.318} {0.3144})
Cam lift
110.104 (10.024
Exhaust
{0.398} {0.395})
2) Using the cylinder gauge to measure the inner diameter of the camshaft bearing.
3) Calculate the difference between the camshaft journal outer diameter and the camshaft bearing inner
diameter. If the value exceeds the standard value, replace the camshaft or camshaft bearing.
0.020-0.063
Standard value (mm {in.})
{0.0008-0.0025}
18-193
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[18. ENGINE]
Under-head
length
• Do not loosen the bolt even if it is overtightened. Do not loosen the bolt even if it is overtightened.
• Be careful that the gear is free from deformation, dent or damage during work.
18-194
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[18. ENGINE]
Wrong installation
preventing drillhole
18
Set the clear plastic scale or edged scale against the upper surface of the cylinder head and the side of the
camshaft gear. Check that the wrong mounting preventing drill hole is located above the scale.
1-5 from front to back.
Engine front
3) Make sure that the end play of the camshaft is in the standard value.
4) Check that crossheads are properly seated on (or
over) individual valves.
Closs head
• To check whether the crossheads are properly seated in place, manually move each crosshead to right and left
to aurally check a clicking sound.
• Off-position of the crossheads on individual valves will cause the upper seat to lift, resulting in valve
dislodgement.
5) Check that the rocker arms are properly assembled to the rocker arm shaft.
6) Check that the adjust screw of the rocker arm is wound up.
Failure to wind up the adjust screw may cause the shaft to bend when tightening the rocker support bolt.
18-195
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[18. ENGINE]
18-196
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[18. ENGINE]
18
Turn over the engine vertically or turn it onto the side during work. This prevents workers from dropping parts in the
flywheel housing.
18-197
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[18. ENGINE]
Standard value
Measured item
(mm {in.})
Shaft outer
57 {2.244}
diameter
Main idle gear
Bushing inner
57 {2.244}
diameter
Shaft outer
50 {1.969}
diameter
Sub idle gear
Bushing inner
50 {1.969}
diameter
Shaft outer
34 {1.339}
diameter
Cam idle gear
Bushing inner
34 {1.339}
diameter
Operation
Standard value
Measured item limit
(mm {in.})
(mm {in.})
0.030-0.090 0.20
Main idle gear
{0.0012-0.0035} {0.0079}
0.025-0.075 0.20
Sub idle gear
{0.0010-0.0030} {0.0079}
0.025-0.075 0.20
Cam idle gear
{0.0010-0.0030} {0.0079}
18-198
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[18. ENGINE]
gear.
2) Mount the thrust plate. Sub idle gear
shaft
Thrust
plate
Bolt
Bolt
18-199
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[18. ENGINE]
Oil pump
gear
Clankshaft gear
18-200
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[18. ENGINE]
18
Note that one of the bolts is tightened from the flywheel housing side.
18-201
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[18. ENGINE]
3) Calculate the gap. If a calculated value exceeds the standard limit, replace the shaft and the bush.
0.025-0.057 0.10
{0.0010-0.0022} {0.0039}
18-202
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[18. ENGINE]
18
2) Using the dial gauge to measure backlash
between the camshaft drive gear and the cam
idle gear. If a measurement reading exceeds the
operation limit, replace a set of the gears.
0.084-0.175 0.30
{0.0033-0.0069} {0.0118}
Cam shaft
0.100-0.178
Standard value (mm {in.})
{0.0039-0.0070}
18-203
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[18. ENGINE]
• If a dial gauge magnet stand cannot stand still, utilize bolt holes in the cylinder block to temporarily mount a
metal plate for measurement.
0.030-0.218 0.30
{0.0012-0.0086} {0.0118}
4. Inspecting for backlash between the bearing case idle gear and supply pump drive gear
1) Remove the bearing case assembly.
Refer to the "Supply pump, Replace"
2) Using the dial gauge to measure backlash between the bearing case idle gear and the drive gear. If a
measurement reading exceeds the operation limit, replace individual gears.
0.020-0.083 0.10
{0.0008-0.0032} {0.0039}
18-204
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[18. ENGINE]
0.030-0.162 0.30
{0.0012-0.0064} {0.0118}
0.030-0.131 0.30
{0.0012-0.0052} {0.0118}
18-205
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[18. ENGINE]
Operation
Standard value
Measured item limit
(mm {in.})
(mm {in.})
0.114-0.160 0.30
Main idle gear
{0.0045-0.0063} {0.0118}
0.040-0.120 0.30
Sub idle gear
{0.0016-0.0047} {0.0118}
0.040-0.120 0.30
Cam idle gear
{0.0016-0.0047} {0.0118}
0.084-0.235 0.30
{0.0033-0.0093} {0.0118}
18-206
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[18. ENGINE]
18
Tightening torque
A 25N・m{250kgf・cm, 18 lbf・ft}
18-207
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[18. ENGINE]
Spring sheet
(upper)
If eye bolts are used, fasten them via washers and use care not to cause a potential risk of damaging the upper
surface of the cylinder head.
Valve
Put tags with relevant cylinder numbers to the valves and valve springs so that the combination of the valve and
cylinder head will not be changed.
18-208
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[18. ENGINE]
0
Valve guide
0
6. Removing the valve seat
0
Dolly
block
Valve sheet
0
0
Valve Electric
welding
Cut out
0
3 parts here.
Replace the valve seat in the following procedure may damage the cylinder head. For secure replacement, we
recommend you to ask a machine processor.
1) Use the unnecessary valve to replace the valve seat. After cutting out three parts from the valve periphery,
weld to the valve seat.
Before welding, apply grease to the bottom surface of the cylinder head to protect from spatter.
2) Place the dolly block (such as a brass bar) to the valve stem head and pull off the valve seat by using the
press.
18-209
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[18. ENGINE]
0.55-0.85 1.1
Intake
{0.0217-0.0335} {0.0433}
1.15-1.45 1.7
Exhaust
{0.0453-0.0571} {0.0669}
2) Measure the angle of the valve seat and valve. If Valve sheet
a measurement value exceeds the permissible Valve
30 ° 45 °
INTAKE EXHAUST
Standard
Measured item Permissible angle
value
C
Lower sheet
18-210
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[18. ENGINE]
Measured item
Operation limit 18
(clearance A)
Standard Operation
Measured item
value limit
Set length 44.8
-
Inner (mm {in.}) {1.764}
spring Set load 128.5 118.2
(N {kgf, lbf}) {13.1, 28.8} {12, 26.5}
18-211
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[18. ENGINE]
Standard value
Measured item
(mm {in.})
Standard value
Measured item
(mm {in.})
3) Calculate the difference between the outer diameter of the valve stem and the inner diameter of the valve
guide. If a measurement reading exceeds the standard value, replace the valve guide.
Standard value
Measured item
(mm {in.})
0.023-0.058
Intake valve oil clearance
{0.0009-00023}
0.050-0.083
Exhaust valve oil clearance
{0.0020-0.0033}
18-212
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[18. ENGINE]
3) Calculate the gap between the outer diameter of the rocker arm shaft and the inner diameter of the rocker
arm bush. If a calculated value exceeds the operation limit, replace the rocker arm shaft or rocker arm bush.
0.030-0.101
0.15 {0.0059}
{0.0012-0.0040}
18-213
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[18. ENGINE]
Valve sheet
• Make sure of orientation (face side and back side) of a valve seat.
• Be careful not to break the valve seat because it is sintered part.
The valve seat with an outer diameter of 41 mm {1.614 in.} is for intake and 39 mm {1.535 in.} for exhaust.
4) Using the special tool to tap and lap the valve while rotating it.
Special tool : S0943-11020 (09431-1020)
Valve wrapping tool
2. Mounting the valve guide
PRESS
1) Apply engine oil to the periphery of the valve Special tool
guide.
2) If a new valve guide is installed, set the special Valve guide end y
tool to the valve seat to prevent slanted insertion face to be flush ç
with special tool
of the valve guide during press-fitting. upper surface
0
18-214
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0
[18. ENGINE]
• During press-fitting with the special tool, use care not to damage a valve stem of the valve guide.
• Before press-fitting, make sure to apply engine oil to the periphery of the valve guide.
• Be careful not to pry the valve guide end when press-fitting.
Valve stem
seal
• After assembling the valve stem seal, check for deformation, crack and inclination of rubber and detached
spring.
• After fitting valve stem seals, check rubbers for deformation, cracks, inclination or spring dislodgement.
• Note that dirt or fouling on the valve or in the valve guide may damage a valve stem seal during insertion of the
valve.
3) After tapping in the valve stem seal, check the Spring part of
height from the spring seat (lower) to the spring valve stem seal
of the valve stem seal.
Spring sheet
(lower)
18-215
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[18. ENGINE]
• Applying engine oil to the contact surface of each part before assembly.
• Mounting each valve securely to the original cylinder position.
Valve
When reusing the valve, check that the valve stem is free from damage.
Spring sheet
(upper)
3) Insert the valve spring retainer to the hole of the spring seat (upper).
4) Use the special tool to compress the valve spring
Valve spring
to fit in the valve spring retainer. Special tool retainer
Special tool : S0947-01170 (09470-1170)
Valve spring press
Spring sheet
(upper)
18-216
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[18. ENGINE]
Valve spring
retainer upper Spring sheet
(upper) dent part
18
Make sure that the upper surfaces of two valve spring retainers are level with each other as well as a concave in the
spring seat (upper).
Constant pitch valve springs do not require vertical orientation (top and bottom) prior to mount.
18-217
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[18. ENGINE]
• Before adjustment, make sure that the tightening bolts of the rocker arm support, nozzle clamp, cylinder head,
and camshaft bearing cap are tightened with the specified torque.
• Making sure that there is no dirt in the crosshead and valve stem head.
Clearance
Close contact
Lock Nut
Check that the rocker arm to be adjusted is not lifted to the cam of the camshaft.
If the No.1 cylinder is at the compression stroke top dead center, you can adjust the valve clearance with a mark on
the table. If the No.4 cylinder is at the compression stroke top dead center, the cylinder with mark can be adjusted.
Cylinder No. 1 2 3 4
Valve arrangement Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No.1 cylinder at the
compression stroke top 〇 〇 〇 〇
dead center
No.4 cylinder at the
compression stroke top 〇 〇 〇 〇
dead center
Clearance
Close contact
Lock Nut
18-218
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[18. ENGINE]
Making the adjust screw projecting beyond the upper surface of the crosshead by at least 10 mm {0.394 in.}.
Correct adjustment cannot be made unless the adjust screw is completely separated from the valve stem.
Close contact
Crosshead
18-219
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[18. ENGINE]
Do not loosen the adjust screw too much. Excessive loosening of the adjust screw will set the condition back to the
original state. Sensory detection with the thickness gauge may be proper but there will be an excessive gap
between the crosshead adjust screw and the valve, which will obstruct proper adjustment.
It is deemed appropriate if the thickness gauge goes in with some unsmoothness during insertion and then moves
smoothly with slight binding feel after insertion.
18-220
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[18. ENGINE]
18.11 EXHAUST
18.11.1 Exhaust Manifold
18.11.1.1 Part layout
18
Tightening torque
A 59N·m{600kgf·cm, 44 lbf·ft}
18-221
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[18. ENGINE]
18.11.1.2 Replacement
1. Removal of exhaust manifold
1) Remove the bolts (3pcs.) and remove the
insulator from the exhaust manifold.
2) Remove the nuts (12pcs.) and remove the
exhaust manifold, gaskets and spacers from the
cylinder head.
( [ K D X V W P D Q L I R O G
Cylinder head
Cylinder head
Excessive tightening with over torque may cause crack in the cylinder head.
18-222
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[18. ENGINE]
Exhaust manifold
18
Black side
Gasket
Mount the gasket with the coating surface (black surface) facing to the exhaust manifold side.
2) Mount the spacers and tighten nuts in the order New exhaust manifold installing case
as shown in the figure.
12 11 10 9 8 7 6 5
Tightening torque : 59 N·m {600 kgf·cm,44 ibf·ft}
1 2 3 4
7 1 4 10
Spacer
• When tightening the nuts, use care to avoid interference of individual spacers with the counterbore areas of the
exhaust manifold flange.
• The sequential order of tightening is determined depending on whether a new or a reused exhaust manifold is
installed.
• Spacers come with 2 different lengths. Do not misassemble them.
18-223
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[18. ENGINE]
18-224
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[18. ENGINE]
AdBlue/DEF SCR
AdBlue/DEF SCR chamber
Front
18
silencer
chamber
DOC
DPR
Upp
Fr
LH
DPR chamber
Upp
Fr
LH
18-225
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[18. ENGINE]
The DPR cleaner and the AdBlue/DEF SCR must be handled with care as they are made from ceramics, are heavy,
and therefore may break easily.
18-226
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[18. ENGINE]
DOC downstream
temperature sensor
SCR upstream
temperature sensor 18
SCR upstream
NOx sensor
Upp
Fr
LH
DPR downstream
temperature sensor
SCR downstream
NOx sensor
18-227
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
3 A
2 A
1 2
;
E
A
;
9 9
9
9 9
6
5
D (M10)
B
5 7
F (M12)
C (M8)
8
Tightening torque
A
(DPR filter to DPR chamber)
64 N·m{653 kgf·cm, 47 lbf·ft}
(SCR to SCR chamber)
(SCR to Rear silencer chamber)
B
64 N·m{653 kgf·cm, 47 lbf·ft}
(DPR filter to Front silencer chamber)
C
35 N·m{343 kgf·cm, 26 lbf·ft}
(Front silencer chamber to DPR filter)
D
64 N·m{653 kgf·cm, 47 lbf·ft}
(Front silencer chamber to Rail)
E
27.6±5 N·m{281±51 kgf·cm, 20±4 lbf·ft}
(Insulator mount nuts)
F
110 N·m{1,079 kgf·cm, 81 lbf·ft}
(Rail to bracket)
18-228
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[18. ENGINE]
AdBlue/DEF indicator
18
Engine ECU
DEF piping Ambient air
temperature
sensor
AdBlue/DEF pressure
sensor (built-in)
AdBlue/DEF piping
Communication wire
NH3
SCR slip
catalyst
AdBlue/DEF
injector
DOC DPR
SCR upstream
DOC downstream NOx sensor
Differential pressure sensor
temperature sensor
DPR downstream
temperature sensor
18-229
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[18. ENGINE]
Post-processing system
CAN line
2 15
Engine ECU
ENGINE 12 14 1
5 6
16
13 8 7
3 4 11
10
CAN line
15
9
1. Conformity table
1 DCU DCU
2 Muffler unit SCR unit
3 DOC DOC
4 DPR DPF
5 SCR SCR catalyst
18-230
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[18. ENGINE]
D D
B
A
G
J
E
F H
I C 18
8
7
1. Conformity table
18-231
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[18. ENGINE]
18.11.2.5 Caution notes for mounting and dismounting of AdBlue/DEF and coolant piping
1. The quick-joints used for AdBlue/DEF piping can cause leakage when they are being connected again after
being disconnected once, because AdBlue/DEF powder may adhere to the seal. When reconnecting, confirm
that there is no AdBlue/DEF powder or other foreign matter adhering to the seal. Wash with warm water if any
AdBlue/DEF powder is noticed.
2. When the work is performed without completion of after-run, the piping will be filled with AdBlue/DEF, and
AdBlue/DEF will flow out when a quick-connector is disconnected. Always confirm that the after-run has been
completed.
'After-run' means that the injection of AdBlue/DEF has ended, but AdBlue/DEF remains in the AdBlue/DEF pump
and in the piping. After stopping the engine, the system returns AdBlue/DEF to the AdBlue/DEF tank so that
remaining AdBlue/DEF does not freeze in cold weather, or dries to form crystals.
3. When work is performed directly after stopping the engine, there is the danger of high-temperature coolant
being sprayed out and causing burns. Always perform the work after the coolant temperature has dropped
sufficiently.
4. As the piping uses molded tubes, do not subject the tubes to excessive force at the time of work.
5. Avoid direct contact with AdBlue/DEF or cooling fluid that has flown from the piping. In case of accidental
contact, wash the affected areas thoroughly.
6. After disconnection, apply vinyl covers or similar to prevent entry of foreign matter into the piping.
7. After joints have been disconnected, immediately apply covers to prevent entry of foreign matter into the
AdBlue/DEF tank, AdBlue/DEF pump, and AdBlue/DEF injector.
8. When applying covers, use separate covers to prevent mixing of AdBlue/DEF and coolant.
9. When disconnecting a quick-connector is difficult, do not use excessive force, but first remove any dirt which
has become attached around the joint; using excessive force to separate a quick-connector can damage it
together with other parts.
10. The piping consists of coolant piping and AdBlue/DEF piping, and this unit cannot be disassembled.
11. Do not use a tool to remove the quick-connector.
12. Perform the work with all harness connectors connected. Working with disconnected parts can cause rust,
therefore it Is recommended to apply covers to the connectors to prevent contact with coolant or AdBlue/DEF.
Quick connector
Male side
Quick connector lock Tube
• If the lock is not pushed correctly for disconnecting, the connecting part may break.
• Do not insert and twist a screwdriver or similar to disconnect.
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1) To connect a quick-connector, confirm that the connector end part is free of dust, dirt, etc. Blow air etc. to
remove any adhering dirt etc. Insert the quick-connector all the way until it engages with a click.
Remove any crystallized AdBlue/DEF from AdBlue/DEF piping by wiping with a shop towel moistened with warm
water or by washing with warm water.
Coolant flow
18
AdBlue/DEF
Without indication tape Injector Blue
tape
To Engine From Engine
AdBlue/DEF flow
Pink
tape
AdBlue/DEF
Injector
Pink
tape
White White
tape tape
AdBlue/DEF AdBlue/DEF
pump tank
Orange
tape Orange
tape
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18.11.2.6 Inspection
1. Periodic inspection items
• The DPR system is to be inspected every 12 months according to the following outline.
1) Confirm that there is no abnormal increase of the engine oil in the oil pan. (The X mark of the oil level gauge
shall not be exceeded.)
If the engine oil should have increased abnormally, there is the possibility that there is an abnormality in the
injection system or that unburned fuel has leaked through the gap between the piston rings and the cylinder liner to
the oil pan.
2) Check for looseness of parts in the exhaust system (exhaust pipe, body flange) and for exhaust gas
leakage.
3) Confirm that the external appearance of the exhaust gas temperature sensor harness is free of
abnormalities (broken covering, missing clips or clamps).
4) Inspect the hoses of the DPR differential pressure sensor and confirm that they are free of deterioration and
cracks. Replace them with new parts if 3 years have passed. Check that the pipes are free of internal
clogging. (Apply compressed air from the pipe tip and confirm passage of the air.)
5) Inspect DPR manual regeneration switch and the indicator lamp in the meter for a burned out bulb and wire
breaks. (When DPR manual regeneration switch is pressed with the engine stopped and the starter key set
to ON, it is normal when the lamp in the switch and the indicator lamp in the meter light up.)
6) Check the exhaust gas pressure.
2. Time for inspection and maintenance for the exhaust gas pressure
1) When using the Hino-DX, check the exhaust gas pressure every 4500 Hour and decide whether
maintenance is required or not.
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Shop visit for inspection First, perform steps 1 to 5, as shown in the periodic inspection schedule.
(Refer to 10-14 page)
Afterwards, connect the Hino-DX, check for past faults, confirm the DPR
Periodic inspection (1 to 5) status, and in case of past fault DTCs, record them in the DX report.
18
First, perform a basic inspection of the engine.
- Inspection of the injection quantity (at the time of idling)
Basic engine - Inspection of the fuel system (fuel filter clogging)
inspection - Inspection of the intake system
(air element clogging, air flow meter inspection)
OK - EGR inspection (confirmation of the ability to follow forced drive opening)
- VNT inspection (confirmation of the ability to follow forced drive opening)
In case of abnormalities on the engine side, inspect the engine side first.
OK NG: The value of “DPR exhaust gas temperature (IN)” does not exceed 450°C [842°F]. If the system cannot
transition to the forced regeneration mode, inspect the following.
• Neutral switch circuit
• Acce le ra tor e me rge ncy circuit
• Malfunction of cancel switch and so on
CAUTION:
Do not perform successive manual regeneration processes.
This is to prevent an accumulation of unburned HC in the EGR system.
If manual forced regeneration of the DPR twice or more often cannot be
avoided because of inspection, drive for approx. 10 minutes or operate the
engine for approx. 20 minutes with the idle volume set to MAX between the
regeneration processes.
This work must be performed because it is required to blow unburned HC
from the EGR and to prevent clogging etc. in the EGR system.
Differential
pressure confirmation DPR change or cleaning
• * "Forced regeneration" here aims to check the regeneration function of the DPR system.
Inspect the temperature surrounding the DPR cleaner using the Hino-DX.
• If you combust soot at the time of this inspection, use the regeneration switch.
(See "About Manual Regeneration" in the Instruction Manual of the Machine.)
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P0545 DOC downstream temperature sensor - out of range (Out of range low)
P0546 DOC downstream temperature sensor - out of range (Out of range high)
Sensor system fault P1427 Differential pressure sensor - out of range (Out of range low)
related to the DPR
system P1428 Differential pressure sensor - out of range (Out of range high)
P2032 DPR downstream temperature sensor - out of range (Out of range low)
P2033 DPR downstream temperature sensor - out of range (Out of range high)
P0122 Intake throttle valve-opening sensor 1 out of range (Out of range low)
P0123 Intake throttle valve position sensor 1 out of range (Out of range high)
Failure of DPR-
P2100 DC motor for intake throttle valve - circuit [Open circuit (circuit low)]
related parts
P2101 Intake throttle valve - functional
P2103 DC motor for intake throttle valve - circuit [Short circuit (circuit high)]
Failure of SCR- P2214 SCR downstream NOx sensor - Performance and Monitoring capability
related parts P2222 Abnormal downstream NOx sensor heater
P2481 SCR upstream temperature sensor - out of range (Out of range low)
P2482 SCR upstream temperature sensor - out of range (Out of range high)
• In case of a failure of the DPR system, perform inspection according to the “inspection flow” on the next page
when the menu "DPR inspection" is displayed.
• Standard values for basic inspection of the engine
Standard values for injection quantity
Standard values for inspection of Complete closing with an instruction for complete closing. The ability to follow with forced
the EGR system drive shall be within ±5 %.
Standard values for inspection of
The ability to follow with forced drive shall be within ±5 %.
the VNT system
2,000 10 or less
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Shop visit for inspection In case of a DTC code, record it in the DX report and then check according to
the following procedure.
In case of a DTC code of the engine system, inspect the engine system first.
DTC code confirmation
In case of a DTC code of the DPR system, confirm the contents of the DPR
status display after inspection of the engine system.
Excessive DPR ON/OFF Detection of abnormal DPR DPR filter disassembly and cleaning
differential pressure flag differential pressure (P244B) Black smoke, injection quantity on the engine side
Inspection of the EGR system
Inspection related to the differential pressure pipe
Clogging alarm level ON/OFF DPR manual regeneration switch Confirmation of the switch activation
flag not activated, or failure of the Switch system failure inspection
switch system (P2463) (Wire break, short-circuit)
Defective manual ON/OFF DPR manual regeneration was DPR filter disassembly and cleaning
regeneration flag not completed (P2458) Inspection of the engine system
Inspection of injection quantity and
EGR system
History flag for ON/OFF There is a record showing
incomplete incomplete DPR
auto-regeneration auto-regeneration processes
processes
ON/OFF There is a record showing Confirmation of the switch operation method
Excessive fuel addition frequent interruption during DPR
quantity flag manual regeneration switch
operation (P24A2)
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Select
% H I R U H U H V H W W L Q J D O O W K H ' 3 5 L W H P V E H V X U H W R V W R S W K H H Q J L Q H S U H V V W K H E U D N H V Z L W F K
D Q G V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q $ I W H U W K D W V H W W K H V W D U W H U N H \ W R 2 1
1) If DPR is normal, the values in the Data display "Status" are OFF.
2) If "ON" is displayed in the Data display, clean, replace or maintenance the DPR suitably. If the DPR services
are complete, then click "Reset all DPR items (R)" button to clear the values (=[OFF]).
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Before doing the "Reset all DPR items (R)", stop the engine, select the neutral gear and set the starter key to the
ON position.
• The soot levels on the multifunctional display will also be reset by resetting all DPR items.
• If manual forced regeneration is performed again for some reason during regeneration after all DPR items were
18
reset through fault diagnosis, resetting is not required from the second time and after.
The same condition is used after the initial resetting has been completed.
• Never stop the unit near any flammable material, including high grass or leaves, during manual regeneration.
• Extreme heat from the exhaust outlet could cause a fire resulting in personal injury and property damage.
• Always keep all flammable materials away from the DPR cleaner, exhaust pipe and tail pipes.
• Never touch the DPR cleaner, exhaust pipe or tail pipe during regeneration. Severe burns and/or other personal
injuries could occur.
• More fuel than usual is contained in the air returned through the EGR to the intake side during DPR
regeneration. If you stop the engine soon after regeneration, this fuel will congeal, which may influence
subsequent engine operation. In order to clean the air in the engine that contains fuel, be sure to perform the 10-
minuite scavenging drive after regeneration has been completed.
• Manual regeneration can be performed even if a small amount of soot has accumulated, so this mode can be
used to inspect the regeneration system.
• When you combust soot using the manual regeneration mode, start the mode using the regeneration switch in
the cabin. ("a" on next page.)
When you inspect the system, start the regeneration mode using the Hino-DX. ("b" on the next page.)
This section mainly explains the manual forced regeneration procedure using the Hino-DX.
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S
12h DP R re ge ne ra tion s witch
levels 3 to 9
• To perform manual forced regeneration, set the attachment of the machine to the parking attitude, stop the
engine, lift up the lock lever and set the starter key to [ON].
• Press the DPR regeneration switch to operate the hydraulic pump relief. "Regenerating" appears on the screen
of the multifunctional display.
• When the hydraulic pump relief operation has been completed and "Regenerating" on the screen goes out, soot
combustion is completed.
2. When you inspect the DPR system
• You can confirm the whole DPR system condition using the Hino-DX.
• The Hino-DX displays engine data in the regeneration operation on the screen. The operation status can be
understood by analyzing the data values.
• The manual forced generation function using the Hino-DX aims to inspect system operation. If the soot level
indicator shown in the multifunctional display is between levels 3 and 9, do not use the Hino-DX, but use the
DPR generation switch in the cabin for regeneration.
• If any fault code concerning the DPR is detected, refer to the fault diagnosis documents and be sure to change
or clean the DPR cleaner. After that, inspect the whole system condition using the manual forced generation
mode of the Hino-DX.
1. Connect the Hino-DX to the machine and set the starter key to [ON].
Flag setting by "Set (C)"→"Customize (C)"→"10-sec DPR lamp blinking / Identifying setting status" is unnecessary.
If you set the flag, ensure to return the setting to "0".
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2. Select the "DPR check (D)" menu in "Check functions (E)" from the Hino-DX menu bar.
Select
18
3. Click the "Reset all DPR items (R)" button in the DPR status display window to reset the values, and then click
the "Manual forced regeneration (E)" button.
To perform manual forced regeneration, stop the engine, lift up the lock lever and set the starter key to [ON].
% H I R U H U H V H W W L Q J D O O W K H ' 3 5 L W H P V E H V X U H W R V W R S W K H H Q J L Q H S U H V V W K H E U D N H V Z L W F K
D Q G V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q $ I W H U W K D W V H W W K H V W D U W H U N H \ W R 2 1
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4. Verify the contents of the displayed caution note, set a check mark for "Comprehended", and then click the
"Next (N)" button.
If you continuously perform manual forced regeneration, perform a 10-minuite scavenging drive before the next
regeneration cycle.
5. After "Manual forced regeneration" appears on the screen, start the engine.
Make the machine to the parking attitude and lift up the lock lever in the idle state.
D $ I W H U S D U N L Q J W K H P D F K L Q H L Q D V D I H S O D F H N H H S L G O L Q J Z L W K W K H J H D U V H W L Q W K H
Q H X W U D O S R V L W L R Q D Q G W X U Q R I I W K H 3 7 2
E % H V X U H W R S U H V V W K H E U D N H V Z L W F K D Q G W R V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q
1) The "1.LIFT UP LOCK LEVER 2.PUSH REGENERATION SW." icon appears on the cluster gauge. Lift up
the lock lever to ensure safety around the machine.
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S
12h
2) If you press the "DPR manual regeneration switch" in the cabin, manual regeneration will start.
18
When the "Regenerating" mark does not appear on the cluster or the engine speed does not idle up even if the
DPR regeneration switch is pressed, you cannot proceed to forced generation.
In such cases, inspect the neutral switch circuit, accelerator emergency circuit, malfunction of the cancel switch and
so on.
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18
7 K H I R U F H G U H J H Q H U D W L R Q L V L Q S U R J U H V V D Q G W K D W \ R X K D Y H W R Z D L W I R U D Z K L O H
D : K H Q V R R W F R P E X V W L R Q L V E H L Q J S H U I R U P H G
: K H Q V R R W F R P E X V W L R Q L V F R P S O H W H G W K H U H J H Q H U D W L R Q P R G H Z L O O D X W R P D W L F D O O \ W X U Q R I I
6 R P H P D F K L Q H V P L J K W R S H Q R U F O R V H W K H L U U H O L H I Y D O Y H V Z K H Q W K H U H J H Q H U D W L R Q L V F R P S O H W H G
$ I W H U W K H K \ G U D X O L F U H O L H I V W D U W V D Q G W K H Q W K H R S H U D W L Q J Q R L V H R I W K H U H O L H I Y D O Y H L V
K H D U G S U H V V > & D Q F H O @ E X W W R Q W R V W R S W K H P D Q X D O I R U F H G U H J H Q H U D W L R Q
& $ 8 7 , 2 1 ! !
$ I W H U W K H P D Q X D O I R U F H G U H J H Q H U D W L R Q L V V W R S S H G W K H U H P D \ E H D F D V H Z K H U H W K H K \ G U D X O L F
U H O L H I D X W R P D W L F D O O \ V W D U W V D J D L Q 1 R W H W K D W W K H U H J H Q H U D W L R Q L V F R P S O H W H G Z K H Q W K H
K \ G U D X O L F U H O L H I H Q G V
, I W K L V K D S S H Q V S U H V V > & D Q F H O @ E X W W R Q W R D E R U W W K H U H J H Q H U D W L R Q
E : K H Q W K H L Q V S H F W L R Q R Q W K H ' 3 5 V \ V W H P L V E H L Q J F R Q G X F W H G
$ I W H U V W D U W L Q J W K H U H J H Q H U D W L R Q S U R F H V V F R Q I L U P W K D W W K H Y D O X H R I ' 3 5 ( [ K D X V W W H P S H U D W X U H
, 1 K D V U L V H Q W R & ^ ) ` R U K L J K H U W K H Q S U H V V W K H U H J H Q H U D W L R Q R U > & D Q F H O @
E X W W R Q W R V W R S W K H U H J H Q H U D W L R Q
D $ I W H U S D U N L Q J W K H P D F K L Q H L Q D V D I H S O D F H N H H S L G O L Q J Z L W K W K H J H D U V H W L Q W K H
Q H X W U D O S R V L W L R Q D Q G W X U Q R I I W K H 3 7 2
E % H V X U H W R S U H V V W K H E U D N H V Z L W F K D Q G W R V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q
2) When the process up through the soot combustion treatment has been completed, the following explanation
appears. Click the "Close (C)" button to end manual forced regeneration.
D $ I W H U S D U N L Q J W K H P D F K L Q H L Q D V D I H S O D F H N H H S L G O L Q J Z L W K W K H J H D U V H W L Q W K H
Q H X W U D O S R V L W L R Q D Q G W X U Q R I I W K H 3 7 2
E % H V X U H W R S U H V V W K H E U D N H V Z L W F K D Q G W R V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q
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7. When the caution box appears, check the content and perform a 10-minuite scavenging drive. The scavenging
drive is completed in 10 minutes. Operate the starter key to stop the engine.
After scavenging drive has been completed, set a check mark for "Comprehended" and click the "Exit (X)"
button.
8. This completes the manual forced regeneration process. When all stages of the manual forced regeneration
have been completed, carry out the differential pressure check.
You can stop manual forced regeneration also by pressing the "DPR manual regeneration" button in the cabin. In
this case, the caution about the scavenging drive does not appear but the 10-minuite scavenging drive should be
performed.
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18
1) If you click “DPR differential pressure check (D)” button, DPR differential pressure check window will be
shown.
2) Click the “Execute (E)” button.
3) Engine rotation will go up automatically to maximum and DPR differential pressure will be recorded.
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4) Click the “Stop (E)” button and you are finished measuring.
Every time you click the "Execute (E)" and "Stop (E)" button, the display will change "Execute (E)" and "Stop (E)"
alternately.
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18
The DPR cleaner and the AdBlue/DEF SCR must be handled with care as they are made from ceramics, are heavy,
and may break easily.
AdBlue/DEF hose
with pink tape
Coolant hose
with blue tape
• Refer to "Caution notes for mounting and dismounting of AdBlue/DEF and coolant piping".
• Do not loosen the Torx bolt shown in the figure.
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• Prepare a container and a shop towel, as coolant will spill when the hoses are disconnected.
• Close the hose with a blind plug as coolant will flow from the hose.
• Install a protective cap on the AdBlue/DEF injector.
P-type clamp
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18
4) Disconnect the connector of the harness on the machine side from the NOx controller.
• Mark the components to ensure that the upstream and the downstream side can be re-installed in their correct
locations.
• The NOx sensor and the NOx controller cannot be disconnected. Always pull the indicated connector.
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A
View A
Do not disconnect
the connector.
NOx sensor
NOx controller
P-type clamp
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Holding band
2) Remove the bolt and the nut, and then remove the differential pressure bracket from the hanger of the
muffler unit.
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P-type clamp
Holding band
Connector
2) Disconnect the connector of the harness on the machine side from the connector of the SCR upstream
temperature sensor.
3) Remove the clamp of the SCR upstream
temperature sensor from the bracket at the "A" in Connector
the figure.
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Upp
LH Fr
Matching mark
2) Remove the 10 bolts and the 10 nuts and remove the rear silencer chamber, the bracket, and the gasket
from the AdBlue/DEF SCR.
Applying matching marks to the bracket facilitates the work at the time of installation.
Upp
LH
Matching mark Fr
4) Remove the 10 bolts and the 10 nuts and remove the AdBlue/DEF SCR chamber, the 2 brackets, and the
gasket from the AdBlue/DEF SCR.
• Applying matching marks to the brackets facilitates the work at the time of installation.
• When the marking of the gas flow direction cannot be seen easily, marking the flow direction can facilitate the
work at the time of installation.
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Do not touch the insulator on the inner side directly because it contains glass fibers.
Mark the AdBlue/DEF SCR so that the top and bottom section can be identified easily.
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The DPR cleaner and the AdBlue/DEF SCR must be handled with care as they are made from ceramics, are heavy,
and may break easily.
1. Insulator installation
1) Install the 2 insulators with 4 bolts and 4 nuts to
the AdBlue/DEF SCR. 18
Insulator recess
• Do not touch the insulators on the inner side directly because they contain glass fibers.
• Do not confuse the insulators in vertical direction.
• Install the insulator so that the stamp "GAS FLOW →" of the AdBlue/DEF SCR case can be seen.
• Mount the insulator with the recessed part matched to the projection of the bracket on the AdBlue/DEF SCR
body.
LH
Matching mark Fr
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Always replace the gasket, the bolts, and the nuts with new parts to prevent leakage of exhaust gas and AdBlue/
DEF.
2) Diagonally tighten the 10 bolts and 10 nuts previously tightened provisionally. (Tighten twice.)
Tightening torque : 64 N·m {653 kgf·cm, 47 lbf·ft}
3) Line up the matching marks and use a new Bracket
gasket, 10 new bolts, and 10 new nuts to
provisionally secure the rear silencer chamber,
and the bracket to the AdBlue/DEF SCR.
Upp
LH Fr
Matching mark
Always replace the gasket, the bolts, and the nuts with new parts to prevent leakage of exhaust gas.
4) Diagonally tighten the 10 bolts and 10 nuts previously tightened provisionally. (Tighten twice.)
Tightening torque : 64 N·m {653 kgf·cm, 47 lbf·ft}
3. Mounting the muffler unit
1) Place the mount rubbers at the muffler unit
installation holes of the bracket.
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3) Set the plates to the mount rubbers on the underside of the bracket, and install the spacers at the center.
Secure the cap screws with the nuts and washers.
Nut
Muffler unit (Stand)
Mount rubber
Base
Mount rubber 18
Spacer
Plate
Wa s he r
Cap screw
5) Apply Loctite #262 to the threaded part of the cap screws and tighten the cap screws in the order shown in
the figure to the specified torque.
Tightening torque :
108±11 N·m {1,101±112 kgf·cm, 80±8.1 lbf·ft}
4. Installation of the exhaust pipe
1) Replace the gasket with a new part, and then install the exhaust pipe to the muffler unit, using bolts and
nuts.
Tightening torque :
59±5.9 N·m {579±57 kgf·cm, 44±4 lbf·ft}
Gasket
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?
2) Connect the connector of the SCR upstream temperature sensor with the socket of the harness on the
machine side.
3) Secure the harness of the SCR upstream temperature sensor with a P-type clamp and a holding band.
P-type clamp
Holding band
Connector
Tightening torque :
26±2.6 N·m {265±26.5 kgf·cm, 19±1.9 lbf·ft}
6. Installation of the tailpipe
1) Replace the gasket with a new part, and then
install the tailpipe on the muffler unit with the
bolts, nuts and U-bolt.
Tightening torque :
Tailpipe Outside nuts
120±12 N·m {1,224±122 kgf·cm, 88±8.8 lbf·ft} Inside nuts
U-bolt (inside)
2.2±0.2 N·m {22±2 kgf·cm, 1.6±0.14 lbf·ft}
U-bolt (outside)
10.8±1.1 N·m {110±11 kgf·cm, 8±0.8 lbf·ft}
Gasket
Tailpipe
U-bolt
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[18. ENGINE]
18
2) Connect the hoses of the differential pressure sensor (2 locations) with the muffler unit and secure them
with hose clamps.
A 28mm {1.10in}
B 18mm
{0.71in}
18-263
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[18. ENGINE]
Holding band
Lock
When bundling the harness, fix it in the orientation shown in the figure, so that there is no contact with the lock side
of the connector.
18-264
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[18. ENGINE]
18
P-type clamp
View A
18-265
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[18. ENGINE]
4) Secure the harness of the NOx sensor with a P-type clamp and a holding band.
Tightening torque :
26±2.6 N·m {265±26.5 kgf·cm, 19±1.9 lbf·ft}
• Install the harness cover, leaving some slack on the sensor side, so that the harness wire cannot be seen.
• When installing the clips, take care that the NOx sensor lead wires do not interfere with the bracket, the bolts,
etc.
• Confirm that the lead wires are not under tension.
P-type clamp
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[18. ENGINE]
18
• Confirm the hose color and install at the correct position.
• Refer to "Caution notes for mounting and dismounting of AdBlue/DEF and coolant piping".
• Do not loosen the Torx bolt shown in the figure.
AdBlue/DEF hose
with pink tape
Coolant hose
with blue tape
18-267
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[18. ENGINE]
The DPR cleaner and the AdBlue/DEF SCR must be handled with care as they are made from ceramics, are heavy,
and may break easily.
AdBlue/DEF hose
with pink tape
Coolant hose
with blue tape
• Refer to "Caution notes for mounting and dismounting of AdBlue/DEF and coolant piping".
• Do not loosen the Torx bolt shown in the figure.
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[18. ENGINE]
• Prepare a container and a shop towel, as coolant will spill when the hoses are disconnected.
• Close the hose with a blind plug as coolant will flow from the hose.
• Install a protective cap on the AdBlue/DEF injector.
P-type clamp
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[18. ENGINE]
4) Disconnect the connector of the harness on the machine side from the NOx controller.
• Mark the components to ensure that the upstream and the downstream side can be re-installed in their correct
locations.
• The NOx sensor and the NOx controller cannot be disconnected. Always pull the indicated connector.
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[18. ENGINE]
A
View A 18
Do not disconnect
the connector.
NOx sensor
NOx controller
P-type clamp
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[18. ENGINE]
Holding band
2) Remove the bolt and the nut, and then remove the differential pressure bracket from the hanger of the
muffler unit.
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[18. ENGINE]
P-type clamp
Holding band
18
Connector
2) Disconnect the connector of the harness on the machine side from the connector of the SCR upstream
temperature sensor.
3) Remove the clamp of the SCR upstream
temperature sensor from the bracket at the "A" in Connector
the figure.
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[18. ENGINE]
DPR cleaner
Y X Matching mark
2) Remove the 8 bolts and the 8 nuts and remove the front silencer chamber, the bracket, and the gasket from
the DPR cleaner.
Applying matching marks to the bracket facilitates the work at the time of installation.
3) Remove the 3 botls and remove the front silencer Front silencer chamber
chamber form the bracket.
Bracket
Matching mark
Z
Y
X
Matching
mark
Z
DPR cleaner
Y X
• Applying matching marks to the bracket facilitates the work at the time of installation.
• When the marking of the gas flow direction cannot be seen easily, marking the flow direction can facilitate the
work at the time of installation.
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[18. ENGINE]
5) Remove the 10 bolts and the 10 nuts and remove the DPR chamber, the bracket, and the gasket from the
DPR cleaner.
6) Remove the 2 bolts and remove the DPR cleaner DPR cleaner
and bracket from the rail.
Z
Bracket
18
Y X Rail Matching mark
The DPR cleaner must be handled with care as it is made from ceramics, is heavy, and may break easily.
Z
Bracket
DPR cleaner
Y X
Always replace the gasket, the bolts, and the nuts with new parts to prevent leakage of exhaust gas.
4) Diagonally tighten the 10 bolts and 10 nuts previously tightened provisionally. (Tighten twice.)
Tightening torque : 64 N·m {653 kgf·cm, 26 lbf·ft}
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[18. ENGINE]
5) Line up the matching marks and install the front Front silencer chamber
silencer chamber to the rail with 3 bolts.
Tightening torque : 110 N·m {1,079 kgf·cm, 81
lbf·ft}
Rail
Matching mark
Z
Y
X
6) Line up the matching marks and use a new Front silencer chamber Bracket
gasket, 8 new bolts, and 8 new nuts to
provisionally secure the front silencer chamber
and the bracket to the DPR cleaner.
DPR cleaner
Y X Matching mark
Always replace the gasket, the bolts, and the nuts with new parts to prevent leakage of exhaust gas.
7) Diagonally tighten the 8 bolts and 8 nuts previously tightened provisionally. (Tighten twice.)
Tightening torque : 35 N·m {343 kgf·cm, 26 lbf·ft}
2. Mounting the muffler unit
1) Place the mount rubbers at the muffler unit
installation holes of the bracket.
3) Set the plate to the mount rubber on the underside of the bracket, and install the spacer at the center.
Secure the cap screw with the nut and a washer.
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[18. ENGINE]
Nut
Muffler unit (Stand)
Mount rubber
Base
Mount rubber
Spacer
Plate
Wa s he r
18
Cap screw
5) Apply Locktite #262 to the threaded part of the cap screws and tighten the cap screws in the order shown in
the figure to the specified torque.
Tightening torque :
108±11 N·m {1,101±112 kgf·cm, 80±8.1 lbf·ft}
3. Installation of the exhaust pipe
1) Replace the gasket with a new part, and then install the exhaust pipe to the muffler unit, using bolts and
nuts.
Tightening torque :
59±5.9 N·m {579±57 kgf·cm, 44±4 lbf·ft}
Gasket
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[18. ENGINE]
?
2) Connect the connector of the SCR upstream temperature sensor with the socket of the harness on the
machine side.
3) Secure the harness of the SCR upstream temperature sensor with a P-type clamp and a holding band.
P-type clamp
Holding band
Connector
Tightening torque :
26±2.6 N·m {265±26.5 kgf·cm, 19±1.9 lbf·ft}
5. Installation of the tailpipe
1) Replace the gasket with a new part, and then
install the tailpipe on the muffler unit with the
bolts, nuts and U-bolt.
Tightening torque :
Tailpipe Outside nuts
120±12 N·m {1,224±122 kgf·cm, 88±8.8 lbf·ft} Inside nuts
U-bolt (inside)
2.2±0.2 N·m {22±2 kgf·cm, 1.6±0.14 lbf·ft}
U-bolt (outside)
10.8±1.1 N·m {110±11 kgf·cm, 8±0.8 lbf·ft}
Gasket
Tailpipe
U-bolt
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[18. ENGINE]
18
Differential pressure bracket
2) Connect the hoses of the differential pressure sensor (2 locations) with the muffler unit and secure them
with hose clamps.
A 28mm {1.10in}
B 18mm
{0.71in}
Holding band
18-279
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[18. ENGINE]
Lock
When bundling the harness, fix it in the orientation shown in the figure, so that there is no contact with the lock side
of the connector.
P-type clamp
18-280
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[18. ENGINE]
A 18
View A
4) Secure the harness of the NOx sensor with a P-type clamp and a holding band.
Tightening torque :
26±2.6 N·m {265±26.5 kgf·cm, 19±1.9 lbf·ft}
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[18. ENGINE]
• Install the harness cover, leaving some slack on the sensor side, so that the harness wire cannot be seen.
• When installing the clips, take care that the NOx sensor lead wires do not interfere with the bracket, the bolts,
etc.
• Confirm that the lead wires are not under tension.
P-type clamp
Coolant hose
without indication tape
AdBlue/DEF hose
with pink tape
Coolant hose
with blue tape
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[18. ENGINE]
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[18. ENGINE]
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[18. ENGINE]
18.11.5.2 Replacement
Filter replacement
Set the starter key to "OFF" and perform the work after waiting for a sufficient time to complete the after-run
(returning the AdBlue/DEF to the AdBlue/DEF tank).
Filter cover
Prepare a container and a shop towel as AdBlue/DEF will spill when the filter cover is removed.
O-ring Equalizer
When a screwdriver or similar is used with excessive force at the time of replacement of the AdBlue/DEF pump
filter and the equalizer, the AdBlue/DEF pump body may be damaged and AdBlue/DEF leakage may be caused.
4) Select black edge color of the filter removal tool Select “BLACK(B)” side
fot the filter color.
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[18. ENGINE]
Filter
3) Apply Mobil velocite Oil No. 6 or equivalent to AdBlue/DEF pump
new O-ring.
O-ring Equalizer
4) Replace with a new equalizer and insert it into the AdBlue/DEF pump.
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[18. ENGINE]
Filter cover
Set the starter key to "OFF" and perform the work after waiting for a sufficient time to complete the after-run
(returning the AdBlue/DEF to the AdBlue/DEF tank).
1. Harness disconnection
1) Remove the holding bands from the harness of
the AdBlue/DEF pump.
2) Disconnect the harness connector from the
AdBlue/DEF pump.
2. Hose disconnection
1) Disconnect the hoses from the AdBlue/DEF
pump.
Refer to "Caution notes for mounting and dismounting of AdBlue/DEF and coolant piping".
• Prepare a container and a shop towel, as coolant will spill when the hoses are disconnected.
• Close the hose with a blind plug as coolant will flow from the hose.
• Install a protective cap on the AdBlue/DEF pump.
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[18. ENGINE]
2. Hose connection
1) Connect the hoses to the AdBlue/DEF pump.
Refer to "Caution notes for mounting and dismounting of AdBlue/DEF and coolant piping".
5
4
2 1
The hoses can be identified by the color of the tapes. Please refer to the figure and install at the correct position.
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[18. ENGINE]
AdBlue/DEF
2 Orange
(backflow)
AdBlue/DEF
3 White
(inlet)
4 Coolant Brown
5 Coolant Yellow
18
• Connect each hoses at the angle shown in the figure.
20
35
40 25
20
3. Harness connection
1) Connect the harness connector with the AdBlue/
DEF pump.
2) Secure the harness of the AdBlue/DEF pump
with holding bands.
4. Fill in coolant
1) Check the coolant quantity and replenish if it is not sufficient.
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[18. ENGINE]
18-290
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[18. ENGINE]
18.11.6.2 Replacement
Set the starter key to "OFF" and perform the work after waiting for a sufficient time to complete the after-run
(returning the AdBlue/DEF to the AdBlue/DEF tank).
1. Hose disconnection
18
Refer to "Caution notes for mounting and dismounting of AdBlue/DEF and coolant piping".
1) Remove the hose clamps, and then disconnect the 2 coolant hoses and the AdBlue/DEF hose from the
AdBlue/ DEF injector.
AdBlue/DEF hose
with pink tape
Coolant hose
with blue tape
• Prepare a container and a shop towel, as coolant will spill when the hoses are disconnected.
• Close the hose with a blind plug as coolant will flow from the hose.
• Install a protective cap on the AdBlue/DEF injector.
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[18. ENGINE]
2. Harness disconnection
1) Disconnect the harness connector from the
AdBlue/DEF injector.
Close the opening of the AdBlue/DEF injector mounting part with tape or similar.
AdBlue/DEF injector
AdBlue/
DEF injector
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[18. ENGINE]
70 mm {2.76 in.}
2) Use a 15 mm {0.59 in.} spanner and connect the
coolant connector to the AdBlue/DEF injector. O-ring
Tightening torque :
5-6 N·m {51-61 kgf·cm, 4-5 lbf·ft}
AdBlue/
DEF injector 18
2. AdBlue/DEF injector installation
1) When replacing injector with new one Gasket
• To replace the injector with a new one, use pliers to
raise the 3 retaining tabs of the gasket, and then
remove the gasket from the AdBlue/DEF injector.
• Remove the gasket belonging to the injector and
install a large gasket with a different
AdBlue/
Retaining tab
DEF injector
Two ga s ke ts One gasket
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[18. ENGINE]
Use a new gasket when the AdBlue/DEF injector is removed and reinstalled.
3. Harness connection
1) Connect the connector of the harness to the
AdBlue/DEF injector.
4. Hose connection
1) Connect the 2 coolant hoses and the AdBlue/DEF hose with the AdBlue/DEF injector, and then secure them
with hose clamps.
AdBlue/DEF hose
with pink tape
Coolant hose
with blue tape
5. Fill in coolant
1) Check the coolant quantity and replenish if it is not sufficient.
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[18. ENGINE]
There are 3 inspection methods for the AdBlue/DEF: AdBlue/DEF analyzer inspection, pH litmus paper inspection,
and refractive index measuring inspection. Use one of these methods for the inspection.
18
1. AdBlue/DEF analyzer inspection
1) Sample the AdBlue/DEF, drip it into the AdBlue/
DEF analyzer, measure the AdBlue/DEF
concentration, and replace the AdBlue/DEF if it is
not at the reference value.
32.5 9
1.30
refractometer, measure the refractive index, and
Freezing point
Antifreeze
1.25
replace the AdBlue/DEF if it is not at the 1.20
reference value. 1.15
1.10
Specific gravity
1.00
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[18. ENGINE]
18.11.7.2 Replacement
AdBlue/DEF replacement
After the starter key has been set to "OFF", wait for a sufficient time to complete the after-run (return of the AdBlue/
DEF solution to the AdBlue/DEF tank) after setting the starter key to "OFF" and then perform the work.
1. Discharging of AdBlue/DEF
1) Remove the 2 bolts, and then remove the cover
plate from the machine.
2) Use a hexagon socket wrench with a width
across flats of 10 mm to loosen the drain plug
and discharge the AdBlue/DEF.
Cover plate
For disposal of AdBlue/DEF, observe the specified methods (waste processing) and pay attention to the protection
of the environment.
2. Filling of AdBlue/DEF
1) Install the drain plug on the AdBlue/DEF tank, using a hexagon socket wrench with a width across flats of 10
mm.
Tightening torque :
50±5 N·m {510±51 kgf·cm, 37±4 lbf·ft}
2) Install the cover plate on the machine, using the 2 bolts.
3) Open the lid.
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[18. ENGINE]
18
• Fill only AdBlue/DEF into the AdBlue/DEF tank.
• When filling AdBlue/DEF into the AdBlue/DEF tank, do not fill to a level above the F-line of the level gauge on the
left side of the tank.
AdBlue/DEF will overflow when this level is exceeded.
• If AdBlue/DEF should overflow from the AdBlue/DEF tank or if it should adhere to the AdBlue/DEF tank or
surrounding parts at the time of filling, immediately wipe it off with a shop towel or similar. If it is left as it is, the
AdBlue/DEF will crystallize and become white, it will become difficult to remove by wiping, so it should be wiped
off while liquid. Difficult-to-remove crystals can be removed more easily by wiping with a shop towel moistened
with warm water.
• When filling-in AdBlue/DEF, take care to prevent the entry of dust etc. into the AdBlue/DEF tank. Entry of dust
etc. can cause failure of the AdBlue/DEF pump and/or clogging of the piping and the AdBlue/DEF injector.
• If tightening of the filler cap of the AdBlue/DEF tank has become difficult because of AdBlue/DEF crystals
sticking to the filling port, do not apply excessive force, but tighten after removing the crystals with a shop towel
or similar. At such a time, take care that no shop towel scraps or similar get into the AdBlue/DEF tank.
• For disposal of AdBlue/DEF, observe the specified methods (waste processing) and pay attention to the
protection of the environment.
• As AdBlue/DEF expands when it freezes, the tank will rupture in case of freezing when AdBlue/DEF is filled in to
the max. level or higher.
• When AdBlue/DEF is filled in with the machine in inclined condition, AdBlue/DEF may overflow before the max.
level of the level gauge is reached.
• Check the level gauge after waiting for at least 1 minute after the key was set to ON.
E F
1 Full tank level
E F
2 Level 2 (Warning)
E F
3 Level 1 (Engine output is restricted.)
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[18. ENGINE]
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[18. ENGINE]
18.11.8.2 Replacement
18
2. Hose disconnection
IN OUT
Refer to "Caution notes for mounting and dismounting of AdBlue/DEF and coolant piping".
1) Remove the hose clamps, and then disconnect the 2 hoses from the coolant cut-off valve.
• Prepare a container and a shop towel as coolant will spill when the hoses are disconnected.
• Close the hose with a blind plug as coolant will flow from the hose.
• Close the coolant cut-off valve with blind plugs as coolant will flow from the valve.
• After disconnection, apply vinyl covers or similar to prevent entry of foreign matter into the piping.
3. Harness disconnection
1) Disconnect the harness connector from the
coolant cut-off valve.
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[18. ENGINE]
2. Harness connection
1) Connect the harness connector with the coolant
cut-off valve.
3. Hose connection
IN OUT
Refer to "Caution notes for mounting and dismounting of AdBlue/DEF and coolant piping".
1) Connect the 2 hoses to the coolant cut-off valve, and then secure them with hose clamps.
4. Fill in coolant
1) Check the coolant quantity and replenish if it is not sufficient.
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[18. ENGINE]
18.11.9 DCU
18.11.9.1 Replacement
DCU removal
1. DCU removal
1) Remove the 3 bolts, and then remove the DCU
with connectors from the machine.
18
2. Connector disconnection
1) Remove the clamps from the harness of the DCU.
Clamps
53-pole connector
Slide
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[18. ENGINE]
53-pole connector
Slide
If pulling with a light force is not possible, check that the slide has opened completely.
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[18. ENGINE]
DCU installation
1. DCU connector connection 86-pole connector Slide
1) Confirm that the slide of the connector on the
harness side is completely open and place the
connector straight onto the connector on the
DCU side.
Connector on
the harness
side 18
53-pole connector Connector on
the DCU side
Connector on
the harness
side
Connector on
Slide
the DCU side
2) Press the part above the connector on the harness side and insert the connector uniformly.
3) Move the slide in the direction indicated by an 86-pole connector
arrow until a "Click" is heard, and then connect Slide
the connector.
53-pole connector
Slide
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[18. ENGINE]
Slide part
When normal
Slide part
When inclined
• Repeat steps (1) and (2) if the slide does not move smoothly.
• As a gap may be caused when the sliding part is inclined, make sure to insert the sliding part exactly parallel to
the connector.
Clamp
2. DCU installation
1) Install the DCU on the machine, using the 3 bolts.
Tightening torque :
10.0±2 N·m {102±20 kgf·cm, 21±1.4 lbf·ft}
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[18. ENGINE]
18
2. Hose disconnection
1) Remove the hose clamps, and then disconnect
the 2 hoses from the differential pressure sensor.
Mark the components, so that the 2 hoses can be re-installed in their correct locations.
18-305
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[18. ENGINE]
Inspection
1. Resistance inspection
1) Use a circuit tester to measure the resistance of
the differential pressure sensor, and replace the
sensor if the standard value is exceeded.
&
%
Differential
pressure sensor $
A↔B 15
B↔C 15
2. Hose connection
1) Connect the 2 hoses to the differential pressure sensor, and then secure them with hose clamps.
B 15mm
{0.59in}
A 20mm
{0.79in}
3. Harness connection
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[18. ENGINE]
1) Connect the harness connector with the differential pressure sensor, and then secure it with a holding band.
18
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[18. ENGINE]
18-308
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[18. ENGINE]
18.11.11.2 Replacement
P-type clamp
18
Mark the components, so that the upstream and the downstream side can be re-installed in their correct locations.
18-309
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[18. ENGINE]
• Mark the components to ensure that the upstream and the downstream side can be re-installed in their correct
locations.
• The NOx sensor and the NOx controller cannot be disconnected. Always pull the indicated connector.
18-310
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[18. ENGINE]
A
View A 18
Do not disconnect
the connector.
NOx sensor
NOx controller
View A
18-311
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[18. ENGINE]
2) Secure the harness of the NOx sensor with P-type clamps and a holding band.
Tightening torque :
26±2.6 N·m {265±26.5 kgf·cm, 19±1.9 lbf·ft}
• When installing the clips, take care that the NOx sensor lead wires do not interfere with the bracket, the bolts,
etc.
• Confirm that the lead wires are not under tension.
• Install the harness cover, leaving some slack on the sensor side, so that the harness wire cannot be seen.
18-312
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[18. ENGINE]
18
Holding band
18-313
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[18. ENGINE]
Holding band
Inspection
1. Resistance inspection Thermometer DOC downstream
1) Use water and a circuit tester to measure the temperature sensor
resistance between the terminals, and replace @
the sensor if the standard value is exceeded. ?
?
0
Heat source @
18-314
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[18. ENGINE]
Detection pin
• In case of reuse, remove any old anti-seize agent from the DOC downstream temperature sensor and apply new
anti-seize agent (Bostik Never-Seez Nickel Special Grade or equivalent) to the threaded part.
• New parts have anti-seize agent applied.
• Do not reuse sensors that have been exposed to strong impacts, which have been dropped, or which have a 18
deformed detection part.
2. Harness connection
1) Connect the DOC downstream temperature
sensor harness with the harness on the machine
side, and then secure it with a holding band.
Holding band
Lock
• Take care that the harness of the DOC downstream temperature sensor is not twisted.
• When bundling the harness, fix it in the orientation shown in the figure, so that there is no contact with the lock
side of the connector.
18-315
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[18. ENGINE]
P-type clamp
18-316
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[18. ENGINE]
Inspection
1. Resistance inspection Thermometer DPR downstream
1) Use water and a circuit tester to measure the temperature sensor
resistance between the terminals, and replace @
the sensor if the standard value is exceeded. ?
?
0
Heat source @ 18
Temperature (°C{°F}) Standard value (kΩ)
Detection pin
• In case of reuse, remove any old anti-seize agent from the DPR downstream temperature sensor and apply new
anti-seize agent (Bostik Never-Seez Nickel Special Grade or equivalent) to the threaded part.
• New parts have anti-seize agent applied.
• Do not reuse sensors that have been exposed to strong impacts, which have been dropped, or which have a
deformed detection part.
Take care that the harness of the DPR downstream temperature sensor is not twisted.
18-317
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[18. ENGINE]
P-type clamp
18-318
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[18. ENGINE]
Inspection
1. Resistance inspection SCR upstream
Thermometer temperature sensor
1) Use water and a circuit tester to measure the
resistance between the terminals, and replace @
the sensor if the standard value is exceeded. ?
?
0
Heat source @
18-319
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[18. ENGINE]
?
2) Install the SCR upstream temperature sensor on
the muffler unit.
Tightening torque :
30±3 N·m {306±31 kgf·cm, 22±2.2 lbf·ft}
Detection pin
• In case of reuse, remove any old anti-seize agent from the temperature sensor upstream of the SCR and apply
new anti-seize agent (Bostik Never-Seez Nickel Special Grade or equivalent) to the threaded part.
• New parts have anti-seize agent applied.
• Do not reuse sensors that have been exposed to strong impacts, which have been dropped, or which have a
deformed detection part.
Take care that the harness of the SCR upstream temperature sensor is not twisted.
18-320
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[18. ENGINE]
2) Secure the harness of the SCR upstream temperature sensor with P-type clamps.
Tightening torque :
26±2.6 N·m {265±26.5 kgf·cm, 19±1.9 lbf·ft}
18
18-321
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[18. ENGINE]
18.12 COOLING
18.12.1 Cooling System
18.12.1.1 Cooling system drawing
Reserver tank
Radiator cap
EGR cooler
Thermostat
Radiator
cover (Outlet)
Coolant
temperature
gauge
Thermostat
case Cylinder head
Thermostat
cover (Inlet) Thermostat Turbocharger
Cylinder block
Drain cock
Coolant pump
Oil cooler
Drain cock
Car heater
18-322
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[18. ENGINE]
18
Tightening torque
18-323
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[18. ENGINE]
Bolt
Stud
Nut
Coolant pump
Perform the work with cardboard or similar covering the radiator core so that it will not be damaged.
1) Remove the bolts (6pcs.) and remove the cooling fan from the fan spacer.
3. Installing the cooling fan
1) Install the cooling fan to the fan spacer using the bolts (6pcs.).(At the same time, set the fan shroud ring to
the mounting position.)
Tightening torque: 28.5±4.5 N・m {290±44 kgf・cm, 21±3 lbf・ft}
4. Installing the shroud ring Shroud ring
1) Install the shroud ring to the bracket using the
bolts (3pcs.). While checking the clearance
between the fan and fan shroud ring is the
standard value.
18-324
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[18. ENGINE]
Coolant pipe A
Thermostat case
18
2. Removal of the thermostat case
1) Remove the bolts and remove the water outlet
pipe from the thermostat case.
Water outlet
pipe
2) Remove the bolts and remove the thermostat Coolant pump
case.
Thermostat case
• Apply it seamlessly.
• Apply the liquid gasket with 1.5-2.5 mm {0.060-0.100 in.} width.
• Mount the case within 20 minutes after applying the liquid gasket.
18-325
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[18. ENGINE]
3) Install a new O-ring in the groove at the top of the Coolant pump
coolant pump. Thermostat case
4) Insert the thermostat case mounting bolts in advance into the thermostat case.
5) Match the thermostat case to the mounting position and provisionally tighten the mounting bolts to the
cylinder head.
6) Provisionally tighten the mounting bolts to the coolant pump.
7) Securely tighten the mounting bolts to the cylinder head and the mounting bolts to the coolant pump in this
order.
Tightening torque: 28.5 N・m {290 kgf・cm, 21 lbf・ft}
8) Replace the O-ring with new ones, and install the
water outlet pipe to the thermostat case.
Tightening torque: 28.5 N・m {290 kgf・cm, 21 lbf・
ft}
Water outlet
pipe
Thermostat case
Flange
Thermostat
Gasket
TOP
Jiggle valve
18-326
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[18. ENGINE]
• As a wrong gasket installation can cause water leakage, make sure during assembly that it is clamped to the
flange part of the thermostat.
• Install the thermostat with the jiggle valve at the top.
18
18-327
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[18. ENGINE]
Heat source
• To keep the thermostat away from the heat sources, support it at the center with wire.
• Stirring the water in the reservoir well to keep the coolant temperature equal.
2) Measuring the temperature at which the T1 : Valve opening temperature (start of valve opening)
thermostat valve starts to open (opening valve T2: Full open lift inspection temperature
temperature).
10mm
{0.3937in.}
Valve lift
The thermostat valve opening valve temperature (T1) is engraved on the thermostat seat.
L1 At cold open
L2 :Temperature at (T2)°C{°F}
L : Valve lift
J
J
J
Thermostat valve
inspection full-open lift Valve lift amount: L
temperature: T2
10mm {0.3937in.}
85°C{185°F}
or more
4) Submerging the thermostat into water at ordinary temperature with the valve fully opened. Check that the
thermostat valve closes completely within five minutes.
5) If found defective in inspection above, replace the thermostat.
18-328
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[18. ENGINE]
18
2. Installation of coolant pump Liquid gasket
1) Remove contamination on the joint surface
between the coolant pump and the cylinder block
using a scraper and degrease the surface.
2) Apply the liquid gasket [Threebond TB1207B
(black) or equivalent] to the coolant pump as
shown in the figure.
• Apply it continuously.
• Apply the liquid gasket at the width of 2 to 3mm {0.0787 to 0.1181in.}.
• Install the coolant pump within 20 minutes after application of the liquid gasket.
• Fill the groove on the coolant pump flange with the liquid gasket.
When the coolant pump is installed using a guide bolt, displacement of the liquid gasket does not occur.
18-329
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[18. ENGINE]
18.13 LUBRICATION
18.13.1 Oil Cooler, Oil Filter and Oil Pump
18.13.1.1 System drawing
Roller pin
Cam Roller
Adjusting Rocker
Valve Crosshead Rocker arm arm
screw shaft
Camshaft
Oil pan
Cam idle
gear shaft
Sub-idle
gear shaft
Turbocharger
Strainer
Main idle
gear shaft
: Lubrication
: Return
18-330
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[18. ENGINE]
18
Tightening torque
B 30N・m{320kgf・cm, 31 lbf・ft}
18-331
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[18. ENGINE]
2 O-ring* 6 Gasket*
Tightening torque
18-332
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[18. ENGINE]
Guide bolts
To avoid the oil cooler element from dropping off, do not unfasten the oil cooler element mounting nuts.
Oil cooler
assembly
It is hard to remove the oil cooler assembly, remove it by placing the flat-blade screwdriver to the protrusion shown
in the figure.
18-333
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[18. ENGINE]
Gasket
Oil cooler
case
2. Removing the safety valve and oil pressure switch Oil cooler case
1) Remove each plug to remove the valve spring
and safety valve from the oil cooler case.
Valve spring
Plug
Safety valve
Oil pressure
switch
Gasket
Note that residual pressure in the oil cooler may cause the engine oil to spew out when disassembling immediately
after the engine stops.
18-334
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[18. ENGINE]
Oil cooler
element
18
2. Inspecting the safety valve
Safety valve
1) Inspect the safety valve sliding surface for wear
and damage. If found defective, replace it.
Sliding
surfaces
Valve spring
Plug
Safety valve
Oil cooler
case
18-335
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[18. ENGINE]
Gasket
Oil cooler
case
Oil cooler
case
Flat face
Assemble the flat side of the D-ring to the oil cooler assembly side.
Oil cooler
Guide bolts
18-336
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[18. ENGINE]
0
0
Guide bolt
0
0
6) Remove the bolts and remove the oil pump from the cylinder block.
0
18.13.1.9 Disassembling the oil pump
1. Removing the driven gear
0
Drive gear
1) Remove the driven gear from the oil pump.
Driven gear
Oil pump
Valve
spring
Seat2
Seat1
Cotter pin Cotter pin
Note that the seat 1, seat 2, and valve spring jump out when the cotter pin is removed.
18-337
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[18. ENGINE]
Standard value
Measured item
(mm {in.})
Standard value
Measured item
(mm {in.})
3) Calculate the difference between the drive gear width and pump chamber depth on the cylinder block side. If
exceeding the operation limit, replace the oil pump.
0.047-0.150 0.15
{0.0019-0.0060} {0.0060}
Standard value
Measured item
(mm {in.})
18-338
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[18. ENGINE]
Measured item
Standard value
(mm {in.})
18
Inner diameter of drive gear
18.0 {0.7087}
bush
3) Calculate the difference between the drive gear shaft outer diameter and bushing inner diameter on the
cylinder block side. When it exceeds the standard value, replace the bushing on the cylinder block side or oil
pump.
Standard value
Measured item
(mm {in.})
Standard value
Measured item
(mm {in.})
3) Calculate the difference between the drive gear outer diameter and pump chamber inner diameter on the
cylinder block side. If exceeding the operation limit, replace the oil pump.
18-339
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[18. ENGINE]
0.093-0.252 0.30
{0.0037-0.0099} {0.0118}
Standard value
Measured item
(mm {in.})
Standard value
Measured item
(mm {in.})
3) Calculate the difference between the driven gear shaft outer diameter and driven gear bushing inner
diameter. If exceeding the operation limit, replace the oil pump or driven gear.
0.040-0.075
0.15 {0.0060}
{0.0016-0.0033}
Standard value
Measured item
(mm {in.})
18-340
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[18. ENGINE]
Measured item
Standard value
(mm {in.})
18
Cylinder block hole
18.0 {0.709}
diameter
3) Calculate the difference between the outer diameter of the driven gear shaft and the cylinder block side hole
diameter. If the value exceeds the standard value, replace the oil pump.
0.073-0.207 0.30
{0.0029-0.0081} {0.012}
Seat2
Seat1
Cotter pin Cotter pin
Oil pump
18-341
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[18. ENGINE]
Apply engine
oil to the
shaded area
Without engine oil applying, defective oil suction may occur when the engine is initially started, which results in
seizure and abnormal wear.
Guide bolt
0
Oil pump
0
0
0
Guide bolts
0
0
• A misaligned gasket may cause defective sealing, which results in outflow of all engine oil in the oil pump when
the engine is stopped. Defective sealing may also result in an insufficient engine oil suction quantity in the initial
rotation when the engine is restarted, which leads to seizure or abnormal wear.
• Note that failure to observe the tightening order may damage the oil pump.
• After tightening, make sure that the gear turns easily by hand.
18-342
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[18. ENGINE]
18
2. Installation of oil strainer
1) Replace the O-ring with new ones and install the oil strainer.
Tightening torque: 30 N·m {320 kgf·cm, 23 lbf·ft}
18-343
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[18. ENGINE]
Tightening torque
18-344
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[18. ENGINE]
18.13.2.2 Replacement
1. Removing the oil pan
1) Remove the bolts and remove the oil pan from the cylinder block.
2. Mounting the oil pan Cylinder Gasket
1) Using the scraper, cut the rear end plate gasket block Rear end plate
to make it flush with the cylinder block lower Flywheel
surface. housing
Scraper
18
cutting
Oil pan
2) Check the joint surface between the cylinder Liquid gasket
block and oil pan for deformation, dirt, or oil. apply position
Cylinder
block
Applying all around
the bolt mounting hole
3) Then, apply the small quantity of liquid gasket (ThreeBond TB1207D: Silver or equivalent, or ThreeBond
TB1217G: Grey or equivalent) to the step areas of the joint parts between the front oil seal retainer and
cylinder block/flywheel housing and around the bolt mounting hole.
Protrusion
Engine front
18-345
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[18. ENGINE]
5) Mount the guide bolts (70 mm {2.756 in.} or more) to the cylinder block. Aligning the new gasket with the
mounting position in a way that its protrusions are set on the intake and flywheel housing sides (the print
seal surface is on the cylinder block side).
Before mounting the gasket, check the print seal for peeling or damage.
• Handle the gasket of the oil pan with care because it can be easily broken.
• Check if the washer is not riding on the flange.
18-346
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[18. ENGINE]
18
confirmation
part of oil
flow
To prevent spread of engine oil, attach a jig which cuts a head cover in half. Cut it to the degree that the camshaft is
covered.
If time until lubrication is long or if lubrication is not performed, the oil pressure may be low or the oil channel may
be clogged. Seizure, abnormal wear or abnormal noise may occur due to insufficient lubrication.
18-347
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[18. ENGINE]
3 Bushing 16 Brush
18-348
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[18. ENGINE]
Tightening torque
18
18-349
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[18. ENGINE]
18.14.1.2 Disassembly
Commutator end
frame
Hold the M lead wire and remove the commutator end frame by lifting.
18-350
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[18. ENGINE]
Spring
Brush
18
Brush lead
Clamp
Center bracket
assembly
Do not hold the M lead wire and hold the yoke assembly outer diameter for removal.
Packing Packing
18-351
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[18. ENGINE]
Center bracket
assembly
When the armature assembly is removed, the washer at the end of the gear may be dropped and lost. Be careful
for handling.
Puller
18-352
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[18. ENGINE]
Carrier pin
18
Make sure that the gear is not damaged or chipped.
Internal gear
Center bracket
11.
1) Remove the shim washer from the center
bracket.
Shim
Pinion stopper
Pinion
18-353
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[18. ENGINE]
Push upward or pull out the chipped part of the clip mouth.
Pinion
Holder
Lever assembly
Lever assembly
18-354
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[18. ENGINE]
Brake plate
Shaft assembly
Washers are available at the upper and lower parts of the carrier plate. Be careful for loss of the washers.
Packing
18-355
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[18. ENGINE]
Yoke assembly
18-356
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Commutator
18-357
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[18. ENGINE]
Undercut length:
0.5 to 0.8 mm
Segment {0.0197 - 0.0315}
Insulating material
0.5 - 0.8
0.2{0.0079} or less
{0.0197 - 0.0315}
11.98{0.4717}
Area A 12{0.4724}
or less
8.98{0.3535}
Area B 9{0.3543}
or less
18-358
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[18. ENGINE]
Brush
Standard value
(mm{in.})
Service limit
(mm{in.})
18
18{0.7087} 13{0.5118} or less
25.90{1.0197}
Area A 26{1.0236}
or less
12.04{0.4740}
Area B 12.1{0.4764}
or less
6. Inspection of bearing
1) Measure the bearing metal inner diameter (1 in
the figure) of the pinion case using a cylinder
gauge. If it is beyond the service limit, replace the 1
bushing.
18-359
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[18. ENGINE]
26{1.0236} 26.2{1.0315}
9{0.3543} 9.2{0.3622}
4) Measure the bearing housing inner diameter (4 in the figure) of the commutator end frame using a cylinder
gauge. If it is beyond the service limit, replace the commutator end frame.
Body
18-360
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[18. ENGINE]
B terminal
2) Push the end of the start magnet switch
assembly (close the internal contact) and make
sure that there is electric continuity between the 18
B terminal and the M terminal using a circuit
tester.
18-361
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[18. ENGINE]
18.14.1.4 Assembly
1. Installation of packing
1) Install a new packing on the center bracket
assembly.
Packing
Shaft assembly
Washers are available at the upper and lower parts of the carrier plate. Be careful for loss of the washers.
Brake plate
5. Installation of lever
1) Lubricate parts (refer to the lubrication point
drawing and the lubrication list). Turn and install
the lever assembly using the clutch as the axis.
Lever assembly
18-362
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[18. ENGINE]
7. Installation of pinion
1) Lubricate parts (refer to the lubrication point
Pinion stopper 18
drawing and the lubrication list) and install the
Pinion
pinion and the pinion stopper.
Retainer clip
Pinion stopper
Pinion
Internal gear
Center bracket
18-363
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[18. ENGINE]
Center bracket
assembly
When the armature assembly is installed, the washer at the end of the gear may be dropped and lost. Be careful for
handling.
Packing Packing
Center bracket
assembly
18-364
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[18. ENGINE]
Spring
Brush
18
Brush lead
Clamp
Hold the M lead wire and remove the commutator end frame by lifting.
Commutator end
frame
18-365
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[18. ENGINE]
19. Lubrication
Refer to the following figure and table for lubricant to be applied.
18-366
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[18. ENGINE]
Table of lubricant
Lubricant
Code Lubricating point Lubricant used Amount (g{oz}) Remark
manufacturer
Pinion case metal and 0.8 - 1.5
1 Multemp AC-N Kyodo Yushi
grease reservoir {0.03 - 0.05}
0.5 - 1
7 Pinion straight Spline Multemp AC-N Kyodo Yushi
{0.02 - 0.04}
0.3 - 0.6
8 Inner sleeve metal Multemp AC-N Kyodo Yushi
{0.01 - 0.02}
0.5 - 1
9 Helical spline Multemp AC-N Kyodo Yushi
{0.02 - 0.04}
1-2
12 Planetary gear metal Multemp AC-N Kyodo Yushi
{0.04 - 0.07}
0.4 - 0.8
13 Lever holder Multemp AC-N Kyodo Yushi
{0.01 - 0.03}
18-367
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[18. ENGINE]
Tightening torque
A 1.9 - 2.5N·m{20 - 25kgf·cm, 1.4 - 1.8 lbf·ft} D 3.9 - 4.9N·m{40 - 50kgf·cm, 2.9 - 3.6 lbf·ft}
18-368
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[18. ENGINE]
Diode
B Fuse Load
Feild coil R
Starter switch
Regulator C
P
18
E
Alternator
18-369
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[18. ENGINE]
Bolt Tab
1) Remove the bolts and remove the cover from the drive end frame.
• Be careful not to break the tab with excessive force when pressing the tabs of the cover for removal.
• Do not push the tabs by screwdriver.
Drive end
frame side
V -belt
• Tie around a general V belt in the pulley groove and fix the pulley with a vice.
• Do not reuse if outer frame of the pulley was damaged.
18-370
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[18. ENGINE]
18
Solder
18-371
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[18. ENGINE]
• At solder of the stator coil and the diode, the end of the diode is clamped. Do not damage the diode by prying.
Deformed diode must not be reused.
• Perform soldering in a short time (within 5 seconds).
End frame
Stator coil
As Screw-lock has been applied to the two regulator fixing bolts, the torque required to loosen the bolts is high; care
must be taken not to strip the bolt thread.
Nut
Loosen the nut to some extent and do not remove it from the B terminal.
18-372
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[18. ENGINE]
Rectifier
18
As Screw-lock has been applied, the torque required to loosen the bolts is high; care must be taken not to strip the
bolt thread.
Field coil
End frame
• When the inner surface of the bearing hole of the end frame etc. has been damaged when pulling the bearing,
the end frame cannot be reused.
• Removed bearing must not be reused.
18-373
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[18. ENGINE]
T S
Wiring diagram
Stator coil
1) Measure the resistance between the U - V, V - W, W - U terminals of the stator coil using a circuit tester, if
the value exceeds the standard value, replace it.
1 or more
Standard value (MΩ)
(Use 500V megger tester)
Field coil
18-374
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[18. ENGINE]
Field coil
1 or more
Standard value (Ω)
(Use 500V megger tester)
Do not measure between the coils, the field coil may be damaged.
Micrometer
25.0{0.9843} 24.98{0.9835}
Micrometer
17.0{0.6693} 16.98{0.6685}
18-375
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[18. ENGINE]
Rectifier
D
Back
view
18-376
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[18. ENGINE]
18
1) Press fit a new front bearing into the drive end frame using a press and jig C.
Bearing cover
• Always fit the inner race part of the bearing when press-fitting.
• Do not damage the shaft.
18-377
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[18. ENGINE]
V-belt
5) Install the collar, fan and pulley on the shaft of the rotor assembly.
Tightening torque:
127 - 157 N·m {1,300 - 1,600 kgf·cm, 94 - 116 lbf·ft}
• Press fit until jig A comes in contact with the end frame.
• Reuse is not possible when the bearing case is deformed at the time of press-fitting.
Field coil
End frame
18-378
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[18. ENGINE]
End frame
Stator coil
18
Do not damage the stator coil during work.
Rectifier
Solder
18-379
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[18. ENGINE]
Nut
After installation of the alternator, connect the wire and tighten the outside nut.
Tightening torque:
3.2 - 4.4 N·m {33 - 44 kgf·cm, 2.4 - 3.1 lbf·ft}
Drive end
frame side
2) Match the position of the tab, and install the cover Cover Tab
Drive end
to the dive end frame, fix the cover with the bolt. frame
Tightening torque:
3.3 - 4.4 N·m {34 - 44 kgf·cm, 2 - 3 lbf·ft}
Bolt Tab
18-380
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[18. ENGINE]
Pulley
B E Approx. 20 Ω
E B Infinite
P E Approx.7 Ω
E P Infinite
Lock connector
5 & 0
/ 3
18-381
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[18. ENGINE]
18.15 TURBOCHARGER
18.15.1 Turbocharger Assembly
18.15.1.1 Parts layout
18-382
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[18. ENGINE]
18
%
%
%
%
%
$
Tightening torque
18-383
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[18. ENGINE]
$
$ $
Tightening torque
A 70N·m{713kgf·cm, 52 lbf·ft}
18.15.1.2 Inspection
1. Inspection of turbine shaft axial play
1) Inspect axial play of the turbine shaft at the
exhaust side using a special tool.
Special tool : S0944-41800(09444-1800)
Tool assembly
2) If the measurement value is beyond the standard
value, ask the manufacturer to overhaul the unit.
0.040 - 0.085
Standard value
{0.0016 - 0.0033}
(mm{in.})
(Only axial play)
Since the assembly is replaced, disassembly and inspection are not allowed.
18-384
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[18. ENGINE]
18.15.1.3 Replacement
1. Removal
1) Remove the boost pipe and U-turn pipe.
2) Disconnect all pipes connected to the turbocharger.
• Loosen union bolt of the coolant pipe, drain coolant and remove the pipe. Disconnect the lower pipe similarly and
remove the oil pipe.
• After removing pipes, be sure to seal oil holes, water holes and cylinder block holes to prevent entry of dirt. 18
3) Remove the bolts fixing the exhaust pipe and the turbocharger and remove the turbocharger.
• After removal, seal holes both at the exhaust manifold and the exhaust pipe to prevent entry of foreign matter.
• If a stud bolt is sticking, remove and replace the stud bolt using a commercially available stud remover.
2. Installation
1) Before installation on the engine, pour new engine oil from the oil inlet and turn the turbocharger with hand
to lubricate the journal bearing and the thrust bearing.
2) Replace the o-ring by new ones, and assemble the exhaust pipe and the turbocharger, and install the
turbocharger on the engine.
Tightening torque:
70 N·m {713 kgf·cm, 52 lbf·ft}
(Turbocharger to exhaust manifold)
• Make sure that there is no dirt or foreign matter in the exhaust pipe system.
• As heat-resistant steel is used for the bolts and nuts, take care that they do not become mixed up with standard
bolts and nuts.
3) Replace the gasket by new ones, install the coolant pipe and the oil pipe to the turbocharger.
• Clean the pipes and confirm that they are not crushed and that the inside of the pipes is free of dirt and foreign
matter.
• Do not use a sealing agent at the installation surfaces of oil pipes and fuel pipes and at the connection parts of
coolant hoses and coolant pipes; small particles can cause clogging, loose connections, damage to
components, as well as other malfunctions.
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[18. ENGINE]
• Confirm that the inside of the intake system is free of dirt and foreign matter.
Do not use a sealing agent at the air intake of the air pipe; small particles can cause clogging, loose connections,
damage to components, as well as other malfunctions.
• Install correctly to prevent leak of air from intake pipe and air hose connections.
18-386
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[18. ENGINE]
Engine overheat (lubrication unit) Deterioration of engine oil Replace engine oil
Large engine oil consumption Wear of piston ring and cylinder liner Replace piston ring and cylinder liner
(piston, cylinder liner and piston ring)
Damage to piston ring Replace piston ring and cylinder liner
Faulty fixing of piston ring Replace piston ring and cylinder liner
Faulty assembly of piston ring Replace piston ring and cylinder liner
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide)
Wear of valve guide Replace valve guide
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of engine
Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Insufficient engine power (air cleaner) Clogging of air cleaner element Clean or replace air cleaner element
18-387
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[18. ENGINE]
Insufficient engine power Piston, cylinder liner and piston ring Refer to large engine oil consumption
section.
Faulty engine start (electric unit) Faulty battery Check battery
Faulty engine start (air cleaner) Clogging of air cleaner element Clean or replace air cleaner element
Faulty engine start (fuel unit) Insufficient fuel Replenish fuel and bleed air from fuel
system
Air entering from connection of fuel Check sealing parts and replace
system
Faulty fuel from fuel system Check and replace sealing parts
Faulty engine start (lubrication unit) Excessive viscosity of engine oil Replace with engine oil with correct
viscosity
Faulty engine start (others) Piston seizure Replace piston, piston ring and cylinder
liner
Bearing seizure Replace bearing and crankshaft
Faulty idling (fuel system) Insufficient fuel Replenish fuel and bleed air from fuel
system
Air entering from connection of fuel Check sealing parts and replace
system
Faulty fuel from fuel system Check and replace sealing parts
18-388
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[18. ENGINE]
Faulty contact of valve seat Adjust or replace valve and valve seat.
Gas leak (cylinder head) Crack of cylinder head Replace cylinder head.
Gas leak (cylinder liner) Crack of cylinder liner Replace cylinder liner.
18-389
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[18. ENGINE]
18.16.1.2 Alternator
Status Cause Action
Lamp is ON. → Charge current does Faulty regulator (open PTr) Replace regulator.
not run (alternator).
Faulty stator coil (disconnection, rare Replace stator coil.
shorting)
Lamp is ON. → Charge current does Disconnection of wire (fuse) Replace wire (fuse).
not run (wiring).
Lamp is ON. → Voltmeter indicates Faulty regulator (shorting of PTr) Replace regulator.
29V or more (alternator).
Faulty tightening of voltage detection Repair, replace voltage detection circuit
circuit (e.g. support) or replace regulator.
Lamp is ON. → Charge current is Faulty regulator (open Tr) Replace regulator.
correctly running (alternator).
Lamp is OFF. → Charge current is Faulty stator coil (disconnection of 1 Replace stator coil.
always limited. → Battery goes flat phase, rare shorting)
(alternator).
Faulty diode (open, shorting) Replace rectifier.
Lamp is OFF. → Charge current is Operation load is large (Load balance is Reduce load
always limited. → Battery goes flat poor).
(operation load).
Lamp is OFF. → Charge current is Faulty regulator (shorting of PTr) Replace regulator.
always large. → Battery fluid runs
Faulty tightening of voltage detection Repair or replace voltage detection
short in a short period of time
circuit (e.g. support) circuit.
(alternator).
Lamp is OFF. → Charge current is Battery is close to the service life. Replace battery.
always large. → Battery fluid runs
short in a short period of time (battery).
Others → Abnormal noise Faulty stator coil (rare shorting, Replace stator coil.
(alternator) grounding)
Others → Abnormal noise (V belt) Faulty tension of V belt (belt slip) Correction
18-390
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[18. ENGINE]
18.16.1.3 Starter
Status Cause Action
Starter does not turn. Turning is low. Faulty connection of starter key Repair connecting area.
Faulty contact of start magnet switch Replace start magnet switch assembly 18
assembly.
18-391
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[18. ENGINE]
18.16.1.4 Turbocharger
Status Cause Action
Oil is quickly reduced Seal ring is excessively worn or Disassemble and repair turbocharger.
damaged due to excessive wear of the
bearing.
Engine oil enters into exhaust gas Check and service engine parts.
before the turbocharger.
Low engine output Gas leak from exhaust system parts Check and repair faulty areas.
Gas leak from exhaust system parts Check and repair faulty areas.
Seizure of bearing (Too hot oil Check lubrication system and repair,
temperature) replace engine oil and turbocharger.
Acceleration (follow-up of Carbon deposit at the turbine (disc Replace engine oil and turbocharger.
turbocharger) is poor (slow). sealing area) makes revolution of the
turbine heavy.
Air and gas leak from intake/exhaust Check and repair faulty areas.
system parts
Seizure of bearing (Too hot oil Check lubrication system and repair,
temperature) replace engine oil and turbocharger.
18-392
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[18. ENGINE]
Air and gas leak from intake/exhaust Check and repair faulty areas.
system parts
Vibration Loosening between turbocharger and Check the turbocharger mounting status
intake/exhaust pipe and between oil and repair faulty areas.
pipe and mounting area
18-393
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[18. ENGINE]
18-394
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-395
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Battery
Accelerator signal 1, 2 Diagnosis switch
Check engine lamp
Glow relay
DPR indicator lamp
O
Neutral switch U
T
P
DPR regeneration switch
U
T
Volume for Supply pump
emergency accelerator
SCV drive signal
temperature
P
Intake throttle valve
sensor
sensor
Water
Common T System
rail DC Motor
Air flow
meter Intake throttle valve
P T T
G
Engine
N
DPR Cleaner
EGR System VNT System
Turbocharger T P T
EGR
Variable geometry DC Motor
DC Motor actuator
18-396
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[18. ENGINE]
18.17.1.3 Inspection
Pre-inspection
1. If an error occurs on the system, The DTC code is indicated in the console panel.
DTC codes of the engine ECU are displayed on the multi-display when the starter switch is set to ON, even when
the Hino-DX is not connected.
2) Connect the engine failure diagnosis connector to the personal computer which installed Hino-DX
through the interface box.
3) Set the starter key to "ON" and start Hino- Failure diagnosis connector
DX.
Special tool : 09993-E9070 Hino-Bowie
(Interface box)
09042-1220 Connecting cable
95171-010** DENSO DST-i set
Hino-Bowie
CD-ROM Hino-DX or DST-i
Connecting cable
Connect to the failure diagnosis
connector at the machine side.
18-397
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[18. ENGINE]
S
12h
First indication
Second indication
18-398
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[18. ENGINE]
Part name Part No. External shape General description and function
Hino Diagnostic
eXplorer — Install the software included in the
(Hino-DX) Hino Diagnostic eXplorer (Hino-DX)
into the computer. For the installation
method, refer to the instruction manual
included with the CD.
• Computer interface
09993 - E9070
Hino-Bowie
*1 • The cable between the personal
computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or USB.
Cable bundled
to the Hino-Bowie
18-399
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Part name Part No. External shape General description and function
Interrupting installation between unit side harness and DCU allows inspection
Signal check harness 09843-E9030
with a tester rod while the power is supplied.
09843-E9030
*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the user’s manual in the
HinoDX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HinoDX CD-ROM. For details, refer to
the user’s manual in the HinoDX CD-ROM.
*2: HinoDX (Ver. 3.0.5 or later), only when use DST-i.
18-400
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[18. ENGINE]
OK: Available
—: Disabled
Tier3 Tier4 Interim Tier4 Final
OS Software ver. Interface Reprog Reprog Reprog
Hino-DX Hino-DX Hino-DX
manager manager manager
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — — 18
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
7
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i — — — — — —
1.0.9 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN OK OK OK OK OK OK
Bowie w/o CAN OK OK — — — —
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
XP
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
DST-i OK OK — — — —
1.0.9 Bowie w/ CAN OK OK — — — —
Bowie w/o CAN OK OK — — — —
• Never stop the unit near any flammable material, including high grass or leaves, during manual regeneration.
• Extreme heat from the exhaust outlet could cause a fire resulting in personal injury and property damage.
• Always keep all flammable materials away from the DPR cleaner, exhaust pipe and tail pipes.
• Never touch the DPR cleaner, exhaust pipe or tail pipe during regeneration. Severe burns and/or other personal
injuries could occur.
• More fuel than usual is contained in the air returned through the EGR to the intake side during DPR
regeneration. If you stop the engine soon after regeneration, this fuel will congeal, which may influence
subsequent engine operation. In order to clean the air in the engine that contains fuel, be sure to perform the 10-
minuite scavenging drive after regeneration has been completed.
18-401
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
• Manual regeneration can be performed even if a small amount of soot has accumulated, so this mode can be
used to inspect the regeneration system.
• When you combust soot using the manual regeneration mode, start the mode using the DPR regeneration
switch in the cabin. ("a" on next page.)
When you inspect the system, start the regeneration mode using the Hino-DX. ("b" on the next page.)
This section mainly explains the manual forced regeneration procedure using the Hino-DX.
S
12h DP R re ge ne ra tion s witch
levels 3 to 9
– To perform manual forced regeneration, set the attachment of the machine to the parking attitude, stop the
engine, lift up the lock lever and set the starter key to [ON].
– Press the DPR regeneration switch to operate the hydraulic pump relief. "Regenerating" appears on the
screen of the multifunctional display.
– When the hydraulic pump relief operation has been completed and "Regenerating" on the screen goes out,
soot combustion is completed.
• When you inspect the DPR system
– You can confirm the whole DPR system condition using the Hino-DX.
– The Hino-DX displays engine data in the regeneration operation on the screen. The operation status can be
understood by analyzing the data values.
• The manual forced generation function using the Hino-DX aims to inspect system operation. If the manual
generation caution appears in the multifunctional display, do not use the Hino-DX, but use the DPR regeneration
switch in the cabin for regeneration.
• If any fault code concerning the DPR is detected, refer to the fault diagnosis documents and be sure to change
or clean the DPR cleaner. After that, inspect the whole system condition using the manual forced generation
mode of the Hino-DX.
1) Connect the Hino-DX to the machine and set the starter key to [ON].
18-402
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Flag setting by "Set (C)" → "Customize (C)" → "10-sec DPR lamp blinking / Identifying setting status" is
unnecessary. If you set the flag, ensure to return the setting to "0".
2) Select the "DPR check (D)" menu in "Check functions (E)" from the Hino-DX menu bar.
18
Select
3) Click the "Reset all DPR items (R)" button in the DPR status display window to reset the values, and then
click the "Manual forced regeneration (E)" button.
To perform manual forced regeneration, stop the engine, lift up the lock lever and set the starter key to [ON].
18-403
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[18. ENGINE]
% H I R U H U H V H W W L Q J D O O W K H ' 3 5 L W H P V E H V X U H W R V W R S W K H H Q J L Q H S U H V V W K H E U D N H V Z L W F K
D Q G V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q $ I W H U W K D W V H W W K H V W D U W H U N H \ W R 2 1
4) Verify the contents of the displayed caution note, set a check mark for "Comprehended", and then click the
"Next (N)" button.
If you continuously perform manual forced regeneration, perform a 10-minuite scavenging drive before the next
regeneration cycle.
5) After "Manual forced regeneration" appears on the screen, make sure safety around the machine and start
the engine.
Make the machine to the parking attitude and lift up the lock lever in the idle state.
18-404
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
D $ I W H U S D U N L Q J W K H P D F K L Q H L Q D V D I H S O D F H N H H S L G O L Q J Z L W K W K H J H D U V H W L Q W K H
Q H X W U D O S R V L W L R Q D Q G W X U Q R I I W K H 3 7 2
E % H V X U H W R S U H V V W K H E U D N H V Z L W F K D Q G W R V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q
1) The "1.LIFT UP LOCK LEVER 2.PUSH REGENERATION SW." icon appears on the cluster gauge.
Lift up the lock lever to ensure safety around the machine.
S
12h
2) If you press the DPR regeneration switch in the cabin, manual forced generation will starts.
18-405
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
When the "Regenerating" mark does not appear on the cluster or the engine speed does not idle up even if the
DPR regeneration switch is pressed, you cannot proceed to forced generation.
In such cases, inspect the neutral switch circuit, accelerator emergency circuit, malfunction of the lock lever and so
on.
18-406
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
7 K H I R U F H G U H J H Q H U D W L R Q L V L Q S U R J U H V V D Q G W K D W \ R X K D Y H W R Z D L W I R U D Z K L O H
D : K H Q V R R W F R P E X V W L R Q L V E H L Q J S H U I R U P H G
: K H Q V R R W F R P E X V W L R Q L V F R P S O H W H G W K H U H J H Q H U D W L R Q P R G H Z L O O D X W R P D W L F D O O \ W X U Q R I I
6 R P H P D F K L Q H V P L J K W R S H Q R U F O R V H W K H L U U H O L H I Y D O Y H V Z K H Q W K H U H J H Q H U D W L R Q L V F R P S O H W H G
$ I W H U W K H K \ G U D X O L F U H O L H I V W D U W V D Q G W K H Q W K H R S H U D W L Q J Q R L V H R I W K H U H O L H I Y D O Y H L V
K H D U G S U H V V > & D Q F H O @ E X W W R Q W R V W R S W K H P D Q X D O I R U F H G U H J H Q H U D W L R Q
& $ 8 7 , 2 1 ! !
$ I W H U W K H P D Q X D O I R U F H G U H J H Q H U D W L R Q L V V W R S S H G W K H U H P D \ E H D F D V H Z K H U H W K H K \ G U D X O L F
U H O L H I D X W R P D W L F D O O \ V W D U W V D J D L Q 1 R W H W K D W W K H U H J H Q H U D W L R Q L V F R P S O H W H G Z K H Q W K H
K \ G U D X O L F U H O L H I H Q G V
, I W K L V K D S S H Q V S U H V V > & D Q F H O @ E X W W R Q W R D E R U W W K H U H J H Q H U D W L R Q
E : K H Q W K H L Q V S H F W L R Q R Q W K H ' 3 5 V \ V W H P L V E H L Q J F R Q G X F W H G
$ I W H U V W D U W L Q J W K H U H J H Q H U D W L R Q S U R F H V V F R Q I L U P W K D W W K H Y D O X H R I ' 3 5 ( [ K D X V W W H P S H U D W X U H
, 1 K D V U L V H Q W R & ^ ) ` R U K L J K H U W K H Q S U H V V W K H U H J H Q H U D W L R Q R U > & D Q F H O @
E X W W R Q W R V W R S W K H U H J H Q H U D W L R Q
D $ I W H U S D U N L Q J W K H P D F K L Q H L Q D V D I H S O D F H N H H S L G O L Q J Z L W K W K H J H D U V H W L Q W K H
Q H X W U D O S R V L W L R Q D Q G W X U Q R I I W K H 3 7 2
E % H V X U H W R S U H V V W K H E U D N H V Z L W F K D Q G W R V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q
• When the process up through the soot combustion treatment has been completed, the following explanation
appears. Click the "Close (C)" button to end manual forced regeneration.
D $ I W H U S D U N L Q J W K H P D F K L Q H L Q D V D I H S O D F H N H H S L G O L Q J Z L W K W K H J H D U V H W L Q W K H
Q H X W U D O S R V L W L R Q D Q G W X U Q R I I W K H 3 7 2
E % H V X U H W R S U H V V W K H E U D N H V Z L W F K D Q G W R V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q
4) When the caution box appears, check the content and perform a 10-minuite scavenging drive. The
scavenging drive is completed in 10 minutes. Operate the starter key to stop the engine.
After scavenging drive has been completed, set a check mark for "Comprehended" and click the "Exit (X)"
button.
18-407
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
5) This completes the manual forced regeneration process. When all stages of the manual forced regeneration
have been completed, carry out the differential pressure check.
You can stop manual forced regeneration also by pressing the "DPR manual regeneration" button in the cabin. In
this case, the caution about the scavenging drive does not appear but the 10-minuite scavenging drive should be
performed.
18-408
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
% H I R U H U H V H W W L Q J D O O W K H ' 3 5 L W H P V E H V X U H W R V W R S W K H H Q J L Q H S U H V V W K H E U D N H V Z L W F K
D Q G V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q $ I W H U W K D W V H W W K H V W D U W H U N H \ W R 2 1
• If you click “DPR differential pressure check (D)” button, DPR differential pressure check window will be
shown.
• Click the “Execute (E)” button.
• Engine rotation will go up automatically to maximum and DPR differential pressure will be recorded.
D $ I W H U S D U N L Q J W K H P D F K L Q H L Q D V D I H S O D F H N H H S L G O L Q J Z L W K W K H J H D U V H W L Q W K H
Q H X W U D O S R V L W L R Q D Q G W X U Q R I I W K H 3 7 2
E % H V X U H W R S U H V V W K H E U D N H V Z L W F K D Q G W R V H W W K H O H Y H U L Q W K H O R F N S R V L W L R Q
• Click the “Stop (E)” button and you are finished measuring.
18-409
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Every time you click the "Execute (E)" and "Stop (E)" button, the display will change "Execute (E)" and "Stop (E)"
alternately.
18-410
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
The P0000 of "P0000 [00]" in this text indicates an SAE code, and [00] indicates a 2-digit code of TCCS.
TCCS 2-DIGT
SAE CODE TROUBLE (Estimated failure cause)
CODE
P0016 13 Engine speed main sensor and Engine speed sub sensor - rationality
P0097 18 Intake air temperature sensor (intake manifold) - out of range (Out of range low)
P0098 18 Intake air temperature sensor (intake manifold) - out of range (Out of range high)
Intake air temperature sensor (air flow sensor built-in) - out of range
P0112 17
(Out of range low)
Intake air temperature sensor (air flow sensor built-in) - out of range
P0113 17
(Out of range high)
P0118 11 Engine coolant temperature sensor - out of range (Out of range high)
P0122 32 Intake throttle valve position sensor 1 - out of range (Out of range low)
P0123 32 Intake throttle valve position sensor 1 out of range (Out of range high)
P0192 74 Common rail pressure sensor (main) - out of range (Out of range low)
P0193 74 Common rail pressure sensor (main) - out of range (Out of range high)
18-411
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
TCCS 2-DIGT
SAE CODE TROUBLE (Estimated failure cause)
CODE
P0204 64 Fuel injector - disconnection (#4cyl)
P0234 34 Overboost
P0237 25 Boost pressure sensor - out of range (Out of range low)
P0546 27 DOC downstream temperature sensor - out of range (Out of range high)
P0628 73 Suction control valve for fuel supply pump - circuit (Circuit low)
P0629 75 Suction control valve for fuel supply pump - circuit (Circuit high)
P1197 74 Common rail pressure sensor (sub) - out of range (Out of range low)
P1198 74 Common rail pressure sensor (sub) - out of range (Out of range high)
18-412
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
TCCS 2-DIGT
SAE CODE TROUBLE (Estimated failure cause)
CODE
P1214 68 Fuel injector driver circuit 2 - circuit (Circuit low)
P2032 27 DPR downstream temperature sensor - out of range (Out of range low)
P2033 27 DPR downstream temperature sensor - out of range (Out of range high)
P2100 31 DC motor for intake throttle valve - circuit [Open circuit (circuit low)]
P2123 22 Accelerator pedal position sensor 1 - out of range (Out of range high)
P2128 22 Accelerator pedal position sensor 2 - out of range (Out of range high)
U0073 8 Engine ECU CAN communication bus for Emission control system - bus off
U1001 9 Engine ECU CAN communication bus for vehicle control - bus off
18-413
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
TCCS 2-DIGT
SAE CODE TROUBLE (Estimated failure cause)
CODE
U1122 8 Engine ECU CAN communication (EGR valve controller)
18-414
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
When measuring terminal of the engine ECU, connect the signal check harness to prevent damage to the
connector. Place the tester rod on the contact box of the signal check harness for measurement.
18
Terminal numbers in the text and the illustrations correspond as shown below in the "Computer pin arrangement".
CAN CA
Machine speed Glow pulg
Neutral switch Starter signal Starter switch 1 communication commun
pulse converter (Signal)
line lin
V11 NUSW V12 ST V13 SSWS V14 VS V15 GCUS V16 CA1L V17
Main/
Power supply 2
- Actuator power - - - Diagnosi
(+BF)
relay 2
18-415
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
CONNECTOR CONNECTOR
(ENGINE ECU SIDE) (ENGINE ECU SIDE)
ENGINE UNIT
SIDE SIDE
CONNECTOR
CONNECTOR
(ENGINE SUB
(ENGINE SUB
HARNESS SIDE)
HARNESS SIDE)
RED WHITE
TERMINAL TERMINAL
E01-E40 V01-V40
BLUE E V
BLACK
TERMINAL TERMINAL
TEST LEAD
E41-E80 V41-V80
18-416
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
18-417
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18.
18.17.1.8
ENGINE]
V
Main/ (Intake heater Check engine
Power supply 1 (Starter cut) Actuator power - - - lamp) DPR refresh light warning light -
(+BF)
Computer pin arrangement
relay 1
V11 NUSW V12 ST V13 SSWS V14 - V15 - V16 CA1L V17 - V18 VB1 V19 BATT V20 -
18-418
Main/
Power supply 2 Glow (Diag. switch)
- Actuator power - - - -
(+BF) Relay
relay 2
V21 +BF V22 - V23 MRL2 V24 GRY1 V25 V26 - V27 - V28 - V29 - V30 -
CAN
PTO switch Engine stop Power supply 2
Starter switch 2 - - communication - Power ground 1 Signal ground 1
switch (+B)
line
V31 - V32 STOP V33 SWSS V34 - V35 - V36 CA1H V37 - V38 VB2 V39 PGD1 V40 CGD1
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
V3 MRL1 Main / Actuator power relay 1 V23 MRL2 Main / Actuator power relay 2
V5 – – V25 – –
V6 – – V26 – –
V17 – – V37 – –
V18 VB1 Power supply 1 (+B) V38 VB2 Power supply 2 (+B)
18-419
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18.
ENGINE]
V
WIF signal Accelerator Sensor power
- - - Sensor ground 7 Sensor ground 9 - -
sensor 1 supply 3
V41 - V42 WIF V43 - V44 - V45 ADG7 V46 ADG9 V47 ACS1 V48 - V49 - V50 AVC3
V51 AVC4 V52 - V53 - V54 - V55 - V56 DPSW V57 ET4+ V58 VB3 V59 PGD2 V60 CGD2
18-420
P.T.O. DPR differential
A-GVA13 Accelerator DOC downstream
- - - - Sensor ground 8 acceclerator
sensor 2 temperature sensor pressure sensor
sensor
V61 - V62 ST02 V63 - V64 - V65 ADG8 V66 ADGC V67 ACS2 V68 ASCS V69 ET3+ V70 EXPS
V71 AVC5 V72 REV V73 - V74 - V75 - V76 - V77 - V78 VB4 V79 PGD3 V80 PGD4
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
V43 – – V63 – –
V44 – – V64 – –
Sensor ground 7
Sensor ground 8
V45 ADG7 (Accelerator sensor 1, P.T.O. V65 ADG8
(Accelerator sensor 2)
accelerator sensor)
Sensor ground 9
18
(Exhaust gas temperature
V46 ADG9 V66 ADGC A-GVA13
sensor, DPR differential
pressure sensor)
V47 ACS1 Accelerator sensor signal 1 V67 ACS2 Accelerator sensor signal 2
DOC downstream
V49 – – V69 ET3+
temperature sensor
V52 – – V72 – –
V53 – – V73 – –
V54 – – V74 – –
V55 – – V75 – –
V56 DPSW DPR refresh switch V76 – –
DPR downstream
V57 ET4+ V77 – –
temperature sensor
V58 VB3 Power supply 3 (+B) V78 VB4 Power supply 4 (+B)
18-421
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18.
ENGINE]
E
Intake throttle Suction control Suction control
valve motor (+) - - - - - - - valve (Main) valve (Main)
No.1, No.2, No.3 No.1 Fuel injector No.2 Fuel injector No.3 Fuel injector No.4 Fuel injectior No.4 Fuel injector
Air flow sensor Sensor power Fuel injector
- drive signal drive signal drive signal power supply drive signal -
(Power) supply 1 power supply
(Main) (Main) (Main) (Main) (Main) (Main)
E11 - E12 AFVB E13 AVC1 E14 IJ1+ E15 INJ1 E16 INJ3 E17 INJ5 E18 IN2+ E19 INJ2 E20 INJ4
18-422
Intake throttle Suction control Suction control
valve motor (-) - - - - - - - valve (Sub) valve (Sub)
E21 MOT- E22 - E23 - E24 - E25 - E26 - E27 - E28 - E29 SP1S E30 SP2S
No.1, No.2, No.3 No.1 Fuel injector No.2 Fuel injector No.3 Fuel injector No.4 No.4 Fuel injector
Sensor power Fuel injector Fuel injector
- - power supply drive signal drive signal drive signal drive signal -
supply 2 power supply
(Sub) (Sub) (Sub) (Sub) (Sub) (Sub)
E31 - E32 - E33 AVC2 E34 I1+S E35 IJ01 E36 IJ03 E37 IJ05 E38 I2+S E39 IJ02 E40 IJ04
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
E2 – – E22 – –
E3 – – E23 – –
E4 – – E24 – –
E5 – – E25 – –
E6 – – E26 – –
E7 – – E27 – – 18
E8 – – E28 – –
E9 SPV1 Suction control valve (Main) E29 SP1S Suction control valve (Sub)
E10 SPV2 Suction control valve (Main) E30 SP2S Suction control valve (Sub)
E11 – – E31 – –
No.1 Fuel injector drive signal No.1 Fuel injector drive signal
E15 INJ1 E35 IJ01
(Main) (Sub)
No.2 Fuel injector drive signal No.2 Fuel injector drive signal
E16 INJ3 E36 IJ03
(Main) (Sub)
No.3 Fuel injector drive signal No.3 Fuel injector drive signal
E17 INJ5 E37 IJ05
(Main) (Sub)
No.4 Fuel injector drive signal No.4 Fuel injector drive signal
E19 INJ2 E39 IJ02
(Main) (Sub)
18-423
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18.
ENGINE]
E
Intake air Common rail
(Oil pressure temperature sensor Fuel temperature pressure
switch) - - - - -
(Air flow sensor -
sensor 1 (Main)
sensor built-in)
E41 OLSW E42 - E43 - E44 - E45 - E46 - E47 THA+ E48 THF+ E49 PCR1 E50 -
CAN
G sensor G sensor
- Ne sensor (+) - Sensor ground 1 Sensor ground 3 Sensor ground 5 communication -
(Supply) (Ground)
line
E51 - E52 NE1+ E53 GVCC E54 GGND E55 - E56 AGD1 E57 AGD3 E58 AGD5 E59 CANH E60 INJ6
18-424
Intake throttle Intake manifold Common rail Common rail Coolant Common rail
Boost pressure
- valve position temparature pressure pressure temperature pressure - -
sensor
sensor 1 sensor (+) sensor 2 (Main) sensor 2 (Sub) sensor sensor 1 (Sub)
E61 - E62 DTS1 E63 ATI+ E64 PCR3 E65 PCR4 E66 THW+ E67 PIM E68 PCR2 E69 - E70 -
CAN
G sensor Air flow sensor
- NE sensor (-) NE sensor (SLD) Sensor ground 2 Sensor ground 4 Sensor ground 6 communication -
(Signal) (Signal)
line
E71 - E72 NE1- E73 G3+ E74 AFSI E75 NESD E76 AGD2 E77 AGD4 E78 AGD6 E79 CAUL E80 IJ06
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
E50 – – E70 – –
E51 – – E71 – –
E54 GGND G sensor (Ground) E74 AFSI Air flow sensor (Signal)
Sensor ground 2
Sensor ground 1
(for Fuel temperature sensor,
E56 AGD1 (for Common rail pressure E76 AGD2
Common rail pressure sensor
sensor 1)
2)
Sensor ground 3
Sensor ground 4
E57 AGD3 (for Intake throttle valve E77 AGD4
(for Boost pressure sensor)
position sensor)
Sensor ground 5
(for Coolant temperature Sensor ground 6
E58 AGD5 E78 AGD6
sensor, Intake air (for Air flow sensor signal)
temperature sensor)
18-425
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Te rm in a l to m e a s u re th e vo lta g e
V38,39 V78,79,80 + S id e - S id e
V18, V38, V58, V78 V39, V59, V79, V80
S ta n d a rd va lu e : 20 V o r m o re
YES
Norma l
18-426
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fra me
YES
Norma l
18-427
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Engine speed main sensor and Engine speed sub sensor - rationality
Fa ult s ymptom The pha s e of the ma in rota tion puls e r a nd the a uxilia ry rota tion puls e r is a bnorma l.
• The a uxilia ry rota tion puls e r ha s not be e n ins ta lle d corre ctly.
P le a s e che ck the pha s e of the ca m ge a r.
S ugge s te d fa ult ca us e
• The ma in rota tion puls e r or the a uxilia ry rota tion puls e r have not be e n ins ta lle d a t
the norma l pos ition.
YES
YES
YES
18-428
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Nozzle stuck
Initialization failure 18
18.17.1.13 DTC code P00AF [35]
EEPROM failure
P 0045 P 00 AF
S ugge s te d fa ult ca us e Fa ilure of VNT a ctua tor or VNT controlle r. Fa ilure of the VNT controlle r.
YES
18-429
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck conne ction of the VNT controlle r conne ctor a nd the VNT
a ctua tor conne ctor.
NO P roce e d to 3
YES
Norma l
NO Fa ult in ha rne s s
YES
18-430
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
• Fue l ta nk e mpty
• Clogging of the low-pre s s ure fue l piping (fue l filte r)
• Fue l le a ka ge (high-pre s s ure piping, low-pre s s ure piping)
S ugge s te d fa ult ca us e
• P re s s ure limite r ope ra tion
• Fa ilure of the common-ra il pre s s ure s e ns or
• S upply pump fa ilure
P 0088
Fa ult s ymptom An a bnorma l low fue l pre s s ure in the common-ra il ha s be e n de te cte d.
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
18-431
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 2635
YES
1. Che ck the fue l filte r a nd fue l pipe for fue l oozing a nd le a ka ge.
YES
3 Che ck the fue l ta nk for clogging of the a ir hole a nd the re ma ining a mount
YES
YES
18-432
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Fa ulty S CV
YES
YES
7 Us ing the Hino-DX, che ck the a ctua l common ra il pre s s ure a t the e ngine s ta rt while monitoring
22 2 MP
S ta n d a rd :
The pre s s ure limite r is
ope n red ucing the pres s ure. Th e p ea k o f th e a c tu a l c o m m o n ra il p re ss u re is 22 2
MPa {2,262 kg f/c m 2 , 32,301 lb f/in 2 } o r u n d e r
Idling
NO P rocee d to 11
YES
18-433
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
222 MP
De pre s s the
a cce le rqtor pe da l.
Re le a s e the
ac ce lerato r pe da l.
Hour
YES
NO De fe ctive le a k pipe
YES
18-434
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. S ta rt the e ngine.
YES
Fa ulty S CV
YES
18-435
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom An a bnorma l high fue l pre s s ure in the common-ra il ha s be e n de te cte d.
18-436
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18
18-437
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The inta ke ma nifold te mpe ra ture ca nnot be re cognize d corre ctly.
NOTICE • In ta ke a ir te m p e ra tu re s e n s o r (in te rc o o le r
o u tle t) c h a ra c te ris tic a b n o rm a lity ju d g e m e n t
is p e rfo rm e d b a s e d o n th e b o o s t p re s s u re
a n d EGR ra te d a ta .
• If EGR s ys tem o r Tu rb o DTC a re d e tec te d ,
p e rfo rm a n o th e r fa ilu re d ia g n o s is s ta rtin g
fro m th e firs t DTC a s s o c ia te d with th e
m a lfu n c tio n .
YES
18-438
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18
3 Ins pe ct the inta ke a ir te mpe ra ture s e ns or (inta ke ma nifold)
YES
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
In ta ke a ir
50 °C {122 °F}:
te m p e ra tu re
S ta rte r s witc h : 2.202 kΩ
s e n s o r (in ta ke
OFF 100 °C {212 °F}:
m a n ifo ld )
50 8.1 Ω
THG – E2
YES
18-439
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
In ta ke a ir
te m p e ra tu re
s e n s o r (in ta ke
S ta rte r s witch :
m a n ifo ld ) 4.5 – 5.5 V
ON
m a c h in e -s id e
c o n n e c to r
THG- – E2
NO Go to s tep 6.
YES
Go to s te p 8.
6 Ins pe ct for s hort-circuit of the inta ke a ir te mpe ra ture s e ns or (inta ke ma nifold) ha rne s s
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
En g in e ECU
(s ig n a l c h e ck
h a rn e s s )
S ta rte r s witch :
ATI+(E63) – ∞ Ω
OFF
Gro u n d
AGD2(E76) –
Gro u n d
YES
18-440
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
7 Ins pe ct dis conne ction of the inta ke a ir te mpe ra ture s e ns or (inta ke ma nifold) ha rne s s
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s 18
En g in e ECU
50 °C {122 °F}:
(s ig n a l ch e ck
S ta rte r s witc h : 2.202 kΩ
h a rn e s s )
OFF 100 °C {212 °F}:
ATI+(E63) –
50 8.1 Ω
AGD2(E76)
YES
YES
18-441
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
20 °C {68 °F}:
In ta ke a ir 2.45 kΩ
te m p e ra tu re 60 °C {140 °F}:
S ta rte r s witc h :
s e n s o r (a ir flo w 0.58 kΩ
OFF
s e n s o r bu ilt-in )
Re fe re n c e va lu e
AFT+ – AFT-
5.85 Ω
(0 °C {32 °F})
YES
YES
18-442
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
18-443
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
GND VCC 2. Dis conne ct the boos t pre s s ure s e ns or conne ctor.
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
Bo o s t p re s s u re
s ens or
S ta rte r s witch :
m a ch in e -s id e 4.75 – 5.25 V
ON
c o n n e c to r
VCC – GND
YES
YES
18-444
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Intake air temperature sensor (intake manifold) - out of range (Out of range low)
Intake air temperature sensor (intake manifold) - out of range (Out of range high)
P 0097 P 0098
Fa ult s ymptom The inta ke ma nifold te mpe ra ture ca nnot be re cognize d corre ctly.
YES
18-445
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
In ta ke a ir
50 °C {122 °F}:
te m p e ra tu re
S ta rte r s witch : 2.202 kΩ
s e n s o r (in ta ke
OFF 100 °C {212 °F}:
m a n ifo ld )
508.1 Ω
THG – E2
YES
18-446
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s 18
In ta ke a ir
te m p e ra tu re
s e n s o r (in ta ke
S ta rte r s witc h :
m a n ifo ld ) 4.5 – 5.5 V
ON
m a c h in e -si d e
c o n n e c to r
THG – E2
NO Go to s te p 5.
YES
Go to s tep 7.
5 Ins pe ct for s hort-circuit of the inta ke a ir te mpe ra ture s e ns or (inta ke ma nifold) ha rne s s
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
En g in e ECU
(s ig n a l ch e ck
h a rn e s s )
S ta rte r s witc h :
ATI+(E63) – ∞ Ω
OFF
Gro u n d
AGD2(E76) –
Gro u n d
YES
18-447
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
6 Ins pe ct dis conne ction of the inta ke a ir te mpe ra ture s e ns or (inta ke ma nifold) ha rne s s
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
En g in e ECU
50 °C {122 °F}:
(s ig n a l c h e ck
S ta rte r s witch : 2.202 kΩ
h a rn e s s )
OFF 100 °C {212 °F}:
ATI+(E63) –
508.1 Ω
AGD2(E76)
YES
YES
18-448
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
18
Clus te r ga ug e (S e cond)
YES
YES
18-449
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
E74 E78 3. Conne ct the s igna l che ck ha rne s s to the e ngine ECU ma chine -
s ide ha rne s s. (Do not conne ct ha rne s s to the ECU.)
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
En g in e ECU
(s ig n a l c h e ck
h a rn e s s )
AFVB(E12) –
S ta rte r s witch :
Gro u n d ∞ Ω
OFF
AFS I(E74) –
Gro u n d
AGD6(E78) –
Gro u n d
YES
18-450
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
E Me a s u re m e n t Te s te r
E12 S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
En g in e ECU
ASGD AFGD (s ig n a l ch e ck
18
E
AFSG
h a rn e s s ) – a ir
flow s e n s o r
E74 E78 m a c h in e -si d e
S ta rte r s witc h : c o n n e c to r
1Ω o r le ss
OFF AFVB(E12) –
AFVB
AFS I(E74) –
AFS G
AGD6(E78) –
AGGD
YES
NO Go to s te p 7.
YES
18-451
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the EGR va lve for da ma ge due to fore ign s ubs ta nce s .
YES
(1) 2. Che ck the time la g (following cha ra cte ris tics ) of the ta rge t EGR
va lve ope ning a nd a ctua l EGR va lve ope ning.
(2)
! CAUTION • Pe rfo rm th e in s p e c tio n wh ile th e e n g in e is
s to p p e d to avo id e n g in e d a m a g e s .
S ta n d a rd va lu e s
Th e re s p o n s e d e lay s h o u ld b e le s s th a n 5 s e c o n d s .
YES
18-452
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. Che ck the ope ra ting s ta tus of the inta ke throttle va lve (for
incorre ct ope ning or s ticky va lve ).
YES
YES
YES
18-453
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck tha t the a ir flow s e ns or conne ctor is prope rly ins ta lle d.
YES
YES
18-454
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e
18
Id lin g revo lu tio n
Fre q u e n cy
(No lo a d )
(kHz)
(r/m in )
1,000 5-6
NO Fa ult in a ir flow s e ns or
YES
18-455
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The boos t pre s s ure ca nnot be re cognize d corre ctly.
1. Che ck the conne ction of the boos t pre s s ure s e ns or conne ctor
(Loos e ne s s a nd poor conta ct).
YES
1. Che ck the ins ta lla tion of the boos t pre s s ure s e ns or.
YES
18-456
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
En g in e ECU
(s ig n a l ch e ck
h a rn e s s )
AVC2(E33 ) –
S ta rte r s witc h :
Gro u n d 1Ω
OFF
P IM(E67) –
Gro u n d
AGD4(E77) –
Gro u n d
YES
18-457
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
4 Ins pe ct for dis conne ction in wire ha rne s s of boos t pre s s ure s e ns or
YES
18-458
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Bo o s t p re s s u re
s ens or
S ta rte r s witc h :
m a c h in e -si d e 4.7 5 – 5.25 V
ON
c o n n e c to r
VCC – GND
YES
YES
18-459
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The boos t pre s s ure ca nnot be re cognize d corre ctly.
NOTICE • If it is d iffic u lt to ch e ck o n ly th e s e n s o r,
p ro c e e d to S te p 5.
S ta n d a rd va lu e : 2-15 kΩ
YES
18-460
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 209-231 kΩ
18
NO • Fa ult in ha rne s s
• Irre gula r conta ct of conne ctors
YES
S ta n d a rd va lu e : ∞ Ω
NO Fa ult in ha rne s s
YES
18-461
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
NO • Fa ult in ha rne s s
• Fa ult in boos t pre s s ure s e ns or
YES
18-462
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
NO • Fa ult in ha rne s s
• Irre gula r conta ct of conne ctors
YES
YES
18-463
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Intake air temperature sensor (air flow sensor built-in) - out of range
Intake air temperature sensor (air flow sensor built-in) - out of range
P 0112 P 0113
Fa ult s ymptom The inta ke a ir te mpe ra ture ca nnot be re cognize d corre ctly.
18-464
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NOTICE • If it is d iffic u lt to c h e ck o n ly th e s e n s o r, 18
p ro c e e d to S te p 3.
S ta n d a rd va lu e
Ou ts id e a ir te m p e ra tu re
Re s is ta n ce
(°C{°F})
16 .0 kΩ -20 {-4}
2.45 Ω 20 {68}
0.58 Ω 60 {140}
YES
S ta n d a rd va lu e : 4.5-5.5 V
NO P rocee d to 3
YES
18-465
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e
Ou ts id e a ir te m p e ra tu re
Re s is ta n c e
(°C{°F})
2.45 Ω 20 {68}
0.58 Ω 60 {140}
YES
YES
18-466
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 0117 P 0118
Clus te r ga ug e (S e cond)
NOTICE • If it is d iffic u lt to c h e c k o n ly th e s e n s o r,
p ro c e e d to S te p 3.
S ta n d a rd va lu e
Wa te r te m p e ra tu re
Re s is ta n ce
(°C{°F})
2.45 kΩ 20 {68}
1.1 5 kΩ 40 {104}
584 Ω 60 {140}
318 Ω 80 {176}
YES
18-467
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 4.5-5.5 V
NO P roce e d to 3
YES
S ta n d a rd va lu e
Wa te r te m p e ra tu re
Re s is ta n c e
(°C{°F})
2.45 kΩ 20 {68 }
1.15 kΩ 40 {104}
584 Ω 60 {140}
318 Ω 80 {176}
YES
18-468
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-469
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Intake throttle valve position sensor 1 - out of range (Out of range low)
2. Dis conne ct the conne ctor of the inta ke throttle va lve pos ition
s e ns or 1 conne ctor.
3. Che ck continuity be twe e n the t e rmina ls VCC a nd DTS 1 of the
DTS 1 VCC inta ke throttle va lve pos ition s e ns or 1 conne ctor.
NOTICE • If it is d iffic u lt to ch e ck o n ly th e s e n s o r,
p ro c e e d to S te p 4.
S ta n d a rd va lu e : Ap p rox. 180 Ω
S ta n d a rd va lu e : Ap p rox. 3 kΩ
18-470
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : Ap p rox. 3 kΩ
18
NO Fa ult in inta ke throttle va lve pos ition s e ns or 1
YES
S ta n d a rd va lu e : Ap p rox. 25-35 kΩ
NO • Fa ult in ha rne s s
• Irre gula r conta ct of conne ctors
YES
18-471
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 4.5-5.5 V
NO • Fa ult in ha rne s s
• Irre gula r conta ct of conne ctors
YES
18-472
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO • Fa ult in ha rne s s
• Fa ult in inta ke throttle va lve pos ition s e ns or 1
YES
18-473
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
18-474
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Intake throttle valve position sensor 1 - out of range (Out of range high)
18
Clus te r ga uge (S e cond)
2. Dis conne ct the conne ctor of the inta ke throttle va lve pos ition
s e ns or 1.
3. Me a s ure re s is ta nce be twe e n the te rmina ls VCC a nd DTS 1 of
DTS 1 VCC the inta ke throttle va lve pos ition s e ns or 1 conne ctor.
NOTICE • If it is d iffic u lt to c h e ck o n ly th e s e n s o r,
p ro c e e d to S te p 5.
S ta n d a rd va lu e : Ap p rox. 180 Ω
S ta n d a rd va lu e : Ap p rox. 3 kΩ
18-475
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : Ap p rox. 3 kΩ
YES
S ta n d a rd va lu e : Ap p rox. 25-35 kΩ
NO • Fa ult in ha rne s s
• Irre gula r conta ct of conne ctors
YES
S ta n d a rd va lu e : ∞ Ω
NO Fa ult in ha rne s s
YES
18-476
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
E33 E62 S ta n d a rd va lu e : ∞ Ω
18
YES
NO • Fa ult in ha rne s s
• Fa ult in inta ke throttle va lve pos ition s e ns or 1
YES
18-477
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO • Fa ult in ha rne s s
• Irre gula r conta ct of conne ctors
YES
YES
18-478
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 0182 P 0183
Fa ult s ymptom The fue l te mpe ra ture ca nnot be re cognize d corre ctly.
• S e ns or fa ilure • S e ns or fa ilure
S ugge s te d fa ult ca us e • Ha rne s s GND s ho rt-circuit • Ha rne s s wire bre a k or B+ s hort-circuit
• Engine ECU fa ult • Engine ECU fa ult
NOTICE • If it is d iffic u lt to c h e ck o n ly th e s e n s o r,
p ro c e e d to S te p 3.
S ta n d a rd va lu e
Fu e l te m p e ra tu re in
Re si s ta n c e (kΩ )
m e a s u re m e n t (°C{°F})
-20 {-4} 13.84-16.33
20 {68} 2.32-2.59
80 {176} 0.31-0.326
YES
18-479
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 4.5-5.5 V
NO P roce e d to 3
YES
S ta n d a rd va lu e
Fu e l te m p e ra tu re in
Re s is ta n c e (kΩ )
m e a s u rem e n t (°C{°F})
80 {176} 0.31-0.326
YES
18-480
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-481
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-482
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Common rail pressure sensor (main) - out of range (Out of range low)
Fa ult s ymptom The common-ra il pre s s ure ca nnot be re cognize d corre ctly.
18
Clus te r ga uge (S e cond)
YES
18-483
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NOTICE • If it is d iffic u lt to ch e ck o n ly th e s e n s o r,
p ro c e e d to S te p 3.
S ta n d a rd va lu e : ∞ Ω
S ta n d a rd va lu e : ∞ Ω
NO Fa ult in ha rne s s
YES
18-484
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Fa ult in ha rne s s
YES
18-485
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
18-486
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
YES
18-487
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Common rail pressure sensor (main) - out of range (Out of range high)
Fa ult s ymptom The common-ra il pre s s ure ca nnot be re cognize d corre ctly.
YES
18-488
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 4.5-5.5 V
18
S ta n d a rd va lu e : 4.5-5.5 V
NO P rocee d to 3
YES
18-489
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-490
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
18-491
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
A fa ult (a bnorma lly high volta ge of the inje ctor cha rge circuit) ha s be e n de te cte d in
Fa ult s ymptom
the ECU.
18-492
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
18
Clus te r ga ug e (S e cond)
P 0606
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
2. Afte r e ra s ing the DTC, che ck tha t the s a me code is dis playe d
a ga in.
YES
18-493
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ilure of inje ctor Fa ilure of inje ctor Fa ilure of inje ctor Fa ilure of inje ctor
Fa ult s ymptom 1 ha s be e n 2 ha s be e n 3 ha s be e n 4 ha s be e n
de te cte d. de te cte d. de te cte d. de te cte d.
Output re s triction exis ts
Output limit et c.
DP R reg e ne rat ion prohibite d
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
18-494
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. Dis conne ct the ECU s ide conne ctor of the s igna l che ck
ha rne s s a nd me a s ure the re s is ta nce be twe e n te rmina ls .
18
S ta n d a rd va lu e : 2 Ω o r le s s
YES
18-495
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ilu re a re a (in je c to r) #1 #2 #3 #4
Te rm in a l to m e a s u re
11 ↔ 12 3↔ 4 5↔ 6 7↔ 8
re s is ta n c e
S tand a rd va lu e : 2 Ω o r le ss
YES
Engine s ub ha rne s s dis conne ction (Che ck the ha rne s s be twe e n the ECU a nd the inje ctor clus te re d conne ctor)
1. Re move the he a d cove r a nd dis conne ct the inje ctor conne ctor
(inje ctor s ide ) of the cylinde r indica te d by the fa ilure code.
2. Me a s ure the re s is ta nce be twe e n the No. 1 te rmina l a nd the No.
2 te rmina l.
YES
18-496
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 10 MΩ o r m o re
YES
18-497
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
NOTICE • Me a s u re th e re s is ta n c e u n d e r a ny o f th e
fo llo win g c o n d itio n s .
S ta n d a rd va lu e
Wa te r te m p e ra tu re
Re s is ta n ce
(°C{°F})
2.45 kΩ 20 {68}
1.1 5 kΩ 40 {104}
584 Ω 60 {140}
318 Ω 80 {176}
YES
18-498
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
Clus te r ga uge (S e cond)
S ugge s te d fa ult ca us e Ha rne s s a bnorma lity or modifica tion, inte rfe re nce of the s pe e d s e ns or s ys te m s igna l
1. The DTC will be dis playe d, once de te cte d ove r 3100 r/min. in
the e ngine revolution. Als o, the fue l inje ction will be s us pe nde d
during the DTC to be de te cte d an d the fue l inje ction will be
re s ume d whe n Engine revolution goe s down le s s tha n 2700 r/
min.
18-499
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Overboost
Clus te r ga ug e (S e cond)
YES
18-500
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
S ta n d a rd :
Ac tu a l o p e n in g mu s t fo llow re q u ire d o p e n in g
YES
18-501
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The boos t pre s s ure ca nnot be re cognize d corre ctly.
• Wire bre a k in the s e ns or s igna l ha rne s s or powe r s upply ha rne s s , GND s hort-
circuit
S ugge s te d fa ult ca us e • Incomple te conne ctor e nga ge me nt
• S e ns or fa ilure
• Engine ECU fa ult
NOTICE • If it is d iffic u lt to c h e c k o n ly th e s e n s o r,
p ro c e e d to S te p 4.
S tand a rd va lu e : 2-15 kΩ
S tand a rd va lu e : 2-15 kΩ
YES
18-502
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 209-231 kΩ
NO P roce e d to 4
18
YES
S ta n d a rd va lu e : 4.5-5.5 V
NO P roce e d to 4
YES
18-503
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-504
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
E33
E77
S ta n d a rd va lu e : 4.5-5.5 V
18
YES
YES
18-505
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
The s pe e d cha nge of the firs t cylinde r ha s be come la rge r tha n tha t of the othe r
Fa ult s ymptom
cylinde rs.
Clus te r ga ug e (S e cond) —
• Broke n pipe be twe e n flow limite r a nd inje ctor pipe, cra cke d pipe, le a ka ge from
pipe joints, e tc.
S ugge s te d fa ult ca us e
• Inje ctor fa ilure
• De fe ctive inje ction nozzle /s e a t
P 0266
The s pe e d cha nge of the s e cond cylinde r ha s be come la rge r tha n tha t of the othe r
Fa ult s ymptom
cylinde rs.
Clus te r ga ug e (S e cond) —
• Broke n pipe be twe e n flow limite r a nd inje ctor pipe, cra cke d pipe, le a ka ge from
pipe joints, e tc.
S ugge s te d fa ult ca us e
• Inje ctor fa ilure
• De fe ctive inje ction nozzle /s e a t
18-506
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 0269
The s pe e d cha nge of the third cylinde r ha s be come la rge r tha n tha t of the othe r
Fa ult s ymptom
cylinde rs .
P 0272
The s pe e d cha nge of the fourth cylinde r ha s be come la rge r tha n tha t of the othe r
Fa ult s ymptom
cylinde rs .
• Broke n pipe be twe e n flow limite r a nd inje ctor pipe, cra cke d pipe, le a ka ge from
pipe joints , e tc.
S ugge s te d fa ult ca us e
• Inje ctor fa ilure
• De fe ctive inje ction nozzle /s e a t
1. Turn the s ta rte r switch to "OFF" pos ition. S top the en gine.
18-507
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-508
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The puls e from the ma in rota tion s e ns or ca nnot be re cognize d.
Output limit e tc. Output re s triction exis ts
Wh e n o n ly th e e n g in e m a in ro ta tio n s e n s o r h a s fa ile d
Fa ult s ymptom The puls e from the ma in rota tion s e ns or ca nnot be re cognize d corre ctly.
18-509
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. Dis conne ct the s igna l che ck ha rne s s conne ctor on the e ngine
ECU s ide.
3. Me a s ure the re s is ta nce be twe e n NE1+ (E52) a nd NE1- (E72)
te rmina ls .
E52
E72 S ta n d a rd va lu e : 108.5-142.5 Ω a t 20°C {68°F}
NO P rocee d to 3
YES
YES
18-510
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
NO Fa ult in e ngine s pe e d ma in s e ns or
YES
18-511
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The puls e from the a uxilia ry rota tion s e ns or ca nnot be re cognize d corre ctly.
Clus te r ga ug e (S e cond)
• Abnorma l puls e r
• Inte rfe re nce nois e
S ugge s te d fa ult ca us e
• S e ns or fa ilure
• Engine ECU fa ult
2. S ta rt the e ngine.
3. Me a s ure the puls e ge ne ra tion be twe e n NE1+ (E52) a nd NE1-
(E72) te rmina ls us ing a n os cillos cope.
E52
E72 S ta n d a rd : 56 p u ls e
1 rotation
56 peak s (pulse)
0V
18-512
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO P roce e d to 2
YES
18
2 Me a s uring re s is ta nce be twe e n s e ns or te rmina ls
S ta n d a rd va lu e : Le s s th a n 2 Ω
NO Fa ult in ha rne s s
YES
18-513
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. S ta rt the e ngine.
S ta n d a rd : 56 p u ls e
1 rotation
56 pea ks (pulse )
0V
YES
18-514
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The puls e from the a uxilia ry rota tion s e ns or ca nnot be re cognize d corre ctly.
18
Clus te r ga uge (S e cond)
E54
YES
Fa ult in e ngine s pe e d s ub s e ns or
18-515
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The puls e from the a uxilia ry rota tion s e ns or ca nnot be re cognize d corre ctly.
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
• Abnorma l puls e r
• Inte rfe re nce nois e
S ugge s te d fa ult ca us e
• S e ns or fa ilure
• Engine ECU fa ult
2. S ta rt the e ngine.
3. Me a s ure the wave form be twe e n te rmina ls E54 a nd E73 of the
E54
s igna l che ck ha rne s s .
E73 S ta n d a rd
S eve n p u ls e s fro m exc e s s to o th to exc e s s to o th
2 rotation
5V
0V
18-516
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18
2 Me a s uring the output wave form on the s e ns or s ide
2. S ta rt the e ngine .
3. Me a s ure the wave form be twe e n te rmina l S IG of the e ngine
a uxilia ry rota tion s e ns or conne ctor (unit ha rne s s s ide ) a nd
te rmina l GND.
S ta n d a rd
S eve n p u ls e s fro m e xc e s s to o th to exc e ss to o th
2 rotation
5V
0V
YES
18-517
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
YES
YES
1. Che ck the ins ta lla tion of the boos t pre s s ure s e ns or.
YES
18-518
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
18-519
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
In ta ke a ir
20 °C {68 °F}:
te m p e ra tu re
S ta rte r s witc h : 7.336 – 5.794 kΩ
s e n s o r (in ta ke
OFF 50 °C {122 °F}:
m a n ifo ld )
2.435 – 2.41 kΩ
THG – E2
YES
18-520
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e s
YES
18-521
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck if s oot is obs tructing the inle t/outle t of the EGR coole r
ga s pa s s a geway.
2. Che ck if the re a re fore ign s ubs ta nce s s tuck to the EGR coole r
coola nt pa s s a geway.
3. Che ck the EGR coole r coola nt pa s s a geway for obs truction due
to de forma tion or othe r da ma ge.
YES
1. Che ck the EGR va lve for da ma ge due to incurs ion of fore ign
s ubs ta nce s.
YES
10 Ins pe ct the S CV
YES
18-522
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Che ck the inje ction qua ntity a nd the rota tiona l fluctua tion.
1. S ta rt the e ngine .
YES
YES
18-523
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The inta ke he a te r re lay is not ope ra ting corre ctly.
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
Te rm in al to m e a s u re th e re sis ta n c e
V39 V79, + S id e - S id e
V80
V24 V39, V59, V79, V80
S tand a rd va lu e : 25 ± 2.5 Ω
S ignal ch e ck ha rne s s
E
Heate r relay C
U
YES
18-524
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 24.8 ± 0.5 Ω
18
NO He a te r re lay fa ilure
YES
18-525
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The exha us t ga s te mpe ra ture ca nnot be re cognize d corre ctly.
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
NOTICE • If it is d iffic u lt to c h e c k o n ly th e s e n s o r,
p ro c e e d to S te p 3.
S ta n d a rd va lu e
Te m p e ra tu re (°C{°F}) Re s is ta n c e
20 {68} 13.7 - 29.8 kΩ
YES
18-526
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
NO P roce e d to 4
YES
V46 V69 2. Conne ct the s igna l che ck ha rne s s on the unit s ide.
V
3. Dis conne ct the conne ctor on the e ngine ECU s ide.
S ta n d a rd va lu e
Te m p e ra tu re ( °C{°F}) Re s is ta n c e
YES
18-527
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
V46
V69 2. Conne ct the s igna l che ck ha rne s s on the unit s ide.
V
3. S e t the s ta rte r switch to "ON" pos ition.
YES
Fa ult in ha rne s s
18-528
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The exha us t ga s te mpe ra ture ca nnot be re cognize d corre ctly.
NOTICE • If it is d iffic u lt to ch e ck o n ly th e s e n s o r,
p ro c e e d to S te p 3.
S ta n d a rd va lu e
Te m p e ra tu re ( °C{°F}) Re s is ta n c e
20 {68 } 13.7 - 29.8 kΩ
YES
18-529
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO P rocee d to 4
YES
V46 V69 2. Conne ct the s igna l che ck ha rne s s on the unit s ide.
V
3. Dis conne ct the conne ctor on the e ngine ECU s ide.
S ta n d a rd va lu e
Te m p e ra tu re (°C{°F}) Re s is ta n c e
20 {68} 13.7 - 29.8 kΩ
YES
18-530
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
V46
V69 2. Conne ct the s igna l che ck ha rne s s on the unit s ide.
V
3. S e t the s ta rte r switch to "ON" pos ition.
YES
Fa ult in ha rne s s
18-531
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom A low volta ge a bnorma lity of the e ngine ECU powe r s upply ha s be e n de te cte d.
Clus te r ga ug e (S e cond)
2. Wa s a ny fa ilure found?
NO Go to s te p 2.
YES
Conne ct the fus e a nd fus ible link s e cure ly, or re pla ce it.
1. Che ck the conne ction of the ba tte ry ca ble s.(fa s te ning fa ilure )
• Ea ch te rmina ls of the ba tte ry
• Te rmina ls of the a lte rna tor
2. Wa s a ny fa ilure found?
NO Go to s te p 3.
YES
18-532
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S ta rt the e ngine .
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
Alte rn a to r B
18
En g in e id lin g te rm in a l – Bo d y 13.5 V o r m o re
Gro u n d
NO Go to s tep 4.
YES
3. S ta rt the e ngine .
4. Us e the e le ctrica l te s te r to me a s ure the volta ge be twe e n the
V18 te rmina ls of the e ngine ECU (s igna l che ck ha rne s s ).
V58,V59
Mea s u rem e n t Te s te r
V38,39 V78,79,80 S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
En g in e ECU
(S in g n a l c h e ck
h a rn e s s )
(+) – (-)
En g in e id lin g 10 to 16 V
V18 – V39
V38 – V59
V58 – V79
V78 – V80
18-533
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
18-534
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom A high volta ge a bnorma lity of the e ngine ECU powe r s upply ha s be e n de te cte d.
2. Wa s a ny fa ilure found?
NO Go to s te p 2.
YES
Conne ct the fus e a nd fus ible link s e cure ly, or re pla ce it.
1. Che ck the conne ction of the ba tte ry ca ble s.(fa s te ning fa ilure )
• Ea ch te rmina ls of the ba tte ry
• Te rmina ls of the a lte rna tor
2. Wa s a ny fa ilure found?
NO Go to s te p 3.
YES
18-535
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S ta rt the e ngine.
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
Alte rn a to r B
En g in e id lin g te rm in a l – Bo dy 14.6 V o r le s s
Gro u n d
NO Go to s te p 4.
YES
3. S ta rt the e ngine.
4. Us e the e le ctrica l te s te r to me a s ure the volta ge be twe e n the
V18 te rmina ls of the e ngine ECU (s igna l che ck ha rne s s ).
V58,V59
Me a s u re m e n t Te s te r
V38,39 V78,79,80 S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
En g in e ECU
(S in g n a l ch e ck
h a rn e s s )
(+) – (-)
En g in e id lin g 10 to 16 V
V18 – V39
V38 – V59
V58 – V79
V78 – V80
18-536
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
4. Ha s DTC P 05 63 be en de te cte d?
YES
18-537
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (S e cond)
1 Ins pe ction
NO Re pa ir the trouble
YES
YES
18-538
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Suction control valve for fuel supply pump - circuit (circuit low)
Suction control valve for fuel supply pump - circuit (circuit high)
P 0628 P 0629
Te rm in al to m e a s u re th e re sis ta n c e
E30 E9 (S P V1) ↔ E30 (S P 2S )
E2 9
E9 (S P V1) ↔ E10 (S P V2)
E29 (S P 1S ) ↔ E30 (S P 2S )
E29 (S P 1S ) ↔ E10 (S P V2)
YES
18-539
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Fa ilure of S CV
YES
Te rm in al to m e a s u re th e re sis ta n c e
S ig n a l c h e ck h a rn e s s S CV
E30
E10 (S P V2)
No .1 (S CVL)
E30 (S P 2S )
E9 (S P V1)
No .2 (S CVH)
E29 (S P 1S )
S tand a rd va lu e : 1 Ω o r le ss
E29
YES
18-540
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-541
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom A low volta ge a bnorma lity of the s e ns or powe r s upply ha s be e n de te cte d.
Clus te r ga ug e (S e cond)
1. Boos t pre s s ure s e ns or conne ctor, Inta ke throttle va lve pos ition
s e ns or 1 conne ctor, common ra il pre s s ure s e ns or 1 conne ctor,
Ca ms ha ft pos ition s e ns or conne ctor by re moving e a ch of one ,
P 0642 fa ult code dis a ppe a rs things che ck.
NO P rocee d to 2
YES
18-542
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : ∞ Ω
NO Fa ulty ha rne s s
YES
18-543
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom A high volta ge a bnorma lity of the s e ns or powe r s upply ha s be e n de te cte d.
Clus te r ga ug e (S e cond)
S ta n d a rd va lu e : 4.9-5.1 V
NO Fa ulty ha rne s s
YES
18-544
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom A low volta ge a bnorma lity of the s e ns or powe r s upply ha s be e n de te cte d.
NO P roce e d to 2
YES
18-545
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
V71
Te rm in al to m e a s u re th e re sis ta n c e
+ S id e - S id e
E13
E33
V50 E56
V71
S ta n d a rd va lu e : ∞ Ω
NO Fa ulty ha rne s s
YES
18-546
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom A high volta ge a bnorma lity of the s e ns or powe r s upply ha s be e n de te cte d.
Te rm in a l to m e a s u re th e vo lta g e
V71
+ S id e - S id e
E13
E13
V50 E56
V71
S ta n d a rd va lu e : 4.9-5.1 V
NO Fa ulty ha rne s s
YES
18-547
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
• Ha rne s s +B s hort-circuit
S ugge s te d fa ult ca us e • ON fa ilure of the ma in re lay
• Engine ECU fa ult
YES
18-548
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom A low volta ge a bnorma lity of the a irflow s e ns or powe r s upply ha s be e n de te cte d.
NO P roce e d to 2
YES
Fa ulty a ir flow s e ns or
18-549
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO P rocee d to 3
YES
Fa ulty ha rne s s
YES
18-550
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom A high volta ge a bnorma lity of the a irflow s e ns or powe r s upply ha s be e n de te cte d.
• Ha rne s s +B s hort-circuit
S ugge s te d fa ult ca us e
• Eng ine ECU fa ult
NO P roce e d to 2
YES
18-551
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-552
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1 Me a s uring re s is ta nce be twe e n volume for e me rge ncy a cce le ra tor te rmina ls
2. Dis conne ct the volume for e me rge ncy a cce le ra tor conne ctor.
3. Me a s ure re s is ta nce be twe e n the te rmina ls of volume for
5V e me rge ncy a cce le ra tor conne ctor.
NOTICE • If it is d iffic u lt to ch e ck o n ly th e s e n s o r,
p ro c e e d to S te p 4.
GND
S IG S ta n d a rd va lu e
Re si s ta n c e
Vo lu m e Te rm in a ls
va lu e
GND - S IG 0Ω
Lo
GND - 5 V 3.1 kΩ
GND - S IG 2 kΩ
Hi
S IG - 5 V 1.1 kΩ
YES
18-553
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NOTICE • If it is d iffic u lt to c h e ck o n ly th e s e n s o r,
p ro c e e d to S te p 5.
S ta n d a rd va lu e : 740-760 kΩ
NO • Fa ult in ha rne s s
• Irre gula r conta ct of conne ctors
YES
S ta n d a rd va lu e : ∞ Ω
NO Fa ulty ha rne s s
YES
18-554
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Fa ulty ha rne s s
YES
AS CS
AVC5 (V71).
AVC5 (V68)
(V71) S ta n d a rd va lu e : 1.1 kΩ o r m o re
YES
18-555
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-556
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Common rail pressure sensor (sub) - out of range (Out of range low)
Common rail pressure sensor (sub) - out of range (Out of range high)
P 1197
Fa ult s ymptom The common-ra il pre s s ure ca nnot be re cognize d corre ctly.
Output limit e tc. None
18
Clus te r ga uge (Firs t) P1 197
P 1198
Fa ult s ymptom The common-ra il pre s s ure ca nnot be re cognize d corre ctly.
Output limit e tc. None
18-557
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
1. Che ck the ins ta lla tion of the common ra il pre s s ure s e ns or.
YES
18-558
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-559
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NOTICE • If it is d iffic u lt to c h e ck o n ly th e s e n s o r,
p ro c e e d to s te p 3.
S ta n d a rd va lu e : ∞ Ω
S ta n d a rd va lu e : ∞ Ω
NO Fa ult in ha rne s s
YES
18-560
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
NO Fa ult in ha rne s s
YES
18-561
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-562
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
YES
YES
18-563
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-564
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The common-ra il pre s s ure ca nnot be re cognize d corre ctly.
18
Clus te r ga uge (S e cond)
• S e ns or fa ilure
S ugge s te d fa ult ca us e
• Eng ine ECU fa ult
YES
YES
18-565
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 0.3-0.7 V
YES
18-566
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
E56 E E49 18
Te rm in a l to m e a s u re th e vo ltag e
+ S id e - S id e
E68
AVC1 (E13 )
P CR1 (E49) AGD1 (E56)
P CR2 (E68)
AVC2 (E33 )
P CR3 (E64) AGD2 (E76)
P CR4 (E65)
S ta n d a rd va lu e : 4.5-5.5 V
E E65 NO
E33
E64 E E76 Re pla ce the common ra il pre s s ure s e ns or.
YES
Select 2. S top the e ngine a nd s e t the s ta rte r switch to the "ON" pos ition.
Engine
3. S e le ct [Engine ] a nd che ck if P 119F ha s be e n de te cte d in [Fa ult
Informa tion].
YES
18-567
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom Common 1 of the inje ctor drive s ys te m is not ope ra ting corre ctly.
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
2. Dis conne ct the s igna l che ck ha rne s s conne ctor on the e ngine
ECU s ide.
3. Me a s ure the re s is ta nce be twe e n the te rmina ls of ECU
E14 conne ctor.
E34
+ s id e - s id e
S ta n d a rd va lu e : ∞ Ω
NO P rocee d to (3)
YES
18-568
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Turn the s ta rte r switch to "OFF" pos ition (with a ll conne ctors of
ECU dis conne cte d).
2. Dis conne ct the inje ctor conne ctor tha t is loca te d o n the fron t
s ide of the ca m hous ing.
3. Me a s ure the re s is ta nce be twe e n the pins of inje ctor conne ctor
(e ngine s ub ha rne s s s ide ) a nd ECU ca s e GND.
1 2 3 4 ! CAUTION • Me a s u re th e re s is ta n c e o f th is c o n n e c to r fro m
5 6 7 8 th e c o n n ec to r te rm in a ls (fe m al e ).
9 10 11 12 • Do n o t d a m ag e th e c o n n e c to r te rm in a ls .
11
No .1 in je c to r
12
3
No .2 in je c to r ECU c a s e GND
4
5
No .3 in je c to r
6
S ta n d a rd va lu e : ∞ Ω
NO Fa ult in ha rne s s
(It is de fe ctive the ha rne s s which re s is ta nce va lue is
out of the s ta nda rd)
YES
18-569
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom Common 1 of the inje ctor drive s ys te m is not ope ra ting corre ctly.
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
NO P rocee d to (3)
YES
18-570
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. Dis conne ct the inje ctor conne ctor tha t is loca te d o n the fron t
s ide of the ca m hou s ing. Turn the s ta rte r switch to "ON"
pos ition .
3. Me a s ure the volta ge be twe e n the pins of inje ctor conne ctor
(e ngine s ub ha rne s s s ide ) a nd ECU ca s e GND.
Fa ilu re p o s itio n
(b re a kin g + s id e - s id e
p o s itio n )
No .1 in je c to r 11
No .2 in je c to r 3 ECU c a s e GND
No .3 in je c to r 6
S ta n d a rd va lu e : Le s s th a n b a tte ry vo ltag e x 3 /4 V
NO Fa ult in ha rne s s
(It is de fe ctive the ha rne s s which volta ge va lue is out
of the s ta nda rd)
YES
18-571
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom Common 2 of the inje ctor drive s ys te m is not ope ra ting corre ctly.
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
2. Dis conne ct the s igna l che ck ha rne s s conne ctor on the e ngine
ECU s ide.
3. Me a s ure the re s is ta nce be twe e n the te rmina ls of ECU
E E18 conne ctor.
E38
+ s id e - s id e
S ta n d a rd va lu e : ∞ Ω
NO P rocee d to (3)
YES
18-572
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Turn the s ta rte r switch to "OFF" pos ition (with a ll conne ctors of
ECU dis conne cte d).
2. Dis conne ct the inje ctor conne ctor tha t is loca te d o n the fron t
s ide of the ca m hous ing.
3. Me a s ure the re s is ta nce be twe e n the pins of inje ctor conne ctor
(e ngine s ub ha rne s s s ide ) a nd ECU ca s e GND.
1 2 3 4 ! CAUTION • Me a s u re th e re s is ta n c e o f th is c o n n e c to r fro m
5 6 7 8 th e c o n n ec to r te rm in a ls (fe m al e ).
9 10 11 12 • Do n o t d a m ag e th e c o n n e c to r te rm in a ls .
7
No .4 in je c to r ECU c a s e GND
8
S ta n d a rd va lu e : ∞ Ω
NO Fa ult in ha rne s s
(It is de fe ctive the ha rne s s which re s is ta nce va lue is
out of the s ta nda rd)
YES
18-573
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom Common 2 of the inje ctor drive s ys te m is not ope ra ting corre ctly.
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
NO P rocee d to (3)
YES
18-574
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. Dis conne ct the inje ctor conne ctor tha t is loca te d o n the fron t
s ide of the ca m hou s ing. Turn the s ta rte r switch to "ON"
pos ition .
3. Me a s ure the volta ge be twe e n the pins of inje ctor conne ctor
(e ngine s ub ha rne s s s ide ) a nd ECU ca s e GND.
Fa ilu re p o s itio n
(b re a kin g + s id e - s id e
p o s itio n )
No .4 in je c to r 7 ECU c a s e GND
S ta n d a rd va lu e : Le s s th a n b a tte ry vo ltag e x 3 /4 V
NO Fa ult in ha rne s s
(It is de fe ctive the ha rne s s which volta ge va lue is out
of the s ta nda rd)
YES
18-575
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The exha us t ga s pre s s ure ca nnot be re cognize d corre ctly.
S ta n d a rd va lu e : 2 - 15 kΩ
S ta n d a rd va lu e : 2 - 15 kΩ
YES
18-576
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : ∞ Ω
18
S ta n d a rd va lu e : ∞ Ω
NO Fa ult in ha rne s s
YES
18-577
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
V71 S ta n d a rd va lu e : ∞ Ω
NO • Fa ult in ha rne s s
• Irre gula r conta ct of conne ctor
YES
18-578
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
V71 S ta n d a rd va lu e : 4.5-5.5 V
YES
18-579
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The exha us t ga s pre s s ure ca nnot be re cognize d corre ctly.
S tand a rd va lu e : 2-15 kΩ
S tand a rd va lu e : 2-15 kΩ
YES
18-580
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 4.5-5.5 V
18
NO P roce e d to 3
YES
18-581
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-582
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 200-250 kΩ
18
YES
V71 S ta n d a rd va lu e : 4.5-5.5 V
YES
18-583
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
S ugge s te d fa ult ca us e Fa ilure of the EGR va lve body or the EGR va lve a ctua tor.
YES
18-584
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 16 to 32 V
NO • Fa ulty ha rne s s
• Fa ulty ba tte ry
YES
YES
Fa ult in ha rne s s
Fa ult in e ngine ECU
18-585
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
S ugge s te d fa ult ca us e Fa ilure of the EGR va lve body or the EGR va lve a ctua tor.
YES
Fa ult in ha rne s s
Fa ult in e ng ine ECU
18-586
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
Clus te r ga uge (S e cond)
NO P roce e d to 3
YES
NO P roce e d to 3
YES
Norma l
18-587
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
Norma l
18-588
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
Clus te r ga uge (S e cond)
Selec t
Engine
YES
18-589
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the conne ction of the DOC downs tre a m te mpe ra ture
s e ns or conne ctor.
S ta n d a rd : Th e a b s e n c e o f p o o r c o n ta c t.
NO Conne ct s e cure ly or re pa ir if ne e de d.
Afte r tha t, proce e d to the s te p 3.
YES
3 Ins pe ct the outs ide of the DOC downs tre a m te mpe ra ture s e ns or
1. Che ck the ins ta lla tion of the DOC downs tre a m te mpe ra ture
s e ns or.
YES
18-590
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Me a s u re m e n t Te s te r
18
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
20 °C {68°F}
DOC
13.7 – 29.8 Ω
d own s tre a m
S ta rte r s witch : 50 °C {122 °F}
te m p e ra tu re
OFF 7.13 – 13.7 kΩ
s ens or
80 °C {176 °F}
TEX1 – GND1
4.13 – 7.13 kΩ
YES
NO Conne ct s e cure ly or re pa ir if ne e de d.
Afte r tha t, proce e d to the s te p 6.
YES
18-591
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the ins ta lla tion of the DP R downs tre a m te mpe ra ture
s e ns or.
YES
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
20 °C {68 °F}
DP R
13.7 – 29.8 Ω
d o wn s tre a m
S ta rte r s witc h : 50 °C {122 °F}
te m p e ra tu re
OFF 7.13 – 13.7 kΩ
s ens or
80 °C {176 °F}
THC0 – E2
4.13 – 7.13 kΩ
YES
18-592
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES 18
Che ck the inje ction qua ntity a nd the rota tiona l fluctua tion.
1. S ta rt the e ngine .
! CAUTION • In s p e c t a fte r e n g in e wa rm -u p .
S ta n d a rd va lu e
En g in e s p e e d In je c tio n q u a n tity
(r/m in ) (q )
800 10 to 30
YES
18-593
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NOTICE • Yo u d o n o t h a ve to im p le m e n t
th e d iffe re n tia l p re s s u re ch e ck
a fte r p e rfo rm in g m a n u a l fo rc e d
re g e n e ra tio n .
YES
11 DP R force d re ge ne ra tion
NOTICE • If th e s ys te m d o e s n o t e n te r th e re g e n e ra tio n
m o d e , c h e ck wh e th e r th e n e u tra l s witc h o r
e m e rg e n cy a c c e le ra to r c irc u its fu n c tio n
c o rre c tly, o r wh e th e r th e lo ck leve r is in th e
c o rre c t p o s itio n .
S ta n d a rd : th e va lu e o f DP R exh a u s t te m p e ra tu re (IN)
h a s ris e n 450°C {842°F} o r h ig h e r.
YES
18-594
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e
En g in e s p e e d Diffe re n tia l p re s s u re
(r/m in ) (kPa )
2000 Be low 10
18
NO Re pla ce the DP R filte r a nd pe rform ma nua l force d
re ge ne ra tion.
NOTICE • Yo u d o n o t h ave to im p le m e n t
th e d iffe re n tia l p re s s u re c h e ck
a fte r p e rfo rm in g m a n u a l fo rc e d
re g e n e ra tio n .
YES
Selec t
Engine
YES
18-595
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The exha us t ga s te mpe ra ture ca nnot be re cognize d corre ctly.
NOTICE • If it is d iffic u lt to c h e ck o n ly th e s e n s o r,
p ro c e e d to S te p 3.
S ta n d a rd va lu e
Te m p e ra tu re (°C{°F}) Re s is ta n c e
20 {68} 13.7 - 29.8 kΩ
18-596
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Temperatur e (C)
18
NO Fau lty DP R downs tre a m te mp e rat ure s e ns or
YES
S ta n d a rd va lu e : 4.5-5.5 V
NO P roce e d to 4
YES
18-597
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Te m p e ra tu re (°C{°F}) Re s is ta n c e
20 {68} 13.7 - 29.8 kΩ
Temperatur e (C)
YES
18-598
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
Fa ulty ha rne s s
18-599
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The exha us t ga s te mpe ra ture ca nnot be re cognize d corre ctly.
NOTICE • If it is d iffic u lt to c h e ck o n ly th e s e n s o r,
p ro c e e d to S te p 3.
S ta n d a rd va lu e
Te m p e ra tu re (°C{°F}) Re s is ta n c e
18-600
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Temperatur e (C)
18
NO Fau lty DP R downs tre a m te mp e rat ure s e ns or
YES
S ta n d a rd va lu e : 4.5-5.5 V
NO P roce e d to 4
YES
18-601
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Te m p e ra tu re (°C{°F}) Re s is ta n c e
Temperatur e (C)
YES
18-602
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
Fa ulty ha rne s s
18-603
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The re is no re ma ining qua ntity in the AdBlue /DEF ta nk.
Output limit e tc. None
S ugge s te d fa ult ca us e The re ma ining qua ntity in the AdBlue /DEF ta nk is ins ufficie nt
DTC de te ction condition The re ma ining qua ntity in the AdBlue /DEF ta nk ha s be e n de te cte d a s 0
NO Go to s te p 2.
Leve l 10 (Gre e n)
YES
NO Go to s te p 3.
YES
18-604
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Go to s tep 4.
YES
YES
YES
18-605
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
YES
18-606
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Improper reductant
18
Clus te r ga uge (S e cond)
S ugge s te d fa ult ca us e A me dium othe r tha n AdBlue /DEF ha s be e n s upplie d to the AdBlue /DEF ta nk
DTC de te ction condition De te ction of a drop in the AdBlue /DEF conce ntra tion
De te ction tha t the AdBlue /DEF conce ntra tion is a t the norma l leve l
Re s e t condition
(De te ction of the conce ntra tion may ta ke s eve ra l minute s )
NOTICE • Th e re a re th re e in s p e c tio n m e th o d s fo r th e
Ad Blu e /DEF: Ad Blu e /DEF a n a lyze r
in s p e c tio n , p H litmu s p a p e r in s p e c tio n , a n d
re fra c tive in d ex m e a s u rin g in s p ec tio n .
S ta n d a rd va lu e
Co n c e n tra tio n : 32.5±2.5%
Co lo r: Co lo rle s s, cle a r
YES
Go to s te p 3.
18-607
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Go to s te p 3.
YES
2. Re move the AdBlue /DEF qua lity s e ns or from the AdBlue /DEF
ta nk.
3. Dis cha rge the AdBlue /DEF from the AdBlue /DEF ta nk a nd
che ck the ins ide of the ta nk for fore ign ma tte r.
S ta n d a rd : No p ro b le m s
! CAUTION • Wa s h th e in s id e o f th e Ad Blu e /
DEF ta n k with d is tille d wa te r o r
with d ilu te d Ad Blu e /DEF.
YES
S ta n d a rd : No p ro b le m s
AdBlue/DEF quality
sen s or meas uring pa rt NO Cle a n the me a s uring pa rt of the AdBlue /DEF qua lity
s e ns or, a nd the n go to s te p 5.
! CAUTION • If th e m e a s u rin g p a rt is
c o n ta m in a te d with o il o r g re a s e ,
wa s h it with a n a lc o h o l-b a s e d
wa s h in g flu id .
YES
18-608
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Ins ta ll the AdBlue /DEF qua lity s e ns or provis iona lly in the
AdBlue /DEF ta nk, the n mount it on the ma chine. (Mount it in
s uch a way tha t the conne ctor of the AdBlue /DEF qua lity
s e ns or ca n be conne cte d.)
2. Fill AdBlue /DEF with the s pe cifie d conce ntra tion into the ta nk.
YES
18-609
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
DC motor for intake throttle valve - circuit [Open circuit (circuit low)]
DC motor for intake throttle valve - circuit [Short circuit (circuit high)]
P 2100 P 2103
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
NO Fa ult in ha rne s s
YES
18-610
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Dis conne ct the inta ke throttle from the inte rcoole r s o tha t the
inta ke throttle va lve will be vis ible.
2. Che ck the inta ke throttle va lve for dra gge d fore ign ma tte rs.
NO P roce e d to 3
YES
YES
Fa ult in ha rne s s
Fa ult in e ngine ECU
18-611
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (S e cond)
• Motor fa ilure
S ugge s te d fa ult ca us e
• Engine ECU fa ult
2. Che ck the inta ke throttle va lve for dra gge d fore ign ma tte rs .
NO P rocee d to 2
YES
18-612
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
YES
Fa ult in ha rne s s
Fa ult in e ngine ECU
18-613
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (S e cond)
• S e ns or fa ilure
S ugge s te d fa ult ca us e
• Engine ECU fa ult
P 2126
Acce le ra tor s e ns or 2 ca nnot be re cognize d corre ctly.
Fa ult s ymptom
P le a s e che ck the s e ns or volta ge.
Clus te r ga ug e (S e cond)
• S e ns or fa ilure
S ugge s te d fa ult ca us e
• Engine ECU fa ult
18-614
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. S e t the clus te r mode to "H" a nd s e le ct the "Lo idle " pos ition.
Acc ele ra to r s en so r 1 Ac c el er at o r s en so r 2
S ta n d a rd va lu e (P 2121 a n d P 2126)
En g in e
Vo ltag e
Me a s u rin g ite m revo lu tio n
(V)
(r/m in )
Lo w id le 1,000 Ap p rox. 1.3
Hig h id le 2,000 Ap p rox. 3.9
NO P roce e d to 2
YES
18-615
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Dis conne ct the 28P IN conne ctor of the me cha tronic controlle r.
S ta n d a rd va lu e (P 2121 a n d P 2126)
En g in e
Vo lta g e
Me a s u rin g ite m revo lu tio n
(V)
(r/m in )
Lo w id le 1,000 Ap p rox. 1.3
Hig h id le 2,000 Ap p rox. 3.9
YES
18-616
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 2122 P 2123
S ta n d a rd va lu e
En g in e
Vo ltag e
Me a s u rin g ite m revo lu tio n
(V)
(r/m in )
Lo w id le 1,000 Ap p rox. 1.3
Hig h id le 2,000 Ap p rox. 3.9
YES
Ha rne s s fa ilure
18-617
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Ab n o rm al va lu e
: 0.3 V o r le s s
: 4.8 V o r m o re
YES
18-618
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 2127 P 2128
S ta n d a rd va lu e
En g in e
Vo ltag e
Me a s u rin g ite m revo lu tio n
(V)
(r/m in )
Lo w id le 1,000 Ap p rox. 1.3
Hig h id le 2,000 Ap p rox. 3.9
YES
Ha rne s s fa ilure
18-619
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Ab n o rm al va lu e
: 0.3 V o r le s s
: 4.8 V o r m o re
YES
18-620
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 2228 P 2229
Fa ult s ymptom The a tmos phe ric pre s s ure s e ns or (in the e ngine ECU) is not ope ra ting corre ctly.
• Te mpora ry e rrone ous ope ra tion be ca us e of ra dio inte rfe re nce e tc.
S ugge s te d fa ult ca us e
• Eng ine ECU fa ult
3. Afte r e ra s ing the DTC, che ck tha t the s a me code is dis playe d
a ga in.
YES
Norma l
(Te mpora ry ma lfunction be ca us e of ra dio inte rfe re nce nois e )
18-621
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom Abnorma l drop of the diffe re ntia l pre s s ure of the DP R ha s be e n de te cte d.
• Ma lfunction in the DP R.
S ugge s te d fa ult ca us e • Fa ilure of the diffe re ntia l pre s s ure s e ns or
• Da ma ge d piping
Selec t
Engine
YES
18-622
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the diffe re ntia l pre s s ure pipe a nd hos e for clogging.
S ta n d a rd : Th e a b s e n c e o f clo g g in g
YES
18
3 Ins pe ction of the DP R diffe re ntia l pre s s ure s e ns or
Me a s u re m e n t ite m S ta n d a rd va lu e (kΩ )
A↔ B 2 to 15
C
B↔ C 2 to 15
B
Diffe re ntia l pre s s ure s e ns or A
NO Re pla ce the DP R diffe re ntia l pre s s ure s e ns or a nd
proce e d to the s te p 10.
YES
YES
5 Ins pe ction of the DOC downs tre a m te mpe ra ture s e ns or conne ctor
1. Che ck the conne ction of the DOC downs tre a m te mpe ra ture
s e ns or conne ctor.
S ta n d a rd : Th e a b s e n c e o f p o o r c o n ta c t.
NO Conne ct s e cure ly or re pa ir if ne e de d.
Afte r tha t, proce e d to the s te p 6.
YES
18-623
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
6 Ins pe ction of the outs ide of the DOC downs tre a m te mpe ra ture s e ns or
1. Che ck the ins ta lla tion of the DOC downs tre a m te mpe ra ture
s e ns or.
YES
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
20 °C {68°F}
DOC
13.7 – 29.8 Ω
d o wn s tre a m
S ta rte r s witc h : 50 °C {122 °F}
te m p e ra tu re
OFF 7.13 – 13.7 kΩ
s ens or
80 °C {176 °F}
TEX1 – GND1
4.13 – 7.13 kΩ
YES
18-624
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES 18
Che ck the inje ction qua ntity a nd the rota tiona l fluctua tion.
1. S ta rt the e ngine .
! CAUTION • In s p e c t a fte r e n g in e wa rm -u p .
S ta n d a rd va lu e
En g in e s p e e d In je c tio n q u a n tity
(r/m in ) (q )
800 10 to 30
YES
18-625
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NOTICE • Yo u d o n o t h a ve to im p le m e n t
th e d iffe re n tia l p re s s u re ch e ck
a fte r p e rfo rm in g m a n u a l fo rc e d
re g e n e ra tio n .
YES
11 DP R force d re ge ne ra tion
NOTICE • If th e s ys te m d o e s n o t e n te r th e re g e n e ra tio n
m o d e , c h e ck wh e th e r th e n e u tra l s witc h o r
e m e rg e n cy a c c e le ra to r c irc u its fu n c tio n
c o rre c tly, o r wh e th e r th e lo ck leve r is in th e
c o rre c t p o s itio n .
S ta n d a rd : th e va lu e o f DP R exh a u s t te m p e ra tu re (IN)
h a s ris e n 450°C {842°F} o r h ig h e r.
YES
18-626
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e
En g in e s p e e d Diffe re n tia l p re s s u re
(r/m in ) (kPa )
2000 Be low 10
18
NO Re pla ce the DP R filte r a nd pe rform ma nua l force d
re ge ne ra tion.
NOTICE • Yo u d o n o t h ave to im p le m e n t
th e d iffe re n tia l p re s s u re c h e ck
a fte r p e rfo rm in g m a n u a l fo rc e d
re g e n e ra tio n .
YES
Selec t
Engine
YES
18-627
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom Abnorma l ris e of the diffe re ntia l pre s s ure of the DP R ha s be e n de te cte d.
• DP R s oot clogging.
• Abnorma l bla ck s moke from the e ngine
S ugge s te d fa ult ca us e
• Fa ilure of the diffe re ntia l pre s s ure s e ns or
• Clogge d or da ma ge d piping
Selec t
Engine
YES
18-628
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO P roce e d to the s te p 8.
YES
18
3 Ins pe ction of the DP R diffe re ntia l pre s s ure pipe a nd hos e
YES
Me a s u re m e n t ite m S ta n d a rd va lu e (kΩ )
A↔ B 2 to 15
C
B↔ C 2 to 15
B
Diffe re ntia l pre s s ure s e ns or A
NO Re pla ce the DP R diffe re ntia l pre s s ure s e ns or,
proce e d to the s te p 5.
YES
YES
18-629
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Che ck the inje ction qua ntity a nd the rota tiona l fluctua tion.
1. S ta rt the e ngine.
! CAUTION • In s p e c t a fte r e n g in e wa rm -u p .
S ta n d a rd va lu e
En g in e s p e e d In je c tio n q u a n tity
(r/m in ) (q )
800 10 to 30
YES
YES
YES
18-630
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
9 DP R force d re ge ne ra tion
NOTICE • If th e s ys te m d o e s n o t e n te r th e re g e n e ra tio n
m o d e , c h e ck wh e th e r th e n e u tra l s witch o r
e m e rg e n c y a c c e le ra to r c irc u its fu n c tio n
c o rre c tly, o r wh e th e r th e lo ck leve r is in th e 18
c o rre c t p o s itio n .
S ta n d a rd : th e va lu e o f DP R exh a u s t te m p e ra tu re (IN)
h a s ris e n 450°C {842°F} o r h ig h e r.
YES
Selec t
Engine
YES
18-631
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 2458 P 2 4 A2
1. Che ck the conne ction of the DOC downs tre a m te mpe ra ture
s e ns or conne ctor.
S ta n d a rd : Th e a b s e n c e o f p o o r c o n ta c t.
NO Conne ct s e cure ly or re pa ir if ne e de d.
Afte r tha t, proce e d to the s te p 2.
YES
18-632
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2 Ins pe ction of the outs ide of the DOC downs tre a m te mpe ra ture s e ns or
1. Che ck the ins ta lla tion of the DOC downs tre a m te mpe ra ture
s e ns or.
YES
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
20 °C {68°F}
DOC
13.7 – 29.8 Ω
d own s tre a m
S ta rte r s witch : 50 °C {122 °F}
te m p e ra tu re
OFF 7.13 – 13.7 kΩ
s ens or
80 °C {176 °F}
TEX1 – GND1
4.13 – 7.13 kΩ
YES
18-633
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
Che ck the inje ction qua ntity a nd the rota tiona l fluctua tion.
1. S ta rt the e ngine.
! CAUTION • In s p e c t a fte r e n g in e wa rm -u p .
S ta n d a rd va lu e
En g in e s p e e d In je c tio n q u a n tity
(r/m in ) (q )
800 10 to 30
YES
18-634
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NOTICE • Yo u d o n o t h ave to im p le m e n t
th e d iffe re n tia l p re s s u re c h e ck 18
a fte r p e rfo rm in g m a n u a l fo rc e d
re g e n e ra tio n .
YES
8 DP R force d re ge ne ra tion
NOTICE • If th e s ys te m d o e s n o t e n te r th e re g e n e ra tio n
m o d e , ch e ck wh e th e r th e n e u tra l s witch o r
e m e rg e n c y a c c e le ra to r c irc u its fu n c tio n s
c o rre c tly, o r wh e th e r th e lo ck leve r is in th e
c o rre c t p o s itio n .
S ta n d a rd : th e va lu e o f DP R e xh a u s t te m p e ra tu re (IN)
h a s ris e n 450°C {842°F} o r h ig h e r.
NOTICE • Yo u d o n o t h ave to im p le m e n t
th e d iffe re n tia l p re s s u re c h e ck
a fte r p e rfo rm in g m a n u a l fo rc e d
re g e n e ra tio n .
YES
18-635
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e
En g in e s p e e d Diffe re n tia l p re s s u re
(r/m in ) (kPa )
2000 Be lo w 10
NOTICE • Yo u d o n o t h a ve to im p le m e n t
th e d iffe re n tia l p re s s u re ch e ck
a fte r p e rfo rm in g m a n u a l fo rc e d
re g e n e ra tio n .
YES
YES
18-636
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
DPR clogged
18
Clus te r ga uge (S e cond)
YES
18-637
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NOTICE • Yo u d o n o t h a ve to im p le m e n t
th e d iffe re n tia l p re s s u re ch e ck
a fte r p e rfo rm in g m a n u a l fo rc e d
re g e n e ra tio n .
YES
3 DP R force d re ge ne ra tion
NOTICE • If th e s ys te m d o e s n o t e n te r th e re g e n e ra tio n
m o d e , c h e ck wh e th e r th e n e u tra l s witc h o r
e m e rg e n cy a c c e le ra to r c irc u its fu n c tio n s
c o rre c tly, o r wh e th e r th e lo ck leve r is in th e
c o rre c t p o s itio n .
S ta n d a rd : th e va lu e o f DP R exh a u s t te m p e ra tu re (IN)
h a s ris e n 450°C {842°F} o r h ig h e r.
YES
18-638
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e
En g in e s p e e d Diffe re n tia l p re s s u re
(r/m in ) (kPa)
2000 Be low 10
18
NO Re pla ce the DP R filte r a nd pe rform ma nua l force d
re ge ne ra tion.
NOTICE • Yo u d o n o t h ave to im p le m e n t
th e d iffe re n tia l p re s s u re c h e ck
a fte r p e rfo rm in g m a n u a l fo rc e d
re g e n e ra tio n .
YES
Selec t
Engine
YES
18-639
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Engine ECU CAN communication bus for Emission control system - bus off
Fa ult s ymptom Abnorma l e ngine CAN communica tion (bus off) ha s be e n de te cte d.
NO Re pa ir the trouble
YES
YES
18-640
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
18
Clus te r ga ug e (S e cond)
CANL CANH
K29 K28
GND S IG VCC
KSL KS K KS J
YES
18-641
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Go to s tep 3.
YES
3 Che ck ha rne s s in CAN H-line be twe e n e ngine joint conne ctor a nd DCU
e ngine joint conne ctor K28 te rmina l a nd the DCU ma chine -s ide
conne ctor (53P ) CAH0 te rmina l.
CAH1
LF5
CAL1
S ta n d a rd va lu e : 1 Ω o r le s s
LF6
TE1 B
CAH0
LF2
TE1A CAH0
LF1 LEY
TE2 B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
YES
18-642
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
4 Che ck ha rne s s in CAN L-line be twe e n e ngine joint conne ctor a nd DCU
CAH1
LF5
18
CAL1
LF6
TE1B
LF2
TE1A CAH0
CAL0
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
YES
18-643
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Conne ct the e ngine joint conn e ctor a nd DCU (53P ) con ne ctor.
+B2
LEP
GND4
LEW
GND1
LET
3. Conne ct the s igna l che ck ha rne s s, a nd us e the e le ctrica l te s te r
+B3
LEQ
GND5
LEX
GND2
LEU
to me a s ure the volta ge be twe e n the te rmina ls of the DCU.
+B4
LER
+B1
LEN
GND3
LEV
S ta n d a rd va lu e : 19 – 32 V
CAL1
LF6
TE1B
LF2
TE1A CAH0
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
YES
YES
18-644
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom CAN commun ica tion with the S CR ups tre a m NOx s e ns or ha s be en s us pe nd e d.
Clus te r ga ug e (Firs t)
18
Clus te r ga ug e (S e cond)
3. Dis conne ct the NOx s e ns or conne ctor a nd che ck the conne ctor
pins for da ma ge a nd rus t.
S ta n d a rd :
Co n n e c to r d is c o n n e c te d o r lo o s e .
Co n n e c to r p in s d a m ag e d o r ru s te d .
NO Go to s te p 2.
18-645
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
4. Mea s ure the volta ge b e twe e n GND LGU (cha s s is s ide of the
NOx s e ns or conne ctor) a nd the minus te rmina l of the ba tte ry
Ba tte ry with a circuit te s te r.
S ta n d a rd va lu e : Be lo w 1V
YES
18-646
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
GND CANH CANL GND VCC 2. Dis conne ct NOx s e ns or conne ctor.
LGU LE9 LE8 LE7 LE6
CAL1
TE1 B
LF6
NO Re pa ir or re pla ce of the CAN ha rne s s be twe e n DCU
LF2
TE1 A
LF1
CAH0
LEY a nd NOx controlle r.
TE2 B CAL0
LF4 LEZ
TE2 A
LF3
IS GW
LES
YES
18-647
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
GND CANH CANL GND VCC 2. Dis conne ct NOx s e ns or conne ctor.
LGU LE9 LE8 LE7 LE6
CAL1
LF6
TE1 B
LF2
NO Re pa ir or re pla ce of the CAN ha rne s s be twe en DCU
TE1A
LF1
CAH0
LEY a nd NOx controlle r.
TE2 B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
YES
18-648
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
7 DTC che ck whe n the S CR ups tre a m NOx s e ns or a nd the S CR downs tre a m NOx s e ns or have be e n
switche d
6. S e le ct "DCU".
NO Re pla ce t he DCU.
YES
18-649
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom CAN communica tion with the S CR downs tre a m NOx s e ns or ha s be e n s us pe nde d.
3. Dis conne ct the NOx s e ns or conne ctor a nd che ck the conne ctor
pins for da ma ge a nd rus t.
S ta n d a rd :
Co n n e c to r d is c o n n e c te d o r lo o s e .
Co n n e c to r p in s d a m a g e d o r ru s te d .
NO Go to s tep 2.
18-650
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
YES
18-651
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
CAL1
LF6
TE1 B
LF2
NO Re pa ir or re pla ce of the CAN ha rne s s be twe en DCU
TE1 A
LF1
CAH0
LEY a nd NOx controlle r.
TE2 B CAL0
LF4 LEZ
TE2 A
LF3
IS GW
LES
YES
CAL1
LF6
TE1 B
LF2
NO Re pa ir or re pla ce the CAN ha rne s s be twe e n DCU
TE1 A
LF1
CAH0
LEY a nd NOx controlle r.
TE2 B CAL0
LF4 LEZ
TE2 A
LF3
IS GW
LES
YES
18-652
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
6 DTC che ck whe n the S CR ups tre a m NOx s e ns or a nd the S CR downs tre a m NOx s e ns or have be e n
switche d
6. S e le ct "DCU".
NO Re pla ce t he DCU.
Counte r
Fron t we ight
(Re a r)
YES
18-653
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom CAN communica tion with the AdBlue /DEF qua lity s e ns or ha s be e n s us pe nde d.
Output limit et c. None
1. Che ck the conne ction of the DCU conne ctor a nd AdBlue /DEF
s e ns or conne ctor (Loos e ne s s a nd poor conta ct).
DCU c on ne ctor
18-654
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
Ad Blu e /DEF
s ens or
GND S ta rte r s witc h :
m a c h in e -si d e 19 – 32 V
ON
c o n n e c to r
VCC – GND
YES
18-655
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
4 Ins pe ct for dis conne ction in CAN H-line be twe e n the DCU a nd AdBlue /DEF s e ns or
CAL1
TE1B
LF6
NO Dis con ne ction or fa ulty con tinuity in CAN H-line
LF2
TE1A
LF1
CAH0
LEY be twe e n the DCU an d AdBlue /DEF s en s or. Re pa ir
TE2B CAL0
LF4
TE2A
LEZ
or re pla ce the ha rne s s.
LF3
IS GW
LES
YES
5 Che ck for dis conne ction in CAN L-line be twe e n the DCU a nd AdBlue /DEF s e ns or
CAL1
CAL0
LF6
TE1B
LF2
TE1A CAH0
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
YES
18-656
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
GND Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
Ad Blu e /DEF
s ens or
S ta rte r s witc h : m a c h in e -si d e
1Ω o r le ss
CAN CAN VB OFF c o n n e c to r –
Hi Lo Gro u n d
GND – Gro u n d
YES
YES
18-657
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom Abn orma l comm un ica tion w ith the AdBlue /DEF S CR s ys te m ha s bee n de te cted .
Output limit e tc. None
YES
Rep la ce the D CU
18-658
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Engine ECU CAN communication bus for Vehicle control - bus off
Fa ult s ymptom Abnorma l e ngine /dia gnos e CAN communica tion (bus off) ha s occurre d.
Clus te r ga ug e (Firs t)
18
Clus te r ga ug e (S e cond)
YES
18-659
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom CAN communica tion with the me cha tronic controlle r ha s be e n s us pe nde d.
1 Ins pe ction of the fus e powe r s upply circuit of the unit s ide controlle r
YES
Sens or Ca s e
EGR a c tu a to r U1122
VNT a c tu a to r U1123
Ma n u a l re g e n e ra tio n
DP R re g e n e ra tio n s witc h
fa ilu re o f DP R
YES
18-660
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom CAN communica tion with the EGR va lve a ctua tor ha s be e n s us pe nde d.
Clus te r ga ug e (Firs t)
18
Clus te r ga ug e (S e cond)
YES
Sens or Ca s e
EGR a c tu a to r U1122
VNT a c tu a to r U1123
Ma n u a l re g e n e ra tio n
DP R re g e n e ra tio n s witch
fa ilu re o f DP R
YES
18-661
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 16 to 32 V
NO Fa ult in ha rne s s
YES
18-662
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom CAN communica tion with the VNT controlle r ha s be e n s us pe nde d.
Clus te r ga ug e (Firs t)
18
Clus te r ga ug e (S e cond)
YES
Sens or Ca s e
EGR a c tu a to r U1122
VNT a c tu a to r U1123
Ma n u a l re g e n e ra tio n
DP R re g e n e ra tio n s witc h
fa ilu re o f DP R
YES
18-663
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 19 V o r m o re
NO Fa ult in ha rne s s
YES
Te rm in al s to m e a s u re th e re s is ta n c e
VNT c o n tro lle r s id e S ig n a l c h e ck h a rn e s s s id e
VNTH CA3H
VNTL CA3L
S ta n d a rd va lu e : 2 Ω o r le s s
NO Fa ult in ha rne s s
YES
18-664
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Engagement side
Male connector Female connector Connector terminals numbers
When a pair of connectors is seen from the engagement side,
the terminal numbers of both connectors are symmetrical (left
and right reversed).
In this manual, the male connector has the terminal No. 1 at
the right top and the female connector has the terminal No. 1
at the left top.
18-665
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
When the connector is small and measuring with a normal test probe is difficult, use a paper clip, a safety pin, a thin
wire, etc. to create a check pin.
Chec k Engine La mp
Cons truction machine
DPR Switch
ECU
Information(CAN)
ECU
DCU
Air Flow AdBlue/DEF
Sens or Pump
NH3 AdBlue/
slip DEF
SCR ca talyst injector
AdBlue/DEF
: Exhaust G a s Temp. Sensor
Tank with
: NOx Sensor Temp. sensor
Quality se nsor
18-666
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Post-processing system 18
CAN line
2 15
Engine ECU
ENGINE 12 14 1
5 6
16
13 8 7
3 4 11
10
CAN line
15
9
1. Conformity table
1 DCU DCU
2 Muffler unit SCR unit
3 DOC DOC
4 DPR DPF
5 SCR SCR catalyst
18-667
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
D D
B
A
G
J
E
F H
I C
8
7
1. Conformity table
18-668
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
DCU
53-pin connector
Machine harness
View in
arrow direction
18
86-pin connector
Machine harness
View in
arrow direction
18-669
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-670
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18.17.2.5 Pre-inspection
• Applicable machine: YQ15–20001~YQ15–20241/LL16–10001~LL16–10145
1. Confirmation of the display contents of indicator lamps and the multi-information display
1) If warnings are shown by indicator lamps and the multi-information display, perform the following inspections
because there are abnormalities in the system.
If the lamp does not go out or flashes after engine start, inspect as described below because there is an
abnormality in the system. 18
2. Warning indication and status when lit
1) AdBlue/DEF quality warning and output limitation
Stage 1
(at the time of Displayed when AdBlue/DEF with insufficient quality is
abnormality detected; the buzzer sounds intermittently.
detection)
18-671
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-672
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
When other faults also occur at the same time, they may not be shown in the multi-information display. Even when
not displayed in the multi-information display, inspection is required when an indicator lamp lights.
18.17.2.6 Pre-inspection
• Applicable machine: YQ15–20242~/LL16–10146~
This function is not provided in some specifications.
1. Confirmation of the display contents of indicator lamps and the multi-information display
18
1) If warnings are shown by indicator lamps and the multi-information display, perform the following inspections
because there are abnormalities in the system.
If the lamp does not go out or flashes after engine start, inspect as described below because there is an
abnormality in the system.
Stage 1
(at the time of Displayed with the warning sound when the DEF/AdBlue
abnormality sensor determines the quality problem of DEF/AdBlue.
detection)
Stage 2
Displayed with the warning sound when a certain period
(1 hour after
of time has passed from Level 1. The engine output is
abnormality
gradually restricted.
detection)
Stage 3
(3.5 hours after
abnormality Displayed with the continuous warning sound when a
detection) certain period of time has passed from Level 2. The
(4 hours after engine output is further restricted than Level 2.
abnormality
detection)
18-673
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
When other faults also occur at the same time, they may not be shown in the multi-information display. Even when
not displayed in the multi-information display, inspection is required when an indicator lamp lights.
18-674
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18.17.2.7 Inspection
Pre-inspection
1. If an error occurs on the system, The DTC code is indicated in the console panel.
2. Reading of failure code
1) Connection of Hino-DX
1) Remove the maintenance cover on the
Maintenance cover
rear cover behind the operator seat by
pushing down the tab at the top (at one
location).
18
2) Connect the engine failure diagnosis connector to the personal computer which installed Hino-DX
through the interface box.
3) Set the starter key to "ON" and start Hino- Failure diagnosis connector
DX.
Special tool : 09993-E9070 Hino-Bowie
(Interface box)
09042-1220 Connecting cable
95171-010** DENSO DST-i set
Hino-Bowie
CD-ROM Hino-DX or DST-i
Connecting cable
Connect to the failure diagnosis
connector at the machine side.
18-675
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Part name Part No. External shape General description and function
Hino Diagnostic
eXplorer — Install the software included in the
(Hino-DX) Hino Diagnostic eXplorer (Hino-DX)
into the computer. For the installation
method, refer to the instruction manual
included with the CD.
• Computer interface
09993-E9070
Hino-Bowie
*1 • The cable between the personal
computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or USB.
Cable bundled
to the Hino-Bowie
18-676
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Part name Part No. External shape General description and function
Interrupting installation between unit side harness and DCU allows inspection
Signal check harness 09843-E9030
with a tester rod while the power is supplied.
18
09843-E9030
*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the user’s manual in the
HinoDX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HinoDX CD-ROM. For details, refer to
the user’s manual in the HinoDX CD-ROM.
*2: HinoDX (Ver. 3.0.5 or later), only when use DST-i.
OK: Available
—: Disabled
Tier3 Tier4 Interim Tier4 Final
OS Software ver. Interface Reprog Reprog Reprog
Hino-DX Hino-DX Hino-DX
manager manager manager
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
7
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i — — — — — —
1.0.9 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN OK OK OK OK OK OK
Bowie w/o CAN OK OK — — — —
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
XP
DST-i OK OK OK OK — —
3.04/3.05 Bowie w/ CAN OK OK OK OK — —
Bowie w/o CAN OK OK — — — —
DST-i OK OK — — — —
1.0.9 Bowie w/ CAN OK OK — — — —
Bowie w/o CAN OK OK — — — —
18-677
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
When the DCU registers a below-zero temperature for the AdBlue/DEF, this function does not operate. Due to the
possibility that the pipe may freeze, the guide value for a freezing condition has been set higher than the actual
AdBlue/DEF freezing temperature (-11°C {12°F}).
3. Work procedure
Perform the test with the engine stopped.
1) Turn the starter key to ON and connect the Hino-DX to the DCU. Select [Aqueous urea solution addition
test] from [Check functions].
2) Select [Leak test].
Leak test
3) After the AdBlue/DEF pressure has increased, make sure that there is an indication of 850 kPa {8.66 kgf/
cm2, 123.7 lbf/in2} to 950 kPa {9.68 kgf/cm2, 138.2 lbf/in2} after the AdBlue/DEF pressure has stabilized.
Please perform an inspection according to the diagnosis procedure of P20E8 and P20E9 if there is no pressure.
18-678
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
Directly after the pressure increase,
the pressure changes once to
950 [kPa] or higher.
Time [sec]
4) Press the button [Close]. The pressure drops and the reverting valve operates.
Close
5) The inspection is completed when it has been confirmed that no DTC codes are generated after updating
the fault information.
If DTC codes are generated, inspect according to the respective diagnosis procedure.
18-679
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Always perform the addition test after removing the AdBlue/DEF injector.
When the test is performed with the AdBlue/DEF injector installed on the muffler, AdBlue/DEF accumulates in the
muffler, which leads to a deterioration of the AdBlue/DEF SCR.
When the DCU registers a below-zero temperature for the AdBlue/DEF, this function does not operate. Due to the
possibility that the pipe may freeze, the guide value for a freezing condition has been set higher than the actual
AdBlue/DEF freezing temperature (-11°C {12°F}).
3. Work procedure
• Perform the test with the engine stopped.
• The test pattern shows three different quantities for adding, but the operation procedure is the same.
– Pattern 1 Addition quantity: 30 cc
– Pattern 2 Addition quantity: 50 cc
– Pattern 3 Addition quantity: 150 cc
1) Turn the starter key to ON and connect the Hino-DX to [DCU].
Select [Aqueous urea solution addition test] from [Function confirmation].
2) Set up the injector and the measuring vessel, and select the test pattern on the Hino-DX screen.
18-680
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
Test pattern
3) The quantity corresponding to the selected pattern is injected from the injector.
After completion of injection, measure the AdBlue/DEF quantity in the measuring vessel.
Standard value
1 25 to 30
2 42 to 50
3 128 to 150
18-681
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
4) Press the button [Close]. The pressure drops and the reverting valve operates.
Close
18-682
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
• When the DCU has indicated a DTC code other than P203F, P207F, or P20EE, a DCU data selection
abnormality (DTC code P204F) has occurred in the engine ECU.
• Delete the DTC code history in the DCU after fault diagnosis and repair have been performed.
P2044 AdBlue/DEF tank temperature sensor - out of range (Out of range low)
P2045 AdBlue/DEF tank temperature sensor - out of range (Out of range high)
18-683
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P2203 SCR upstream NOx sensor and Heater - Circuit (Circuit short)
P2482 SCR upstream temperature sensor - out of range (Out of range high)
18-684
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
YES
1. Che ck the conne ction of the exte rna l re s is tor conne ctor
(Loos e ne s s a nd poor conta ct).
YES
1. Che ck the conne ction of the DCU 86P conn e ctor (Loos e ne s s
a nd poor conta ct).
YES
18-685
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the ins ta lla tion of the a mbie nt a ir te mpe ra ture s e ns or.
YES
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
YES
18-686
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
S ta rte r s witc h :
Exte rn a l 18
re s is to r 2,0 00±100Ω
OFF
ER+ – ER-
YES
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
Am b ie n t a ir
te m p e ra tu re
S ta rte r s witc h : s ens or
4.5 – 5.5 V
ON m a c h in e -si d e
c o n n e c to r
HH1+ – HH1-
NO Go to s te p 8.
YES
Go to s tep 10.
18-687
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
ATS- ATS S
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
DCU 86P
m a ch in e -s id e
S ta rte r s witch :
c o n n e c to r ∞ Ω
OFF
ATS S – Gro u n d
ATS - – Gro u n d
YES
18-688
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
9 Ins pe ct for dis conne ctions of the a mbie nt a ir te mpe ra ture s e ns or ha rne s s
ATS- ATS S
18
(A) (B)
Am b ie n t a ir Am b ie n t a ir
Exte rn a l
te m p e ra tu re te m p e ra tu re
re s is ta n c e (Ω )
°C (°F) s e n s o r (Ω )
Re fe re n c e va lu e :
-10 (14)
9,280
YES
YES
18-689
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the ins ta lla tion of the e ngine coola nt te mpe ra ture
s e ns or.
YES
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
En g in e c o o la n t 20 °C {68 °F}:
S ta rte r s witch : te m p e ra tu re 2.59 – 2.32 kΩ
OFF s ens or 80 °C {176 °F}:
WTM+ – WTM- 0.326 – 0.310 kΩ
YES
YES
18-690
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the ins ta lla tion of the S CR ups tre a m te mpe ra ture
s e ns or.
YES
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
197.67 to 205.33 Ω
S CR u p s tre a m (0 °C {32 °F})
S ta rte r s witc h : te m p e ra tu re 216.77 to 224.37 Ω
OFF s ens or (25 °C {77 °F})
FAT+ – FAT- 235.73 to 243.25 Ω
(50 °C {12 2 °F})
YES
1. Che ck the conne ction of the AdBlue /DEF pump te mpe ra ture
s e ns or conne ctor (Loos e ne s s a nd poor conta ct).
YES
18-691
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-692
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 0072 P 0073
• De fe ctive ha rne s s
• De fe ctive ha rne s s
18
• Exte rna l re s is ta nce fa ilure
• De fe ctive conne ctor
S ugge s te d fa ult ca us e • De fe ctive conne ctor
• Fa ilure of the outs ide a ir te mpe ra ture
• Fa ilure of the outs ide a ir te mpe ra ture
s e ns or body
s e ns or body
S ta n d a rd va lu e
5,500 ± 275 Ω (0 °C {32 °F})
3,365 ± 168.25 Ω (10 °C {50 °F})
1,700 ± 85 Ω (25 °C {77 °F})
Re fe re n c e va lve
9,280 Ω (-10 °C {14 °F})
YES
18-693
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : S ta n d a rd va lu e : (A) + (B)
(A) (B)
Am b ie n t a ir Am b ie n t air
Exte rn a l
te m p e ra tu re te m p e ra tu re
re s is ta n c e (Ω )
°C (°F) s e n s o r (Ω )
Re fe re n c e va lu e :
-10 (14)
9,280
25 (77) 1,700 ± 85
YES
18-694
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Ba tte ry a bnorma l
YES
Te rm in a l 6
Te rm in a l 7
Ch a s s is GND
Te rm in a l 8
Te rm in a l 9
S tand a rd va lu e : 19 – 32 V
NO Ha rne s s a bnorma l
YES
18-695
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Te rm in a l 1
Te rm in a l 2
Te rm in a l 3 Ch a ss is GND
Te rm in a l 4
Te rm in a l 5
S ta n d a rd : Co n d u c tivity
YES
18-696
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ymptoms on the
Inje ction of AdBlue /DEF is s toppe d.
ma chine
S ugge s te d fa ult ca us e —
18-697
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-698
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
The te mpe ra ture diffe re nce be twe e n the 2 s e ns ors in the DCU is 15 °C {59 °F} or
DTC de te ction condition
more
1. Re pla ce the DCU. (Afte r re pla cem e nt, pe rform a "Le a k te s t".)
18-699
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
DTC de te ction condition The volta ge of the DCU te mpe ra ture s e ns or is 0.85 V or lowe r.
1 DCU re pla ce me nt
18-700
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1 DCU re pla ce me nt
18
1. Re pla ce the DCU. (Afte r re pla cem e nt, pe rform a "Le a k te s t".)
18-701
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S witching off of the ma in re lay ha s be e n de te cte d be fore a fte r-run exe cution (a fte r
DTC de te ction condition
s ta rte r switch OFF)
18-702
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-703
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd : Co n d u c tivity
YES
YES
As the DCU be fore the re pla ce me nt wa s ab norma l, ins ta ll the new DCU (Afte r rep la cem e nt, pe rform a "Lea k te s t".)
NO DCU re pla ce me nt
(Afte r re pla ce me nt, pe rform a "Le a k te s t".)
YES
Norma l
18-704
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom Fa ilure of the AdBlue /DEF pump te mpe ra ture s e ns or ha s be e n de te cte d
S ugge s te d fa ult ca us e Fa ilure of the AdBlue /DEF pump te mpe ra ture s e ns or ha s be e n de te cte d
• Te mpe ra ture ris e a t the time of cut-off va lve re le a s e (thawing) be low the thre s hold
va lue
DTC de te ction condition
• At the time of a cold s ta rt, the re is a la rge diffe re nce be twe e n the outs ide a ir
te mpe ra ture s e ns or a nd the ins ide a ir. 18
Re s e t condition The a bove de te ction conditions have be e n cle a re d
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the a mbie nt a ir te mpe ra ture s e ns or.
S ta n d a rd va lu e
5,500 ± 275 Ω (0 °C {32 °F})
3,365 ± 168.25 Ω (10 °C {50 °F})
1,700 ± 85 Ω (25 °C {77 °F})
Re fe re n ce va lu e
9,280 Ω (-10 °C {14 °F})
YES
18-705
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : (A) + (B)
(A) (B)
Am b ie n t a ir Am b ie n t a ir
Exte rn a l
te m p e ra tu re te m p e ra tu re
re s is ta n c e (Ω )
°C (°F) s e n s o r (Ω )
Re fe re n c e va lu e :
-10 (14)
9,280
25 (77) 1,700 ± 85
YES
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the S CR ups tre a m te mpe ra ture s e ns or.
S ta n d a rd va lu e
197.67 to 205.33 Ω (0 °C {32 °F})
216.77 to 224.37 Ω (25 °C {77 °F})
235.73 to 243.25 Ω (50 °C {122 °F})
YES
18-706
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the e ngine coola nt te mpe ra ture s e ns or.
S ta n d a rd va lu e (m e a s u re o n e o f th e fo llo win g p o in ts )
: 2.45 kΩ (wa te r te m p er a tu re 20 °C {68 °F}) 18
: 1.15 kΩ (wa te r te m p er a tu re 40 °C {104 °F})
: 584 Ω (wa te r te m p e ra tu re 60 °C {140 °F})
: 318 Ω (wa te r te m p e ra tu re 80 °C {176 °F})
YES
2. Turn the s ta rte r key from "OFF" dire ctly to e ngine s ta rt.
3. Imme dia te ly a fte r s ta rting the e ngine, confirm by touch tha t the
pre s s ure in the coola nt piping on the downst re a m s ide of the
cut-off va lve ris e s .
YES
18-707
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. Dis conne ct the joints on both e nds of the coola nt piping, blow
in a ir from one s ide a nd confirm tha t it come s out a t the othe r
s ide.
YES
18-708
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
DTC de te ction condition Eve n whe n the inje ctor is ope ne d, the pre s s ure doe s not drop to 750 kPa or lowe r
18
The a bove conditions a re re s e t us ing one cycle of e ngine ON → OFF, a nd if the
Re s e t condition
a bove conditions pe rs is t, they ca n be re s e t with the next e ngine ON cycle
1. Ins pe ct the AdBlue /DEF piping (be twe e n pump a nd inje ctor) for
bre a ka ge, be nding, a nd colla ps e d s e ctions.
2. Dis conne ct the joints on both e nds of the AdBlue /DEF piping
(be twe e n pump a nd inje ctor), blow in a ir from one s ide a nd
confirm tha t it come s out a t the othe r s ide.
YES
18-709
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Go to s tep [3].
If AdBlue /DEF pre s s ure is a bnorma l, proce e d to
fa ilure dia gnos is me thod (P 20E8, P 20E9).
YES
Norma l (clogging from AdBlue /DEF crys ta lliza tion is a pos s ibility)
1. Re pla ce the AdBlue /DEF inje ctor with new one a nd che ck the
AdBlue /DEF a ddition qua ntity.
(1) With the inje ctor dis conne cte d from the muffle r, pe rform
the AdBlue /DEF a ddition te s t a ga in.
S ta n d a rd : Th e Ad Blu e /DEF a d d itio n q u a n tity is with in
th e lim its .
YES
18-710
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-711
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
• AdBlue /DEF ta nk te mpe ra ture s e ns or fa ilure
S ugge s te d fa ult ca us e • Ha rne s s fa ilure
• De fe ctive conne ctor
YES
18-712
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom The AdBlue /DEF inje ctor doe s not ope ra te
S ymptoms on the ma chine Inje ction of AdBlue /DEF is s toppe d.
S ugge s te d fa ult ca us e S ticking of the AdBlue /DEF inje ctor
DTC de te ction condition A condition with little cha nge of the drive curre nt continue d for 50 s e conds
Re s e t condition The drive curre nt cha nge is within the norma l ra nge 18
1 AdBlue /DEF a ddition qua ntity ins pe ction
YES
Norma l (Te mpora ry clogging from AdBlue /DEF crys ta lliza tion)
18-713
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 2048 P 2049
Fa ult s ymptom The AdBlue /DEF inje ctor doe s not ope ra te
S ymptoms on the ma chine Inje ction of AdBlue /DEF is s toppe d.
• De fe ctive ha rne s s
S ugge s te d fa ult ca us e • De fe ctive conne ctor
• Fa ilure of the AdBlue /DEF inje ctor
A volta ge of 0.2 V or lowe r during inje ctor A volta ge of 2 V or highe r during inje ctor
DTC de te ction condition
ope ra tion ope ra tion
The a bove conditions a re re s e t us ing one The a bove conditions a re re s e t us ing one
cycle of e ngine ON → OFF, a nd if the cycle of en gine ON → OFF, a nd if the
Re s e t condition
a bove conditions pe rs is t, they ca n be a bove conditions pe rs is t, they ca n be
re s e t with the next e ngine ON cycle. re s e t with the next e ngine ON cycle.
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the AdBlue /DEF inje ctor.
S ta n d a rd va lu e : 11.4 to 12.6 Ω
YES
18-714
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Ha rne s s a bnorma l
YES
18-715
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom De te ction of an a bnorma lity of the pre s s ure s e ns or in the AdBlue /DEF pump
• Inje ction of AdBlue /DEF is s toppe d.
S ymptoms on the ma chine
• The NOx purifica tion function ha s s toppe d a nd the exha us t ga s ha s de te riora te d
DTC de te ction condition Imme dia te ly a fte r key ON, the pre s s ure va lue is 50 kPa or highe r or -50 kPa or lowe r
1. S top the e ngine, wa it for s ome time, s e t the s ta rte r key to "ON",
a nd the n che ck for output of the DTC code P 204B a s a pa s t
fa ult.
(Monitor the pre s s ure with the H ino-DX a nd confirm tha t it is –
50 kPa {–0.5 kgf/cm 2 , –7.3 lbf/in 2 } to 50 kPa {0.5 kgf/cm 2 , 7.3
lbf/in 2 }.)
YES
Norma l (this wa s ca us e d by s e tting the s ta rte r ke y to "ON" be fore re turning to the e quiva le nt of a tmos phe ric
pre s s ure )
18-716
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 204C P 204D
Fa ult s ymptom De te ction of a n a bnorma lity of the pre s s ure s e ns or in the AdBlue /DEF pump
S ymptoms on the ma chine Inje ction of AdBlue /DEF is s toppe d. 18
• De fe ctive ha rne s s
S ugge s te d fa ult ca us e • De fe ctive conne ctor
• Fa ilure of the AdBlue /DEF pump pre s s ure s e ns or body
1 Ins pe ct the AdBlue /DEF pump conne ctor a nd DCU 86-P in conne ctor
2. Che ck the conne ction of the AdBlue /DEF pump conne ctor.
(Loos e ne s s a nd poor conta ct)
4. Wa s a ny fa ilure found?
NO Go to s te p 2.
YES
18-717
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
3
2. Me a s ure the conductivity be twe e n the following te rmina ls of
4 the DCU 86-pin conne ctor (on the ma chine ha rne s s s ide ) a nd
the AdBlue /DEF pump conne ctor (on the ma chine ha rne e s
s ide ).
S ta n d a rd : Co n d u c tivity
YES
Go to s te p 3.
3 Che ck for s hort-circuit in wire ha rne s s of AdBlue /DEF pump (pre s s ure s e ns or)
2. Me a s ure the re s is nta nce betw e e n the te rmina ls of the DCU 86-
pin ma chine s ice conne ctor.
Me as u re m e n t S ta n d a rd
Te s te r c o n n e c tio n s
c o n d itio n s va lu e
DCU 86-p in m a ch in e h a rn e s s
s id e c o n n e c to r
S ta rte r key:
19 te rm in a l – 18 te rm in al ∞ Ω
OFF
19 te rm in a l – 17 te rm in al
18 te rm in a l – 17 te rm in al
YES
Go to s te p 4.
18-718
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
4 Che ck the s hort-circuit in wire ha rne s s of AdBlue /DEF pump (pre s s ure s e ns or) 2
Me a s u re m e n t S ta n d a rd
Te s te r c o n n e c tio n s
c o n d itio n s va lu e 18
DCU 86-pi n m a c h in e h a rn e ss
s id e c o n n e c to r
S ta rte r ke y:
17 te rm in a l – Bo d y GND ∞ Ω
OFF
18 te rm in a l – Bo d y GND
19 te rm in a l – Bo d y GND
YES
Go to s te p 5.
4
4. Wa s a ny fa ilure found?
NO Go to s te p 6.
YES
Pe pla ce the AdBlue /DEF pump. (Afte r re pla ce me nt, us ing the Hino-DX, pe rfom a "Le a k te s t".)
18-719
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
DCU unit
86 pins connector 53 pins connec tor
17 18 19
4. Wa s a ny fa ilure found?
NO Go to s tep 7.
YES
Rep la ce the D CU (Afte r re pla ce me nt, us ing the H ino-DX, pe rfom a "Lea k te s t".)
NO P re ce dure comple te d.
(Us ing the Hino-DX, pe rform a "Le a k te s t".)
YES
(Che ck with the new AdBlue /DEF pump mou nte d.)
Rep la ce the D CU (Afte r re pla ce me nt, us ing the H ino-DX, pe rfom a "Lea k te s t".)
P re ce dure comple te d.
18-720
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom De te ction of a n a bnorma lity of the AdBlue /DEF ta nk te mpe ra ture s e ns or
• De fe ctive ha rne s s
S ugge s te d fa ult ca us e • De fe ctive conne ctor
• Fa ilure of the AdBlue /DEF ta nk te mpe ra ture s e ns or body
At the time of a cold s ta rt, the re is a la rge diffe re nce be twe e n the outs ide a ir
DTC de te ction condition
te mpe ra ture a nd the ins ide a ir. 18
Re s e t condition The a bove de te ction conditions have be e n cle a re d
YES
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the a mbie nt a ir te mpe ra ture s e ns or.
S ta n d a rd va lu e
5,500 ± 275 Ω (0 °C {32 °F})
3,365 ± 168.25 Ω (10 °C {50 °F})
1,700 ± 85 Ω (25 °C {77 °F})
Re fe re n ce va lu e
9,280 Ω (-10 °C {14 °F})
YES
18-721
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : (A) + (B)
(A) (B)
Am b ie n t a ir Am b ie n t a ir
Exte rn a l
te m p e ra tu re te m p e ra tu re
re s is ta n c e (Ω )
°C (°F) s e n s o r (Ω )
Re fe re n c e va lu e :
-10 (14)
9,280
25 (77) 1,700 ± 85
YES
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the S CR ups tre a m te mpe ra ture s e ns or.
S ta n d a rd va lu e
197.67 to 205.33 Ω (0 °C {32 °F})
216.77 to 224.37 Ω (25 °C {77 °F})
235.73 to 243.25 Ω (50 °C {122 °F})
YES
18-722
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the e ngine coola nt te mpe ra ture s e ns or.
S ta n d a rd va lu e (m e a s u re o n e o f th e fo llo win g p o in ts )
: 2.45 kΩ (wa te r te m p er a tu re 20 °C {68 °F}) 18
: 1.15 kΩ (wa te r te m p er a tu re 40 °C {104 °F})
: 584 Ω (wa te r te m p e ra tu re 60 °C {140 °F})
: 318 Ω (wa te r te m p e ra tu re 80 °C {176 °F})
YES
1. Afte r de le ting the pa st fau lts in the ECU with Hino -DX, indica te
the curre nt fa ilure code a ga in.
18-723
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 205C P 205D
The a bove de te ction conditions have The a bove de te ction conditions have
Re s e t condition
be e n cle a re d be e n cle a re d
Select
3. S e le ct [Engine ] a nd che ck if a CAN communica tion s ys te m
Engine
ma lfunction (U02A2) ha s be e n de te cte d in [Fa ult Informa tion].
YES
18-724
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
YES
18-725
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom De te ction of a n a bnorma lity of the AdBlue /DEF pump motor
S ymptoms on the ma chine Inje ction of AdBlue /DEF is s toppe d.
S ugge s te d fa ult ca us e Fa ilure of the AdBlue /DEF pump motor
The diffe re nce be twe e n the ta rge t s pe e d of the motor a nd the a ctua l s pe e d is too
DTC de te ction condition
la rge
The diffe re nce be twe e n the ta rge t s pe e d of the motor a nd the a ctua l s pe e d is within
Re s e t condition
the norma l ra nge
18-726
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
P 20A0 P 20 A2 P 20 A3
18
Fa ult s ymptom De te ction of fa ilure of the reve rting va lve of the AdBlue /DEF pump
Inje ction of AdBlue /DEF is Inje ction of AdBlue /DEF is
S ymptoms on the ma chine Only wa rning dis play
s toppe d. s toppe d.
• De fe ctive ha rne s s
S ugge s te d fa ult ca us e • De fe ctive conne ctor
• AdBlue /DEF pump fa ilure
18-727
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd : Co n d u c tivity
YES
YES
18-728
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom De te ction of fa ilure of the reve rting va lve of the AdBlue /DEF pump
DTC de te ction condition The pump pre s s ure doe s no t drop eve n whe n a fte r-run is s ta rte d
18
Re s e t condition The a bove ha s be e n cle a re d
1 Che ck the ope ra tion of the AdBlue /DEF pump (reve rting va lve ) [Hino-DX]
YES
YES
18-729
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-730
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the coola nt cut-off va lve.
YES
18-731
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-732
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-733
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Engi ne coolant
The rmometer
Tem pe ratur e s enso r
AdBlue/D CU tank
DCU
YES
18-734
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the e ngine coola nt te mpe ra ture s e ns or.
S ta n d a rd va lu e (m e a s u re o n e o f th e fo llo win g p o in ts )
: 2.45k Ω (wa te r te m p er a tu re 20 °C {68 °F}) 18
: 1.15k Ω (wa te r te m p er a tu re 40 °C {104 °F})
: 584 Ω (wa te r te m p e ra tu re 60 °C {140 °F})
: 318 Ω (wa te r te m p e ra tu re 80 °C {176 °F})
YES
YES
18-735
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
! CAUTION • Be c a re fu l o f bu rn s fro m h o t e n g in e c o o la n t.
YES
Norma l
2. Dis conne ct the joints on both e nds of the coola nt piping, blow
in a ir from one s ide a nd confirm tha t it come s out a t the othe r
s ide.
YES
18-736
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom De te ction of a bnorma l pre s s ure in the AdBlue /DEF piping
S ymptoms on the ma chine Inje ction of AdBlue /DEF is s toppe d.
• Le a ka ge from the AdBlue /DEF piping, de fe ctive conne ctor
S ugge s te d fa ult ca us e
• AdBlue /DEF pump fa ilure, clogge d filte r
18-737
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1 Ins pe ct the AdBlue /DEF qua ntity, Che ck the DTC his tory
NO Go to s tep 2.
YES
1. Che ck the tighte ning torque of the AdBlue /DEF pump filte r ca p.
(Che ck for the AdBlue /DEF le a ka ge or crys ta lliza tion from the
AdBlue /DEF ta nk filte r ca p.)
Tig h te n in g to rq u e :
20+5 N?m {204+51 kg f?c m , 15+4 lb f?ft}
2. Wa s the filte r ca p tighte ned corre ctly with the corre ct torque ?
YES
18-738
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. Wa s a ny fa ilure found?
NO Go to s te p 4.
18
YES
NO Go to s te p 5.
YES
Re pla ce the AdBlue /DEF line (conne ctor a nd hos e ) be twe e n AdBlue /DEF ta nk a nd pump.
The unit ca n be re le a s e d a fte r AdBlue /DEF ta nk bre a the r hos e cle a ning.
18-739
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. Wa s a ny fa ilure found?
NO Go to s tep 6.
O-ring
YES
Re pla ce the AdBlue /DEF line (conne ctor a nd hos e ) be twe e n AdBlue /DEF ta nk a nd pump.
The unit ca n be re le a s e d a fte r AdBlue /DEF ta nk bre a the r hos e cle a ning.
6 Ins pe ct the ins ide of AdBlue /DEF ta nk a nd AdBlue /DEF pick-up unit (AdBlue /DEF s e ns or)
4. Wa s a ny fa ilure found?
NO Go to s tep 7.
YES
Rep la ce AdBlue /DEF, AdBlue /DEF pu mp inle t con ne ctor, AdBlue /DEF pick-up unit (AdBlue /DEF s en s or) a nd
AdBlue /DEF line be twe e n AdBlue /DEF ta nk a nd pump.
Re move the fore ign obje cts a nd cle a n the AdBlue /DEF ta nk.
NOTICE
Th e Ad Blu e /DEF ta n k mu s t b e cle a n e d with fre s h wa te r o r d ilu te d Ad Blu e /DEF.
The unit ca n be re le a s e d a fte r AdBlue /DEF ta nk bre a the r hos e cle a ning.
18-740
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Re pla ce the AdBlue /DEF pump inle t conne ctor a nd che ck the
AdBlue /DEF pre s s ure.
6. Clos e Hino-DX.
7. Dis conne ct the e le ctrica l conne ctor from the AdBlue /DEF
pump (with s ta rte r switch ON pos ition) a nd wra p the
dis conne cte d conne ctor by the pla s tic ba g for preve ntion of
wa te r/AdBlue /DEF e nte ring.
9. Dis conne ct the e le ctrica l conne ctor from the DCU a nd wra p the
dis conne cte d conne ctor by the pla s tic ba g for preve ntion of
wa te r/AdBlue /DEF e nte ring.
10. Dis conne ct the AdBlue /DEF s uction line from inle t conne ctor of
the AdBlue /DEF pump.
18-741
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
11. Re pla ce the inle t conne ctor of the AdBlue /DEF pump to new
one (Oil the O-ring with Mobil ve locite oil No. 6 or e quiva le nt).
Tig h te n in g to rq u e :
4.0 to 5.0 N?m {41 to 51 kg f?c m , 3.0 to 3.6 lb f?ft}
12. Conne ct the AdBlue /DEF s uction line to inle t conne ctor of the
AdBlue /DEF pump.
13. Conne ct the e le ctrica l conne ctor to the DCU a nd the AdBlue /
DEF pump.
14. S e t the s ta rte r switch to the "ON" pos ition, a nd conduct the
AdBlue /DEF pump le a k te s t with Hino-DX a ga in. And re a d the
AdBlue /DEF pump pre s s ure on the s cre en .
NO Go to s tep 8.
YES
18-742
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. Dis conne ct the AdBlue /DEF s uction line be twe e n the AdBlue /
DEF ta nk (1) a nd the AdBlue /DEF pu mp (2) a nd con ne ct the
S S T a s the picture s hown.
SST
S p e c ia l to o l : S 0920-E0020 Ho s e s u b -a s s y, u e ra
AdBlue/D EF
pump (2) 5. S e le ct [DCU].
NO Go to s te p 9.
YES
18-743
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
AdBlue/DEF sens or 2. Fill a cle a n s ma ll conta ine r with cle a n AdBlue /DEF.
AdBlue/DEF SST
pump (2)
3. Dis conne ct the S S T AdBlue /DEF ta nk-s ide conne ctor (1) a nd
put the conne ctor into the conta ine r conta ining the AdBlue /
DEF.
YES
The ca us e is clogge d AdBlue /DEF pick-up unit (AdBlue /DEF s e ns or). Re pla ce AdBlue /DEF s e ns or.
The unit ca n be re le a s e d a fte r AdBlue /DEF ta nk bre a the r hos e cle a ning.
18-744
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom De te ction of a bnorma l pre s s ure in the AdBlue /DEF piping
S ymptoms on the ma chine Inje ction of AdBlue /DEF is s toppe d.
• Le a ka ge from the AdBlue /DEF piping, de fe ctive conne ctor
S ugge s te d fa ult ca us e
• AdBlue /DEF pump fa ilure, clogge d filte r
The pre s s ure doe s not drop a fte r the pre s s ure ris e in the AdBlue /DEF piping ha s
DTC de te ction condition
be e n comple te d
18
Re s e t condition Afte r comple tion of the pre s s ure incre a s e, the pre s s ure is within the norma l ra nge
18-745
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
4. S e le ct [Engine ].
5. S e le ct "DP R de pos ition qua ntity" from the cus tomiza tion ite ms
a nd cha nge the P M de pos ition qua ntity to [3.0 g/L].
Sample grap h
Cond ition (1): P re s s ure raises over 1,000 k Pa {145 .0 ps i} for more tha n 2 se co nd s.
Cond ition (2): P re s s ure raises up an d no t droppe d.
Cond ition (3): P re s s ure raises over 1,250 k Pa {181 .3 ps i} for more tha n 5 se co nd s.
10. Is the condition (1), (2) or (3) found in the corre cte d da ta ?
YES
18-746
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
AdBlue/DEF hose
(ba ckflow line) 18
AdBlue/DEF hose
(ba ckflow line )
2. Dis conne ct the AdBlue /DEF hos e (ba ckflow line ) be twe e n the
AdBlue /DEF ta nk a nd the AdBlue /DEF pump.
3. Blow a ir from ups tre a m s ide (AdBlue /DEF pump s ide ) of the
AdBlue /DEF hos e a nd che ck if the hos e is clogge d.
5. Blow a ir from ups tre a m s ide (AdBlue /DEF hos e s ide ) of the
AdBlue /DEF conne ctor on the AdBlue /DEF s e ns or a nd che ck if
the conne ctor/pipe is clogge d.
6. Wa s a ny fa ilure found?
NO Go to s te p 3.
18-747
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
Tig h te n in g to rq u e :
4.0 to 5.0 N?m {41 to 51 kg f?c m , 3.0 to 3.6 lb f?ft}
Back f low
co nnect or
2. Is the condition (1), (2) or (3) found in the corre cte d da ta ?
YES
18-748
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ilure of the AdBlue /DEF inje ctor a nd/or clogging of the AdBlue /DEF piping (pump
S ugge s te d fa ult ca us e
↔ inje ctor)
1. Che ck the AdBlue /DEF pipe (pre s s ure line ) a nd che ck if the re
a re no dis conne ctions , clogging, corros ion, or cra cks .
YES
18-749
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
(2) 2. Re move the AdBlue /DEF inje ctor from the muffle r.
4. S e le ct [DCU].
YES
P roce dure comple te d. AdBlue /DEF crys ta l clogging is cons ide re d re s olve d.
2. Re pla ce AdBlue /DEF inje ctor with a new one. (Do not ins ta ll it
on the muffle r.)
Select
DCU
3. S e t the s ta rte r switch to the "ON" pos ition.
YES
New inje ctor ins ta lle d in the muffle r. P roce dure comple te d.
18-750
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
YES
18-751
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Select
6. Pe rform a DP R force d re ge ne ra tion.
DCU
YES
1. Che ck the ins ta lla tion of the e ngine coola nt te mpe ra ture s e ns or
(Loos e ne s s a nd poor conta ct).
YES
18-752
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e
18
Wa te r te m p e ra tu re
Re s is ta n ce
(°C{°F})
2.4 5 kΩ 20 {68}
1.15 kΩ 40 {104}
584 Ω 60 {140}
318 Ω 80 {176}
YES
YES
18-753
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Select
3. Era s e the ma lfunction his tory us ing Hino-DX.
DCU
YES
18-754
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the ups tre a m NOx s e ns or.
S ta n d a rd va lu e : Ap p rox. 60 Ω
NO Ha rne s s a bnorma l
YES
S ta n d a rd : Co n tin u ity
NO Ha rne s s a bnorma l
YES
18-755
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e : 19 - 32 V
YES
18-756
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-757
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
• De fe ctive ha rne s s
S ugge s te d fa ult ca us e • De fe ctive conne ctor
• Fa ilure of the NOx s e ns or
DTC d e te ction condition De te ction in the NOx controlle r du ring ope ra tion of the NOx s e ns or
YES
18-758
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Go to s te p 3.
YES
1. Che ck the ins ta lla tion of the e ngine coola nt te mpe ra ture
s e ns or.
YES
18-759
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
S ta n d a rd va lu e
Wa te r te m p e ra tu re
Re s is ta n c e
(°C{°F})
2.45 kΩ 20 {68 }
1.15 kΩ 40 {104}
584 Ω 60 {140}
318 Ω 80 {176}
YES
YES
Select
3. S e le ct [DCU] a nd che ck if P 2204 ha s be e n d e te cte d in [Fa ult
DCU
Informat ion ].
YES
Re pla ce the DCU. (Afte r re pla cem e nt, pe rform a "Lea k te s t".)
18-760
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
2 NOx s e ns or re pla ce me nt
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the S CR ups tre a m te mpe ra ture s e ns or.
S ta n d a rd va lu e
197.67 to 205.33 Ω (0 °C {32 °F})
216.77 to 224.37 Ω (25 °C {77 °F})
235.73 to 243.25 Ω (50 °C {122 °F})
YES
18-761
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the e ngine coola nt te mpe ra ture s e ns or.
S ta n d a rd va lu e (m e a s u re a c c o rd in g to o n e o f th e
fo llowin g ite m s )
: 2.4 5 kΩ (wa te r te m p er a tu re 20 °C {68 °F})
: 1.15 kΩ (wa te r te m p er a tu re 40 °C {104 °F})
: 584 Ω (wa te r te m p e ra tu re 60 °C {140 °F})
: 318 Ω (wa te r te m p e ra tu re 80 °C {176 °F})
YES
Pe rform a DP R force d re ge ne ra tion a nd confirm tha t the DTC code P 2209 is not indica te d.
18-762
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
• De fe ctive ha rne s s
S ugge s te d fa ult ca us e • De fe ctive conne ctor
• Fa ilure of the NOx s e ns or
DTC d e te ction condition De te ction in the NOx controlle r du ring ope ra tion of the NOx s e ns or
18
YES
18-763
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Go to s te p 3.
YES
1. Che ck the ins ta lla tion of the e ngine coola nt te mpe ra ture s e ns or
is prope rly ins ta lle d.
YES
18-764
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. S e le ct [Engine ].
Select
3. S e le ct [Engine coola nt te mpe ra ture ] from [Da ta Monitor] on the
Engine
me nu.
YES
YES
18-765
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the ins ta lla tion of the boos t pre s s ure s e ns or.
YES
1. S ta rt the e ngine.
Select
3. S e le ct [Actua l boos t pre s s ure ] from [Da ta Monitor] on the
Engine
me nu.
YES
1. Che ck the ins ta lla tion of the inta ke ma nifold te mpe ra ture
s e ns or.
YES
18-766
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Mea s u rem e n t
c o n d itio n s
Te s te r
c o n n e c tio n s
S ta n d a rd va lu e s 18
In ta ke m a n ifo ld 20 °C {68 °F}:
S ta rte r s witch : te m p e ra tu re 7.336 – 5.794 kΩ
OFF s ens or 50 °C {122 °F}:
THG – E2 2.435 – 2.41 kΩ
YES
YES
SC R downs tre a m NOx s en s or is fa ulty. Ins ta ll a new S CR downs tre a m NOx s e ns or.
18-767
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
DTC de te ction condition No cha nge in the NOx va lue during ope ra tion of the NOx s e ns or
YES
YES
YES
18-768
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18
5 Ins pe ct the S CR ups tre a m te mpe ra ture s e ns or conne ctor
YES
1. Che ck the ins ta lla tion of the S CR ups tre a m te mpe ra ture
s e ns or.
YES
18-769
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
197.67 to 205.33 Ω
S CR u p s tre a m (0 °C {32 °F})
S ta rte r s witc h : te m p e ra tu re 216.77 to 224.37 Ω
OFF s ens or (25 °C {77 °F})
FAT+ – FAT- 235.73 to 243.25 Ω
(50 °C {12 2 °F})
YES
YES
1. Che ck the ins ta lla tion of the S CR ups tre a m te mpe ra ture
s e ns or.
YES
18-770
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s 18
20 °C {68 °F}:
DP R
13.7 – 29.8 kΩ
d o wn s tre a m
S ta rte r s witch : 50 °C {122 °F}:
te m p e ra tu re
OFF 7.13 – 13.7 kΩ
s ens or
80 °C {176 °F}:
TEX1 – GND1
4.1 – 7.13 kΩ
YES
18-771
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the downs tre a m NOx s e ns or.
S ta n d a rd va lu e : Ap p rox. 60 Ω
NO Ha rne s s a bnorma l
YES
S tan d a rd va lu e : 19 - 32 V
YES
18-772
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
• De fe ctive ha rne s s
S ugge s te d fa ult ca us e • De fe ctive conne ctor
• Fa ilure of the NOx s e ns or
DTC d e te ction condition De te ction in the NOx controlle r du ring ope ra tion of the NOx s e ns or
18
Re s e t condition No fa ult in the NOx controlle r.
YES
18-773
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Re s e t condition No he a te r fa ilure in the NOx controlle r a fte r ris e of the exha us t ga s te mpe ra ture
NO Ha rne s s a bnorma l
YES
2 NOx s e ns or re pla ce me nt
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the S CR ups trea m te mpe ra ture s en s or.
S ta n d a rd va lu e
197.67 to 205.33 Ω (0 °C {32 °F})
216.77 to 224.37 Ω (25 °C {77 °F})
235.73 to 243.25 Ω (50 °C {12 2 °F})
YES
18-774
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. S e t the s ta rte r key to "OFF", a nd the n dis conne ct the conne ctor
of the e ngine coola nt te mpe ra ture s e ns or.
compone nt s ide ).
S ta n d a rd va lu e (m e a s u re o n e o f th e fo llowin g p o in ts )
: 2.45 kΩ (wa te r te m p e ra tu re 20 °C {68 °F}) 18
: 1.15 kΩ (wa te r te m p e ra tu re 40 °C {104 °F})
: 584 Ω (wa te r te m p er a tu re 60 °C {140 °F})
: 318 Ω (wa te r te m p er a tu re 80 °C {176 °F})
YES
Pe rform a DP R force d reg e ne ra tion a nd confirm that the DTC code P 2222 is no t indica te d.
18-775
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
YES
1. Che ck the ins ta lla tion of the S CR ups tre a m te mpe ra ture
s e ns or.
YES
18-776
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Me a s u re m e n t Te s te r
c o n d itio n s c o n n e c tio n s
S ta n d a rd va lu e s 18
197 .67 to 205.3 3 Ω
Exh a u s t g a s (0 °C {32 °F})
S ta rte r s witc h : te m p e ra tu re 216 .77 to 224.37 Ω
OFF s ens or (25 °C {77 °F})
FAT+ – FAT- 235 .73 to 243.2 5 Ω
(50 °C {12 2 °F})
YES
18-777
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
EXT+ EXT-
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
DCU 86 P
m a c h in e -si d e
S ta rte r s witc h :
c o n n e c to r ∞ Ω
OFF
EXT+ – Gro u n d
EXT- – Gro u n d
YES
18-778
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
5 Ins pe ct dis conne ction of the S CR ups tre a m te mpe ra ture s e ns or ha rne s s
EXT+ EXT-
18
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
197.67 to 205.33 Ω
DCU 86P (0 °C {32 °F})
S ta rte r s witch : m a ch in e -s id e 216.77 to 224.37 Ω
OFF c o n n e c to r (25 °C {77 °F})
EXT+ – EXT- 235.73 to 243.25 Ω
(50 °C {122 °F})
YES
YES
18-779
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
YES
1. Che ck the ins ta lla tion of the S CR ups tre a m te mpe ra ture
s e ns or.
YES
18-780
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Me a s u re m e n t Te s te r
c o n d itio n s c o n n e c tio n s
S ta n d a rd va lu e s 18
197.67 to 205.33 Ω
S CR u p s tre a m (0 °C {32 °F})
S ta rte r s witc h : te m p e ra tu re 216.77 to 224.37 Ω
OFF s ens or (25 °C {77 °F})
FAT+ – FAT- 235.73 to 243.25 Ω
(50 °C {122 °F})
YES
EXT+ EXT-
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
DCU 86 P
m a c h in e -si d e
S ta rte r s witc h :
c o n n e c to r ∞ Ω
OFF
EXT+ – Gro u n d
EXT- – Gro u n d
YES
18-781
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
5 Ins pe ct dis conne ction of the S CR ups tre a m te mpe ra ture s e ns or ha rne s s
EXT+ EXT-
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
197.67 to 205.33 Ω
DCU 86P (0 °C {32 °F})
S ta rte r m a c h in e -si d e 216.77 to 224.37 Ω
s witc h : OFF c o n n e c to r (25 °C {77 °F})
EXT+ – EXT- 235.73 to 243.25 Ω
(50 °C {12 2 °F})
YES
YES
18-782
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Output limit e tc. NOx e mis s ion is not be ing controle d. The output will be gra dua lly lowe re d ove r time.
The exha us t te mpe ra ture mus t ris e a nd the indica te d va lue mus t be the s a me a s the
Re s e t condition
va lue of the DP R downs tre a m exha us t ga s te mpe ra ture s e ns or
YES
YES
18-783
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the ins ta lla tion of the S CR ups tre a m te mpe ra ture
s e ns or.
YES
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
197.67 to 205.33 Ω
S CR u p s tre a m (0 °C {32 °F})
S ta rte r s witch : te m p e ra tu re 216.77 to 224.37 Ω
OFF s ens or (25 °C {77 °F})
FAT+ – FAT- 235.73 to 243.25 Ω
(50 °C {12 2 °F})
YES
YES
18-784
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the ins ta lla tion of the S CR ups tre a m te mpe ra ture
s e ns or.
YES
Me a s u re m e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
20 °C {68 °F}:
DP R
13.7 – 29.8 kΩ
d own s tre a m
S ta rte r s witc h : 50 °C {122°F}:
te m p e ra tu re
OFF 7.13 – 13.7 kΩ
s ens or
80 °C {176 °F}:
TEX1 – GND1
4.1 – 7.13 kΩ
YES
YES
18-785
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
• DCU fa ilure
• Abnorma l ba tte ry volta ge
S ugge s te d fa ult ca us e
• De fe ctive ha rne s s
• De fe ctive conne ctor
YES
18-786
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
CAL1
LF6 Me a s u re m e n t Te s te r
TE1B
LF2
S ta n d a rd va lu e s
TE1A
LF1
CAH0
LEY
c o n d itio n s c o n n e c tio n s
TE2B CAL0
LF4 LEZ
TE2A
LF3
DCU 53 P
m a c h in e -si d e
IGS W
c o n n e c to r –
LES
YES
18-787
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
2. S e le ct [DCU].
YES
18-788
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Che ck the conne ction of the e ngine joint con ne ctor a nd DCU
conne ctor (Loos e ne s s a nd poor conta ct).
CANL CANH
K29 K28
GND S IG VCC
KSL KS K KS J
Muffler sub
ha rne s s a nd
upper ha rne s s
connector
YES
18-789
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
NO Go to s tep 3.
YES
3 Che ck ha rne s s in CAN H-line be twe e n e ngine joint conne ctor a nd DCU
CAL1
S ta n d a rd va lu e : 1 Ω o r le s s
LF6
TE1 B
CAH0
LF2
TE1A CAH0
LF1 LEY
TE2 B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
YES
18-790
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
4 Che ck ha rne s s in CAN L-line be twe e n e ngine joint conne ctor a nd DCU
CAH1
LF5
18
CAL1
LF6
TE1 B
LF2
TE1A CAH0
CAL0
LF1 LEY
TE2 B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
NO Go to s te p 5.
YES
S ta n d a rd va lu e : 1 Ω o r le s s
424E
424D
YES
18-791
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
6 Che ck continuity be twe e n the uppe r ha rne s s conne ctor a nd DCU conne ctor
TE1B
LF2
424D
TE1A
LF1
CAH0
LEY S tand a rd va lu e : 1 Ω o r le ss
TE2B
LF4
CAL0
LEZ
CAH0
TE2A
LF3 CAL0
NO Che ck dis conne ction of the uppe r ha rne s s, re pla ce
the uppe r ha rne s s .
IS GW
LES
YES
1. Conne ct the e ng ine joint conne ctor a nd DCU (53 P ) conn e ctor.
GND1
+B3
2. S e t the s ta rte r switch to the "ON" pos ition.
+B2 GND4 GND1
LEP LEW LET
+B3
LEQ
GND5
LEX
GND2
LEU 3. Conne ct the s igna l che ck ha rne s s , a nd us e the e le ctrica l te s te r
+B4
LER
+B1
LEN
GND3
LEV to me a s ure the volta ge be twe e n the te rmina ls of the DCU.
S tand a rd va lu e : 19 – 32 V
CAH1
LF5
CAL1
LF6 NO Che ck the DCU powe r s upply circuit.
TE1B
LF2
TE1A CAH0
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
YES
18-792
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-793
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18-794
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
Engine sid e
DCU
Macha tron ic
controlle r
Cab si de
YES
18-795
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
18-796
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
CAH1
CAL1
CAH1
LF5
CAL1
LF6
TE1B
LF2
TE1A CAH0
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A
LF3
52 1A 52 0A
IGS W
LES
S ta n d a rd va lu e : 1 Ω o r le s s
NO Go to s tep 5.
YES
18-797
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
4 Che ck ha rne s s in CAN line be twe e n e ngine joint conne ctor CN-12F a nd DCU
CAH1
CAL1
CAH1
LF5
CAL1
LF6
TE1B
LF2
TE1A CAH0
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A
LF3
52 1C
IGS W
LES
52 0C
CN-12F
S tan d a rd va lu e : 1 Ω o r le ss
YES
Re pla ce the DCU. (Afte r re pla cem e nt, pe rform a "Lea k te s t".)
18-798
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
1. Move the s e a t.
18
CN-104F
CN-73M
E13 3
52 0A
CN-73M CN-104 F
354
52 1A
S ta n d a rd va lu e : 1 Ω o r le s s
YES
18-799
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
CAH1
CAL1
CN-73M
CAH1
LF5
CAL1
LF6
E133 35 4
TE1B
LF2
TE1A CAH0
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A
LF3
IGS W
LES
CN-73M
S tan d a rd va lu e : 1 Ω o r le ss
YES
Re pla ce the DCU. (Afte r re pla cem e nt, pe rform a "Lea k te s t".)
18-800
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
YES
1. Conne ct the e ngine joint conne ctor a nd DCU 53P conne ctor.
GND1
+B3
2. S e t the s ta rte r switch to the "ON" pos ition.
YES
YES
18-801
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
DTC de te ction condition De te ction tha t CAN informa tion is no longe r tra ns mitte d from the e ngine ECU
YES
1. Che ck the DTC code of the e ngine ECU a nd confirm tha t the re
is no a bnorma lity.
YES
DCU re pla ce me nt (a fte r re pla ce me nt, us ing the Hino-DX, pe rform a "Le a k te s t")
18-802
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
3. Dis conne ct the NOx s e ns or conne ctor a nd che ck the conne ctor
pins for da ma ge a nd rus t.
S ta n d a rd :
Co n n e c to r d is c o n n e c te d o r lo o s e .
Co n n e c to r p in s d a m a g e d o r ru s te d .
NO Go to s tep 2.
18-803
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
YES
18-804
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
GND CANH CANL GND VCC 2. Dis conne ct NOx s e ns or conne ctor.
LGU LE9 LE8 LE7 LE6
CAL1
LF6
TE1 B
LF2
NO Re pa ir or re pla ce of the CAN ha rne s s be twe en DCU
TE1 A
LF1
CAH0
LEY a nd NOx controlle r.
TE2 B CAL0
LF4 LEZ
TE2 A
LF3
IS GW
LES
YES
18-805
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
GND CANH CANL GND VCC 2. Dis conne ct NOx s e ns or conne ctor.
LGU LE9 LE8 LE7 LE6
CAL1
LF6
TE1 B
LF2
NO Re pa ir or re pla ce of the CAN ha rne s s be twe e n DCU
TE1A
LF1
CAH0
LEY a nd NOx controlle r.
TE2 B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
YES
18-806
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
7 DTC che ck whe n the S CR ups tre a m NOx s e ns or a nd the S CR downs tre a m NOx s e ns or have be e n
switche d
6. S e le ct "DCU".
YES
18-807
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
DTC de te ction condition De te ction tha t the NOx s e ns or no longe r tra ns mits CAN informa tion
3. Dis conne ct the NOx s e ns or conne ctor a nd che ck the conne ctor
pins for da ma ge a nd rus t.
S ta n d a rd :
Co n n e c to r d is c o n n e c te d o r lo o s e .
Co n n e c to r p in s d a m a g e d o r ru s te d .
NO Go to s te p 2.
YES
18-808
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
18-809
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
CAL1
LF6
TE1 B
LF2
NO Re pa ir or re pla ce of the CAN ha rne s s be twe e n DCU
TE1 A
LF1
CAH0
LEY a nd NOx controlle r.
TE2 B CAL0
LF4 LEZ
TE2 A
LF3
IS GW
LES
YES
CAL1
LF6
TE1 B
LF2
NO Re pa ir or re pla ce t he CAN ha rne s s be twe e n DCU
TE1 A
LF1
CAH0
LEY a nd NOx controlle r.
TE2 B CAL0
LF4 LEZ
TE2 A
LF3
IS GW
LES
YES
18-810
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
6 DTC che ck whe n the S CR ups tre a m NOx s e ns or a nd the S CR downs tre a m NOx s e ns or have be e n
switche d
6. S e le ct "DCU".
7. Afte r the DTC ha s be e n cle a re d, re a d the DTC a ga in.
Whe n the DTC U02 9E a nd U029 D a re de te cte d
s imulta ne ous ly, pe rform s te ps from 4 to 5 a ga in.
YES
18-811
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
Fa ult s ymptom CAN communica tion with the AdBlue /DEF s e ns or ha s be e n s us pe nde d
Clus te r ga ug e (Firs t)
Clus te r ga ug e (S e cond)
DCU c on ne ctor
YES
18-812
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
18
YES
Mea s u rem e n t Te s te r
S ta n d a rd va lu e s
c o n d itio n s c o n n e c tio n s
Ad Blu e /DEF
s ens or
GND S ta rte r s witch :
m a ch in e -s id e 19 – 32 V
ON
c o n n e c to r
VCC – GND
YES
18-813
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
4 Ins pe ct for dis conne ction in CAN H-line be twe e n the DCU a nd AdBlue /DEF s e ns or
CAL1
TE1B
LF6
NO Dis conne ction or fa ulty continuity in CAN H-line
LF2
TE1A
LF1
CAH0
LEY be twe e n the DCU a nd AdBlue /DEF s e ns or. Re pa ir
TE2B CAL0
LF4
TE2A
LEZ
or re pla ce the ha rne s s .
LF3
IS GW
LES
YES
5 Che ck for dis conne ction in CAN L-line be twe e n the DCU a nd AdBlue /DEF s e ns or
CAL1
CAL0
LF6
TE1B
LF2
TE1A CAH0
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A
LF3
IS GW
LES
YES
18-814
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
YES
YES
18-815
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]
[18. ENGINE]
DCU failure
1 DCU re pla ce me nt
1. Re pla ce the DCU. (Afte r re pla cem e nt, pe rform a "Le a k te s t".)
18-816
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0049E02] [0617CsCshWbYs]