HYDRAULIC EXCAVATOR SHOP SK200-8 MANUAL model SK210:c-8 INDEX SPECIFICATIONS SECTION MAINTENANCE SECTION SYSTEM SECTION Sac DISASSEMBLY SECTION TROUBLESHOOTING ENGINE SECTION PROCEDURE OF INSTALLING OPTIONS SECTION KOBELCO Book Code No. SSYN0018E01 0-1GENERAL SAFETY INFORMATION [Awarning] Do not operate or perform any maintenance on this machine until all instructions found in the OPERA- ‘TOR’S MANUAL and this MANUAL have been thor- ‘oughly read and understood. Improper operation or maintenance of this machine ‘may cause accidents and could result in serious in- jury or death. Always keep the manual in storage. Ifitis missing or damaged, place an order with an authorized our Distributor for a replacement. Ifyou have any questions, please consult an autho- rized our Distributor. (1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safe- ty rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication 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, focal 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: WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows: [A WARNING] 2) 0-2 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 and its components and is represented as fol- lows: [Acaution) (4) Itis very difficult to forecast every danger that may ‘occur during operation. However, safety can be en- sured by fully understanding proper operating pro- Cedures for this machine according to methods recommended by Manufacturer. (5) While operating the machine, be sure to perform work with great care, so as not to damage the ma- chine, of allow accidents to occur. (6) Continue studying the manual until all Safety, Oper- ation and Maintenance procedures are completely understood by all persons working with the ma- chine.SAFETY PRECAUTIONS ‘The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR'S MANUAL for the machine. Improper performance of lubrication or mainte~ nance procedures are dangerous and could result in injury or death, Read and understand the MAN- UAL before performing any lubrication or mainte- nance. ‘The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important o use caution when performing service work. A knowledge of the system and or components is im- portant bofore the removal or disassembly of any com- ponent. Because of the size of some of the machine compo- rents, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting proce- dures when removing any components. Weight of com- ponents table is shown in the section ; ‘SPECIFICATIONS. ‘The following is a list of basic precautions that must al- ways be observed. (1) Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine (2) Always wear protective glasses and protective shoes when working around machines. In particu- lar, wear protective glasses when using hammers, punches or drifts on any part of the machine or at- tachments. Use welders gloves, hoodigoggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fit- ting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery, (8) Disconnect the battery and hang a "Do Not Oper- ate" tag in the Operators Compartment. Remove ig- nition keys, (4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine 50 itdoes not roll while working on of under the ma- chine, Hang a *Do Not Operate" tag in the Opera- tors Compartment. (8) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack 0-3 stands, capable of supporting the machine, before performing any disassembly, [AWARNING| Do not operate this machine unless you have read and understand the instructions in the OP- ERATOR’S MANUAL. Improper machine opera- tion is dangerous and could result in injury or death. (6) Relieve all pressure in air, oll or water systems be- fore any lines, fitings or related items are nected or removed. Always make sure all raised ‘components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. (7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the ma- chine. f this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correct- ly to prevent it from dropping unexpectedly, (8) Use steps and grab handles when mounting or dis- ‘mounting @ machine. Clean any mud or debris from steps, walkways or work platforms before using. ‘Always face to the machine when using steps, lad- ders and walkways. When it is not possible to use the designed access system, provide ladders, scaf- folds, or work platforms to perform safe repair oper- ations. To avoid back injury, use a hoist when lifting com- ponents which weigh 20kg (45ibs) or more. Make sure all chains, hooks, slings, etc., are in good con- dition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. (10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in fines, tubes and compartments. (11)Be careful when removing cover plates. Gradually back off the last two capsorews or nuts located at opposite ends of the cover or device and carefully ry cover loose to relieve any spring or other pres- sure, before removing the last two capscrews or nuts completely, (12)Be careful when removing filer caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liq- uuids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot, ie @)(13)Always use the proper tools that are in good condi-_(21)Do not operate a machine if any rotaling part is tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera~ you understand how to use them before performing tion. Any high speed rotating component that has any service work. been damaged or altered should be checked for (14)Reinsiall all fasteners with the same part number. balance before reusing. Donot use a lesser quality fastenerifreplacements _(22)Be careful when servicing or separating the tracks are necessary. (crawiers). Chips can fly when removing or install (18)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and formed only with the benefit of the appropriate ref- Jong sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away ‘from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged frorn the sprockets. Block the ma- erence information and by personne! adequately ‘rained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and eleotrodes, rods or wire to provide @ weld metal strength equivalent at chine to prevent it from moving. least to that of the parent metal. Make sure to dis- connect batlery before any welding procedures are attempted. (16)Do not damage wiring during removal operations. Reinstall the wiring so its not damaged nor will be ‘damaged In operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring toa line contain- ing fluid. (17)Be sure all protective devices including guards and shields are properly installed and functioning cor- rectly before starting a repair. if guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed. (18)The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a faling attachment. Don't fell to lower the attach ment and place the bucket to the ground before starting the work (19)Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Donot bend ‘strike high pressure tines or install ones which have been bent or damaged. Inspect lines, tubes ‘and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in ‘@ high velocity oll stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. (20)Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are stalled correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oll spray onto hot ex- haust components in event of a line, tube or seal failure must be installed correctly. 0-4‘Book Code No. $k200-8 SK210LC. Title Distribution Year-Month ‘SSYNO118E01 20068 OUTLINE ‘S5YNO218E01 NEE SPECIFICATIONS ‘SSYNO318E01 30068 /ATTACHMENT DIMENSIONS ‘SSYN1118E01 0088 TOOLS S5YN1218E01 STANDARD MAINTENANCE] 2006-8 TIME SCHEDULE ‘SSYN1318E01 MAINTENANCE STANDARD 2006-8 AND TEST PROCEDURE ‘S5YN2118E01 MECHATRO CONTROL 2006-08 SYSTEM ‘SSYN2218E01 cnees HYDRAULIC SYSTEM ‘SSYN2318E01 a tes Fag ELECTRIC SYSTEM SSYN2418E01 a fies Fag COMPONENTS SYSTEM ‘S5YN2518E01 |AIR-CONDITIONER SYSTEM ag ‘S5YN3118E01 ry DISASSEMBLING 2006-8 Fe & ASSEMBLING ba SBvN219E01 Fy ‘ATTACHMENT a ‘S5YN3318E01 g UPPER STRUCTURE 2006-8 4 oe rat TRAVEL SYSTEM Ko soynastaeot BY ERROR CODES Seer: BY TROUBLE cd ‘S5YN4818E01 us Sm TROUBLE DIAGNOSIS MODE i sovnerigrnt ENGINE YN41-45001~ Yoroe00: a APPLICABLE MACHINES 0-5NOTE: This Manual is prepared as a technical material in which the information necessary for the maintenance and repairing services of our hydraulic excavators are collected, and is categorized into 7 Chapters, Specitica- tion, Maintenance, System, Disassembly, Trouble- shooting, Engine, and Installation Procedures for Optional Attachment. ‘The Chapter “Specification” describes the specifi- cations for entire machine and material, which are instructive for replacement and repairing of attach- ments. ‘The Chapter "Maintenance" describes the material, which is helpful for maintenange 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 Allachment” describes the supplements added on request as required 0-6 This Manual may be properly revised due to the im- provement of products, modification of specifications, elc, And there are cases where the system on actual machine and a part of the contents of this manual may differ due to the variations of specification by countries. For the section in which the description is hardly under- stood, contact our distributor. ‘The number is assigned to every part handled in this Manual on account of the description, but the parts, which cannot be supplied as service parts are con- tained. Therefore, the order must be placed with re- ‘spective formal number with due confirmation on the Parts Manual for applicable machine.1. OUTLINE ‘TABLE OF CONTENTS 1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS w..rnnsesennssennet 13 1.1.4 PREPARATION BEFORE DISASSEMBLING... Satta 4.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING. nnn AQ 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ...ccscsesuen 4.1.4 ELECTRICAL EQUIPMENT td 1.1.5 HYDRAULIC PARTS 7 7 7 7 wot 5 1.1.6 WELD REPAIR... soon . 15 1.1.7 ENVIRONMENTAL ISSUES aa 15 1.2 INTERNATIONAL UNIT SYSTEM 16 Book Code No. S5YN0118E01 144. OUTLINE [ Issue Date of issue Applicable Machines Remarks | | 'SK330~-8 : LC10-07001~ S8YNO118E01 | i K | ies eee stu 2006 | sxas0L¢-8 : Y010-03601~ (ASIA, OCE) ‘ ‘August 2008 8200-8: YNtT-46001~ + Kl [SK210LC-8 : YQ11-06001~4. OUTLINE 4.1. GENERAL PRECAUTIONS FOR 2) Attach "Don't operate" tag to control lever, and MAKING REPAIRS begin a meeting before starting the work 3) Before starting inspection and maintenance 1.1.1 PREPARATION BEFORE stop the engine. DISASSEMBLING 4) Confirm the position of first-aid kit and fire i extinguisher, and also where to make contact for emergency measure and ambulance to prepere for accidents and fire 5) Choose a hard, lever and safe place, and put attachment on the ground without fail 6) Use hoist, ets, to remove parts of heavy weight (23kg [50 lb] or more) 7) Use proper tools, and change or repair defective tools. (1) Knowledge of operating procedure Read Operator's Manual carefully to understand the operating procedure. (2) 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 8) Machine and attachment required to workin the parts lifting condition should be supported with (2) Inspecting machines supports or blocks securely. Confirm the disassembling section before starting 4.4.3. DISASSEMBLING AND ASSEMBLING work, determine the disassembly procedure taking HYDRAULIC EQUIPMENT the conditions in work shop into account, and request to procure necessary parts in advance, (4) Recording Record the following items to keep contact and (1) Removing hydraulic equipment assy Prevent malfunction from recurring, 1) Before removing pipes, release the pressure of 41) Inspecting date, place hydraulic oil tank, or open the cover on the 2) Model name, Serial number and Record on Tetum side to tank, and take out the filter. hour mater 2). Drain the oil in the removed pipes into pan to prevent the ol! rom spilling on the ground 3) Pipes with plugs or caps to prevent ail leaking, entry of dust, ete 4) Clean the outside surface of equipment, otc before disassembling, and drain hydraulic ot and gear oil before putting them on working bench, 3} Trouble condition, place, cause 4) Visible oil leak, water leak and damage 5) Clogging of filters, oil level, oi quality, oil contamination and looseness. 6) Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour meter. (8) Arrangement and cleaning in service shop 1) Tools required for repair work, (2) Disassembling hydraulic equipment 41). Since performance and function of hydraulic equipment after disassembly and assembly 2 peer the places to put the disassembled results in immunity from responsibility on the La manufacture’s side, disassembly, assembly 3) Prepare oil pans for leaking oil, ete. and modification without permission are strictly prohibited, 4.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING 2) IFitis unavoidably necessary to disassemble and modify, it should be carried out by experts oF personnel qualified through service training, (1) Sefety 4) Before disassembling, read Disassembling 1) Wear appropriate clothing, safety shoes, safety Instruction in advance, and determine if the helmet, goggles, and clothes with long sleeves. disassembly and assembly are permitted or not 1-31 OUTLINE @ 4) 15) 5) For parts which are required to use jig and tools, don't fal to use the specified jig and tools. For parts which can not be removed in the specified procedure, never force removal. First check for the cause. The removed patts should be pul in order and tagged so as to install on proper places without confusion, 8) a) 8) For common parts, pay attention to the quantity and places Inspecting parts 1) Check that the disassembled paris are free from adherence, interference and uneven working face. 2) Measure the wear of parts and clearance, and record the measured values. 3), If an abnormality is detected, repair or replace the parts. Reassembling hydraulic equipment 41) During the parts cleaning, ventilate the room. 2) Before assembly, clean parts roughly first, and then completely. 3) Remove adhering oll by compressed air, and apply hydraulic oll or gear oil, and then assemble them, 4), Replace the removed O-ring, back-uprings and oll seal with new ones, and apply grease oil on them before assembling 5) Removes dirt and water on the surtace on which liquid sealant ere applied, decrease them, and apply liquid sealant on them, 6) Before assembling, remove rust preventives on new parts 7). Use special tools to fit bearings, bushing and oi seal 8) Assemble parts matching to the marks. 9) After completion, check that there is no omission of parts. Installing hydraulic equipment 1) Confirm hydraulic oil and lubrication oi 2) Air release is required in the following cases ; 4. Change of hydraulic oi Replacement of parts on suction pipe side Removing and attaching hydraulic pump Removing and attaching swing motor Removing and attaching travel motor Removing and attaching hydraulic cyl 1-4 114 (AWARNING| If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. 3) For air bleed of hydraulic pump and swing ‘motor, loosen drain plug on the upper part, start engine, and run in fow idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely. For air bleed of travel motor and hydraulic, cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed. 4) [WARNING] For cylinder, don’t move it to the stroke end at beginning. 5) Air in pilot circuit can be bleed out by only operating digging, swing and travating motions thoroughly Check hydraulic oil level Move attachments to hydraulic oil cheok position, and check hydraulic oil level of tank. Refill oii the oil level is lower than the specified level How to check oil level of hydraulic ail tank 8) [eee eet ed Or et ora of tank {ie indiestore oe macs, the any 'Sacceptabie ELECTRICAL EQUIPMENT (1) The disassembly of electrical equipment is not allowed. (2) Handle equipment with care s0 as not to drop itor bump it. (8) Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire (4) Check that connector is connected and locked completely. (8) Engine key off before removing and connecting connector,4, OUTLINE (6) Engine key off before touching terminals of starter, and alternator. (7) Remove battery grounding terminal before beginning work close to battery and battery relay with fools. (8) Wash machine with care so as not to splash water ‘on electrical equipment and connector. (9) When water has entered in the waterproofed connector, the removing of water is not easy. So. check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting, [AS WARNING] Battery fluid is dangerous. The battery fluid is dilute sulfuric acid, and causes ‘scald and loss of eyesight by adhering on eyes, skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical advice. + When it has adhered on skin ; Wash with soap and water. + When it has got in eyes ; Wash in water for 10 minutes or moro immediately. + When it has spilled out in large quantity ; Use sodium bicarbonate to neutralize, or wash away with water. + When it was swallowed ; Drink milk or water. + When it has adhered on cloth Wash it immediately. 4.4.5 HYDRAULIC PARTS: (1) 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. (2} Flexible hose (F hose) + Evenifthe connector and length of hose are the same, the parts difer according to the withstanding pressure. Use proper parts. + Tighten ttotne spectig torque, and check that I its free from twist, over tension, interference and cil leak 1.1.6 WELD REPAIR (1) The weld repair should be carried out by qualified personnel in the specified procedure after disconnecting the grounding cable of battery. Ifthe grounding cable is not disconnected, the electrical equipment may be damaged. (2) Remove parts which may cause fire due to the entry of spark beforehand. Repair attachments which are damaged, giving particular attention to the plated section of piston rod to protect it from sparks, and don't fail to cover the section with flame-proof clothes. @ 4.1.7 ENVIRONMENTAL ISSUES (1) Engine should be started and operated in the place where air can be sufficiently ventilated. (2) Waste disposal The foliowing parts follows the regulation. Waste oil, waste container and battery (8) Precautions for handling hydraulic oi! Hydraulic oil may cause inflammation of eyes. Wear goggles to protect eyes on handling it + When it has got in eyes Wash eyes with water until the stimulusis gone. + When itwas swallowed : Don't force him to vorit it, but immediately receive medical treatment. + When it has adhered on skin ; Wash with soap end water. (4) Others For spare parts, grease and oil, use KOBELCO genuine ones4. OUTLINE 1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations Introduction Tablet-4 Atthough this manual uses the SI units system. Outline QUANTITY [UNIT SYMBOL | FORMULA of SI units system is described here. Frequency hertz He tHe=tis Given hereinunder are an excerpt of the units that are Force Inewton N ig: mis? related to this manual Proscure and 1. Etymology of SI Units stress [Pesce i Ar English : International System of units Energy, Work 2. Construction of SI Unit System and Quantity of joule J Nem heat Base units Power __|watt Wi, ws Tabet | ___ Fea) _[ Brive units Quantity of | ouiomb c ee ‘Supplemen | r-|of base unts electricity ro [Stunts Lt taryunte Table 1-3 y [ st unit 1 | Table 1-2 a Electrie isystem|f =" Peers. potential | caring peculiar one sesignatons afore, | it v WIA jh [ebe'm4 | Voltage, and a El iv Prefixes of SI pone {n-th power of 10, where n is an integer force a Quantity of slaticelectricty (1) Basic Units and Electric |'*"° 7 Ae Tablet-1 capacitance (QUANTITIES DESIGNATION | SIGN Electric on 9 VIA Length Meter ™ resistence a Mass Kilogram kg Celcius [Peleus Tins Second > temperature [229728 & co | 27a.15)« Current lAmpere. degree. Thermodynamic Kelvin K Muminance Jur. us Simin temperature Gram molecule Mol mol ree oe Luminous intensity Candela cd Tablet-5 PREFIX POWER eee aya DESIGNATION SIGN Tablet-2 Giga 6 10" QUANTITIES DESIGNATION | SIGN Mega M ‘108 Piain angle Radian rad Kilo k 10° Solid angle [Steradian st Hesto h 10° Deca da 10 (3) Derived Units of Basie Units Seal 5 08 Tablet-3 Conti c 10° QUANTITIES DESIGNATION SIGN Mi m 108 ‘Area [Square meter mm Micro a 10 Volume Cubic meter me Nano n 102 Velocity [Meter per second ms Pico B 10 Acceleration [Meter per second / second | mis? Density Kilogram per cubic meter_|_kglm* 1-6(6) Unit Conversion Table ‘QuanTimes [vis | S1_[ REMARKS Mass kg | kg Force kgf | ON ‘Akgf=9.807N 807Nem Torque kgfm | Nem | kat Pressure | kgtfom? | MPa__ tkgfom'=0.098MPa Motive power| PS | kW | 1PS=0.7355kW Revolution | rp.m_| minx | trp.m=tmin- 1-7 4, OUTLINE4, OUTLINE [MEMO]2. SPECIFICATIONS TABLE OF CONTENTS 2.4. NAME OF COMPONENTS 23 2.2 GENERAL DIMENSIONS. : 24 2.24 $K200-8/SK210LC-8 [5.65m (18f-in) Boom +2. 94m (9-8) Standard Arm+0.80m?(1.05curyd) Bucket Shoe}...2-4 22.2 SK200-8/SK210LC-8 [5.65m (18f-6in}+2.4m (7ft-10in) Short Arm+0.93me (1.22curyd) Bucket Shoe].....24 2.2.3 SK200-B/SK210LC-8 [5.65m (18f1-6in) Boom+3.5m (148-Gin) Long Arm+0.70m (0.92curyd) Bucket SHOE)... 25: 2.3 WEIGHT OF COMPONENTS 26 24 TRANSPOTATION sn DB 241 OVERALL DIMENSIONS OF MACHINE ON A TRAILER, 28 24.2 DIMENSIONS OF ATTACHMENT 7 7 oo 2-8 2.5 SPECIFICATIONS AND PERFORMANCE ... . 7 244 25.1 SPEED AND CLIMBING CAPABILITY. 244 25.2 ENGINE... 7 seit 244 2.8.3 HYDRAULIC COMPONENTS 24 254 WEIGHT eal lt 214 2.6 TYPE OF CRAWLER. sos Seeeseeeeeaeee 242 27 TYPE OF BUCKET. se os F en BAZ, 2.8 COMBINATIONS OF ATTACHMENT. oo 7 a 243 2.9. ENGINE SPECIFICATIONS .escscunns 244 2.9.1 SPECIFICATIONS sons : ror 244 2.9.2 ENGINE CHARACTERISTIC CURVE (HINO JOSE-TA) 215 Book Code No. S5YN0218E01 2-12. SPECIFICATIONS issue Date of Issue ‘Applicable Machines Remarks SK200-8 : YN11-45001~ ISsyNO218E01 First edit 1, 2006 eee SK210LC-8 : Y11-06001~ (ASIA, OCE)2. SPECIFICATIONS 2.41 NAME OF COMPONENTS ARM CYLINDER ARM BUCKET, CYLINDER SLEWING BEARING IDLER LINK: SLEWING MOTOR FUEL TANK FUEL TANK | wyomauuc tan CONTROL VALVE BUCKET, SHOE AND TRACK LINK. FRONT IDLER IDLER ADJUST _-—~ UPPER ROLLER, ROTALY MULTI CONTROL VALVE (OPTION) LOWER ROLLER BATTERY 232. SPECIFICATIONS 2.2 GENERAL DIMENSIONS 2.24 $K200-8/SK210LC-8 [5.65m (18f-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m (1.05cusyd) Bucket Shoe] i lil Unit : mm(ft-in) iil 8 t a | ealhnrents b | _arrasi989 see 2200 (92°) ——— 2 pe99) (IF Note Dimensions marked * do not include the height of the shoe lug, [ Jinclude LC specifications, 2.2.2 $K200-B/SK210LC-8 [5.65m (18ft-6in)+2.4m (7ft-10in) Short Arm+0.93m' (1.22curyd) Bucket Shoe] Unit : mmift-in) 242. SPECIFICATIONS 2.2.3 SK200-8'SK210LC-8 [5.65m (18ft-Gin) Boom+3.5m (11ft-6in) Long Arm+0.70m: (0.82euryd) Bucket Shoe] ss0¢ary _Unit: mm(fe-in) Dimensions marked * do not include the height of the shoe lug, [ Jinolude LC specifications. 2-52. SPECIFICATIONS 2.3 WEIGHT OF COMPONENTS Unit; kg (Ib) Model $K200-8 SK210L0-8 item Machine complete 20,200 (44,500) | 20,600 (45,400), 1. Upper frame assy (Assembly of following :) 9,500 (27.000) = 1.4 Upper frame 41,770 (3,900) . 4.2 Counter weight (Semi-weighted) 4,840 (10,280) + 4.3Cab 260 (570) + 1.4 Engine *840 (1,190) « 1.8 Hydraulic oll tank 7150 (330) . 1.6 Fuel tank "110 (240) - 1.7 Slewing motor (including reduction unit) 210 (460) | « 1.8 Control valve *230(510) | « 1.9 Boom oylinder “170 (875) x2 < 4.10 Pin (for mounting boom) 70 (180) « 4.41 Pump "130 (290) © 4.42 Radiator (including intercooler) 790 (200) « 2. Lower frame assy (Assembly of following :) 2.4 Lower frame 2.2 Slewing bearing 2.3 Travel motor (Including reduction unit) 2.4 Upper roller 2.5 Lower roller 2.6 Front idler 2.7 Idler adjuster 2.8 Sprocket 2.9 Swivel joint 2.40 Track link with 600mm (23.6in) shoes assy Track link with 700mm (27.6in) shoes assy Track link with 800mm (31.Sin) shoes assy 6730 (74,840) 2,260 (4,980) 250 (550) 280 (670) x2 | 20 (44) x 2 30 (66) x14 | 110(240)x2 | 100 (220) x 2 50 (110) x2 *30 (66) 4,260 (2,780) x 2 1,470 (3,240) x 2 1,600 (3,530) x 2 7,430 (18,720) 2,420 (5,340) 30 (66) x 16 4,350 (2,980) x 2 1,560 (3,840) x 2 4.700 (3,750) x 2 2.10.4 Track link assy 540 (1.120) x2_| 540 (1,190) x2 3, Attachment (Assembly of following / STD -) 3.420 (7,540) = {5.65m (18ft-6in) Boom + 2.94m (9ft-Bin) Arm + 0.80m° (1curyd) Bucket} 3.1 Bucket assy (STD) 640 (1,410) ‘ 3.2 STD Arm assy (Assembly of following :) 1,050 (2,318) . 3.2.1 STD Am 1660 (1,455) . 3.2.2 Bucket cylinder "140 (310) - 3.2.3 Idler link 20 (Ad) x2 . 3.2.4 Bucket link 90 (198) « 3.2.5 Pin (2pes. for mounting bucket cylinder / 2pcs. for mounting bucket)| 100 (220) + 3.3 Boom assy (Assembly of following :) 1,730 (3.818) = 3.3.4 Boom 1,310 (2,890) = 3.3.2 Arm cylinder "255 (580) « 3.3.3 Pin (Mounting arm + Mounting arm cylinder) 80 (180) e 262. SPECIFICATIONS, Unit; kg (Ib) : Model 7 aa 8K200- 8 SK210LC-8 Item 4. Lubricant and water (Assembly of following |) 550 (1.270) < 441 Hydraulic oll 200 (440) « 4.2 Engine oil 20 (48) « 4.3 Fuel 310 (680) © 4.4 Water 20 (44) < (Chote) Marks * show dry weight. 272. SPECIFICATIONS 24 TRANSPOTATION 2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER (1) 5.65m (18f-6in) Boom+2.94m (9ft-Bin) Arm+0.80r» (1,05curyd) Bucket Mode] SK200-8 SK200LC-8 item ‘Width 600mm (23.6in) shoes 2,800 (Sf-2in) 2,990 (9it-40in) Weight 20,200kg (44,500 Ibs} 20,6009 (48,400 tbs) Unit : mm (ftein) 2280 (759) s7s0(i2s) mean woe cater), ese aey SECTION AA * marks indicate LC specifications, 282. SPECIFICATIONS 2.4.2 DIMENSIONS OF ATTACHMENT (1) Boom Type| item LengthxHeighbawiath eer m (fein) Weight kg (Ibs) 5.85m (18f1-6in) Boom 5:2" 22 1,670 (3,680) 1.87 x 0.67 (2) ARM AND BUCKET 2.4m (7ie10in) Arm + 0.93m »(1.22cusyd) Bucket 2.94m (9feBin) Arm + 0.80m >(1,05euryd) Bucket 3.5m (T1f-6in) Arm + 0.70m2 (0.82curyd) Bucket 475 x 0.9% 1.33 (157211) 5.29 0.9 x1.16 (aT ar2"11"%4') 5.88 x 0.9 1.08 (1935211"937") 1,740 (3.840) 1,680 (3,700) 1,880 (4,150) 2.4 m (T-10in) Arm 2.94 m (9ft-in) Arm 3.5 m (1Mft-6in) Arm 3.40 x 0.86 x 0.56 (CN232"10°% 110") 3.94 x 0.86 x 0.56 (1241x2401 10") 4.53 x 0.87 x 0.56 (14'10"%2'10°%1'10") Type Item LengthxHeighbWith LxHxW m (in} Weight kg (68) (3) Arm Type| Item: LengitntHeighbavviath LxHxW m (fein) Weight kg (Ibs) 41,020 (2,250) 4,044 (2.300) 4,260 (2,780) 292. SPECIFICATIONS (4) Bucket Type Hoe bucket LongthoeHeighbWidth Tg] 197 x 4.26 0.87 [1.87 x 120x107 | 1.37 x 1.26% 1.16 [1.97 x 1.26 4.33 Lew aexa2%2t07) | (eraser) | 4era'25a'10") | (4'et4'2sa'4") Weight ig (Ibs)]__ 520 (1,150) 630 (1,390) (640 (1,410) 740 (7,560) Bucket capacity mcuvd| 0.51 (0.67) 0.70 (0.92) | STD0.80(1.05) | _0.93(1.22) Type Hoe bucket [Slope finishing bucket LengthaHeighixWiath ig g| 137%1.26%1.16 | 1.26%0.90%2.20 LHW (aorxa'2'x3t0) | (artxatt'x7'3") Weight kg (Ibs)|__750 (1,650) 890 (7.960) Buoket capacity inv curyd| 0.80 (1.05) HD 0.82 (1.07) © Slope finishing bucket 2-102. SPECIFICATIONS 25 SPECIFICATIONS AND PERFORMANCE 2.5.1 SPEED AND CLIMBING CAPABILITY ee Meee $k200- 8 sK210Lc-8 ttem Swing speed imin= ep) 72.5 (12.5) Travel -speedi2- Favel speed (t-speed/2- a (miei) 3616.0 (2.2/8.7) speed) : a 7 Gradeabiity ‘% (degree) 70 (35) oe 252 ENGINE Eaghe meae EGRET Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-cherger ‘4-112 mmx 130 mm | (4.41 in 5.12 in) Type Number of cylinders—BorexStroke Total displacement I 5.123 L (312.61 ourin) Rated oulput/ Engine speed 144 KW (155 PS)/ 2,000 min* Maximum torque / Engine speed | 572 Nem (422 Ibfefty 1,600 mint Starter i T Hf 24. V7 5.0KW Alternator 7 2A VI12KW. ina 2.5.3 HYDRAULIC COMPONENTS. Hydraulic pump iz Variable displacement axial piston pump x 2 + gear pump x 1 Hydraulic motor (swing) ‘Axial piston motor x 1 BH Variable displacement axial piston motor x2 (with counterbalance valve) Control valve B-spool control valve x1 Cylinder (Boom, Arm, Bucket) Oil cooler Air-cooled type Hydraulic motor (travel) Double action cylinder 2.5.4 WEIGHT Unit: kg (Ibs) Fully equipped weight 20,200 (44,500), 20,600 (45,400) Upper structure 9,500 (21,000) < Lower machinery 7 (600mm grouser shoe) 6,730 (14,840) 7,130 (18,720) ‘Attachment 7 §.65m (18 ft-6in) Boom+2.94m (Stt-Bin) Arm 3,420 (7,540) | « +0.80m (1,05euryd) Bucket 2412. SPECIFICATIONS 26 TYPE OF CRAWLER Shape Shoe width mm (in) Sere eee Ground realy kPa Grouser shoe Socam |STD 2,800 (9'2") 45 (6.53) Lc 2,990 (9'10") 43 (6.24) ISTO 2,900 (9'6") 40 (5.80) le uc | 3,090(102") 38 (6.51) STD | _3,000(910") 35 (6.08) 46 LINKS| 800 (31.5) Lc. 3,190 (108") 33 (4.79) Note) Use 600mm (23.6") grouser shoes on rough ground (areas covered with racks and gravel). If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, ete.) 27 TYPE OF BUCKET ee stuck ge weer | TERI | Number] W or wio | “=#25UY| woignt ith side] Without side | oftace teu tooth | side cut mycurya) [P| cutter | cutter | “| SIE CUBE | ghover_| Ko (bs) Hoe bucket 0.39 520 | 70 (210" (26") | yes }9.51(067)) iggy) | 870210") | 77028 3 w (1150) 0.62 tl a 630 0.70 (0.82)} (5,99) | 1080 ('7)) 980(9") | 5 w YES | 360) {Covania Sty) 0.59 oe er) | w Yt 640 Meas) | (ory | P1608 10] 1.080 6) 5 eS | 410) {SE Asia STO} 1 | 0.80 (1.05)| 0.59 ane er w bo Side pin. | (077) | 2780 (910%) 1,080 (96) | 4 YES | 460) type 0.67 . : 710 | 990429] song) | 1990449] 122004 | 5 w YES | c's) 2-122. SPECIFICATIONS. 2.8 COMBINATIONS OF ATTACHMENT A oe Bucket ‘Available Arm Type [NeaPes capacity) — Struck | 2.84m (a-Si) Arm | 8.5m (THf-Gin) | 2.4m (7R-10in) Arm li im (curya) me (curya) _ (STD) |__+arm (Sh 0.51 (0.67) 0,39 (0.51) oO Oo O° 9.70 (0.92) 0.52 (0.68) ° 9° Oo [Oceania STD} 0.89 (0.7) ® A ° Hoe bucket 0.80 (1.05) (SE.Asia STO] 0.80 (1.08) 0.59 (0.77) ° A ° Side pin type 0.93 (1.2) 0.67 (0.88) A x Breaker - — oO ° Nibbler = = O° ° Note © Standard combination O General operation : Excavation or loading of sand, gravel, and clay A Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel) Prohibited combination : There are problems from the view points of strength and stability. + Use the attachments recommended by KOBELCO. The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibilty ARCAUTION Hf any other bucket, except for the backhoe bucket, is tuned over and used for excavation, damage to the arm and bucket may occur, 2-4132. SPECIFICATIONS 29 ENGINE SPECIFICATIONS 2.9.1 SPECIFICATIONS Applicable machine Engine model Type, ‘SK200- 8, SK210LC -8 HINO JOSE-TA Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger Number of cylindersBoraxStroke om (in) 4x 112 x 190 (4.41 x 5.12) Total displacement ce (cusin) 5,123 (313) Compression ratio 18.0 Rated output Maximum torque kW (PS) at min’) Nem (ibeft) at 194 (155) at 2,000 572 (422) at 1,600 mins High iting min 2,000 #30 Low idling rain 1.000 +30 Injection starting pressure MPa (psi) 50 (7.250) ‘Thermostat action erica 380 (170) 1963 (194) Firing order 7-3-4-2 MPa (ps) ‘Compression pressure 3.4-3.7 (499-537) at 280 at mins Fuel injection timing o Valve clearance Open Chose iébefore top | d0°after bottom Valve clearance Intoke valve | 0:8 mmatoosl | Ges oint | dead point Cxnaust vane | 048 mnatcoe |store bolton | 1Sraer top dead dead point point Starter capacity Vk 245.0 Generator capacity (Alternator) VxA 24x60 Cooling fan drive method 650 (25.6") x suction type 7 fans, V-belt drive, pulley ratio Crank / Fan= 0.89 Full evel 18.0 (4.76) Engine oi! quantity L (gal) Low level 18.0 (3.96) Total 21.5 (6.68) Dry weight kg (ibs) 580 (7,260) Fuel consumption ratio GikWen (Gipsy) 217 (160) Allowable inclination (Limited by E/G lubrication) Dimension (LxWxH) Rotating direction mm {in) Front / Rear and Right / Left: 35° 1,063 x 725 x 895 (@i-5.86in x 26 bin x 89.2in) Counterclockwise seeing from fiywheel side 2442.9.2 ENGINE CHARACTERISTIC CURVE (HINO JO5E-TA) Condition to be measured: The net value is indicated, measuring without cooling fan. ‘© marks show the rated point 2. SPECIFICATIONS, (N +m) 600 (kw) i rm 8 — 500 @ | e 120) 400 & T y i — 7 300 100) | 5 807 7 5 3 E | % 60}— llg/kW-h) 40 260 & é | Zz + aI 240 2 g 3 20 — 220 8 [| | | 4 — + 200 4 | | g | : O00 1000 400 1800-2200 2600 3000 ENGINE SPEED (min-1) Fuel consumption volume Fuel consumption rate X kW X Load factor (@) 0.835 X 1000 = PATON x tak x 0.835 X 1000 a: Standard load factor (0.70~0.80) w 29.6 a. Lh Fuel consumption in regular operation (load factor 0.70-0. 20.7 Linm23.7 Lih 2415 80)2. SPECIFICATIONS [MEMO] 2-16TABLE OF CONTENTS 3.4 BOOM eae a 3.1.1 BOOM DIMENSIONAL DRAWING... 3.1.2 BOOM MAINTENANCE STANDARD. 3.2 ARM. 3.2.1 ARM DIMENSIONAL DRAWING. 3.22 ARM MAINTENANCE STANDARD 3.3 BUCKET . Set 3.3.1 BUCKET DIMENSIONAL DRAWING 9.3.2 BUCKET DIMENSIONAL TABLE 3.3.3. LUG SECTION DIMENSIONAL DRAWING 3.3.4 BOSS SECTION DIMENSIONAL DRAWING. 34 3. ATTACHMENT DIMENSIONS 312 312 312 343 344 Book Code No. S5YN0318E013. ATTACHMENT DIMENSIONS issue Date of Issue “Applicable Machines Remarks jSK200-8 : YNT1-45001~ IS8YNO318E01 First ect A [erect wgust, 2008 | e<940LC-8 : YQ11-06001~ (ASIA, OCE}3. ATTACHMENT DIMENSIONS 3.41 344 BOOM BOOM DIMENSIONAL DRAWING SECTION X-X ig. 3-1 Boom dimensional drawing Unit: mm (fein) STD = 5.65M (181t-6in) BOOM ee 7 No NAME DIMENSION. ‘A Boomlength 5,650 (186") = B [Boom foot wiath 670 (26.4") ~ [Boom end inner with 347 (13.7") - D —_|Boom end outer width 482 (19°) - E__ [Height of boom cylinder rod pin 4,008.5 (3: - F Height of arm oylinder (head side) pin 1,203.5 (311 i G _|pistance between pins of boss R2,589 (8'6") - H [Distance between pins of bracket 2,829.5 (9'3") - | |Arm cylinder (head side) inner width 126 (4.96") = J Outer wicth of bracket on the arm cylinder (rod side) 468 (18.4") - mounting 1 [Boom foot pin dia 6 90 (354°) = 2 [Boom cylinder (rod side) pin dia 0 85 (3.35") - 63 Pin dia. of boom end. 0 90 (3.54") - d4__|Arm cylinder (head side) pin dia. 9 85 (3.35") = 3-33. ATTACHMENT DIMENSIONS 34.2 BOOM MAINTENANCE STANDARD (1) Clearance of pin and bushing on boom section ASIA eee Unit : mm (in) ‘Sandard value Clearance 1 sym} in | Repai tal Item Pin partNo. | a. aig | Pin aia ate S| Standard oe Service | Remedy tolerance| value | lit tolerance| level | +0020) +0217 | +0287 @ 90. |(+0,0008)| +0.0088)| (+0,0003) A | Boomtoot | YNO2B01719P4 eee (3.5433)} -0.020 | +0.071 | +0054 (-0.0008) | (+0.0028)| (+0.0020) 9 | 70243 | = 0.288 Boom cylinder 085 | 0.010)| (0.011) 8 ‘YNo2B01720: acao | (Head side) | YN0?°P1720P1 Jos a4gsy), OR, | +0.085 | +0.085 | More ou HH ( ) |¢+0.0083)] (+0.0033)| than | 25 teeing +o.020 | +0247 | +0267 | 20 | (on) [Nn Boom cylinder | | (+0.0008) (+0.0097)} (+0.0105) | (0.08) i © | (Rod sidey | YN°B01721P4 =0.020 | +0.093 | +0.073 685 | (0.0008) | (#0.0037)| (+0.0097) | (3.3465) + 0.030 | +0.252 | +0.282 ‘Acm oylinder (+0,0012)] ¢+0.0098)| (40.0111) © | Head side) | YN0E01889P1 -0.030 | -0.099 | +0.069 I (-0.0042} | (-0.0039) | (+0.0027) 3-43. ATTACHMENT DIMENSIONS OCEANIA Unit: mm {in) 1 Standard valve Clearance sym. i ue tem Pin part No. india. | PY" | standard | PP" | service | Remedy bol Pin dia id bie tolerance | value limit tolerance level +0020 | +0217 | +0297 A | Boom foot | ywoaBor7iget | 290, |(+0.0008) (+0.0085)) (0.0008) (3:5433)} -0.020 | +0071 | +0051 (-0.0008) | (+0.0028)] (+0.0020) i + 0.283 | +0289 ° Boom cylinder 088 (+0.010)} (0.011) -0.010 © | ead side) | YN02801720°1 | 2465) doote | *2085 | +0.085 | More Be {-0-00%6) | 40.0033) (+0.0033)} than | 25 ines soar | +0267 | 20 | (a) |Ponne Boom cylinder i (+0.0097)} (+0.0105) | (0.08) © | Rod sidey | YNO#BOI72IPT +0.020 | +0.093 | +0.073 9.85 |(+0.0008) (+0.0037)| (+0.0097) |(3.3465)| -0.020 | +0.230 | +0.250 ‘Arm cylinder (-0.0008)] (+0.009) | {+0.010) | D | load side) | YN02BO1722°4 | ogee -rboie I (+0.003) | (+0,002) 3-53, ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the boom eylinder installation section [La PL4 ea | xa] 2) SECTION B-B SECTION AA Fig, 3-3 Clearance in thrust direction on the boom cylinder installation section Unit ; mm (in) ‘Clearance X adjusted with shim Basic size fislori Eas) Pin length Sec item Remedy Siandard |Reparabie| Service No.| Size No.} Length vatue | ievel_|_ timit Boom oo AA [Boom foot tr LE84L| 05 (0.02) pur] 23! cee 676 | orless (327) i (26.6) 20 | 258 Bot ellen 105 (0.08) | (0.10) ep [Boom cylinder vt tp L419} 06-10 pil 241 (Head side) 411 | (0.02~0.04) (9.49) Upper trame aan Shim a adjust i t cc [Boom oxtiner POMevInEeT | 4) 443) | 6-20 | 30 | 40 pus) 738 | (Rod side) “) 468 | (0.02~0.08)} (0.12) | (0.18) (28.0) Boom Ls (18.4) [Arm oylinder ies pup [Armeylinder 7 ig L472) | 06-10 | 2.0 28 [ay 4) 260 (Head side) 726 | (0.02-0.04)] (0.08) | (0.10) (10.2) fee (4.38) 3-63.2 324 ARM ARM DIMENSIONAL DRAWING 3, ATTACHMENT DIMENSIONS SECTION Y-Y SECTION 2-2 Fig. 3-4 ARM DIMENSIONAL DRAWING YN12500904F1 (ASIA) Unit : men (fein) 2.94m (9f-8i S4m (91-8in) ARM) 3800802F1 (CE) Code] NAME DIMENSION |Code] NAME DIMENSION C_|Arm iength 2,940 (98")_| _N_|Bracket inner with 126 4.96") Distance between pins of boss : iia aepuaneelt R874 (84.4") | [Bracket inner width 111 (437°) Dit [LD of boss, 2110 (433°) | P [idler ink dimension 530 (248°) D2 |1.D of boss: 085 (3.35")_|_Q_|Bucket link dimension 610 24") BE loeb ease: 2105 (4.13%) | R [Relontbeween pins ofboss andl 3 7, 55 loenter Distance between pins of boss ae 7 Fs loa ereelat R2,169 (7'1") | dt [Pin dia 280 (3.15") Distance between pins of boss F in 5 epee R420 16.5") | 42 |Pin dia. 270 (2.76") Height between pins of boss and 7 7 & racket 665.5 (26.2") | 03 [Pin dia 085 (2.35") Height between pins of boss and : 7 Hl precket 3212.3") | d4 |Pindia 290 (3.54") K_[Arm top end boss width 325 (12.8") | a5 |Pindia 280 (3.159) [Arm link section boss width 323 (127°) M_[Boss width 342 (13.5°) 3-73. ATTACHMENT DIMENSIONS 3.2.2 ARM MAINTENANCE STANDARD (4) Clearance of pin and bushing Fig, 3-5 Clearance of pin and bushing on arm section ASIA Unit: men Gin) ‘Standard dimensions ‘Glearance No. ltom FinpatNo, | gig | Pindia. | Bushingid.| Standard | Repairatie| Senice | Remody tolerance | tolerance | value | _level_| _ limit 70.253 | +0333 Seeere (70,0100) | (0.0131) A. |Anm point 0.020 | +0.080 | +0.100 280 | (0.0008) | (+0.0031) | (+0.0039) 'y12802407P4 ae (3.1496)| -0.080 [+0284 | 70.204 [Bucket ink 0.0031) | (+0.0172) | (0.0143) (Bucket sida) 40.158 | 40.178 (10.0081) | (+0.0069) 0.253 | 0.313 ter tok on o70 0.0100) | (0.0123) © Connectespan}ywraR024061 E20) a osretiooa os of arm) (40.0076) | (+0.0078) o +0232 | 0.292 1p [Bucket ink ©) | (40.003) | (20.0715) (Idler link side) 0.060 | 40.161 | 40.161 Ha z (+0.0063) | (+0.0063)| 2.0 25 an eiieenaa (0.0024) | _¢ 2B02412P1 s0.338 | oe) | oon | sho py [Bucket oyinger 080 (40.0133) orpin (Rod side) (9.1498) 0.278 | 40.141 (+0,0109) | (0.0086) +0.141 | 40.308 ‘Bucket cylinder (10.0056) | (40.0121) © loca ane) |YN1280241304 paren Sta (0.0012) (90.0044) 0.030 [+0252 | 40.282 JArm cylinder 685 | (0.0012) | (+0,0089) | (40.0111) F Jerod side) |YNO2BOTEIOPT | 3 3455) 40.079 | +0.049 (0.0031) | (+0.0019) +0.020 | 40.202 | 10.312 ‘Arm foot nfo 090 | (40.0008) | (0.0118) | (+0.0123) i coon Pan |YNIZBO2415P1 | 13 5433)| 0.020 | 20.195 | 40.175 0.0008) | (40.0077) | (+0.0089) 3-83. ATTACHMENT DIMENSIONS OCEANIA Unit: mm fin} ‘Standard dimensions Clearance No. Item PinpartNo. [oo iq | Pindia. |Bushingid.| Standard [Repairable] Service | Remedy tolerance | tolerance | value | level | limit +0283 | +0313 Saas (40.0100) | (+0.0123) Ast ene -0.020 | +0080 | +9.100 80 | (0.0008) | (+0.0031) | (10.0039) peeeoeeioet (3.1496) | -0.060 40.220 +0.280 [Bucket ink 0.0024) | (0.009) | (40.0110) (Bucket side) 40.076 | +0.006 (+0.0030) | (0.0038) 0.285 | 40.325 ater ink fi 070 (0.011%) | 0.0120) © feomerosnennszeczwer |, “0.0112) | (40.0128 {+0,0050) | (+0.0050) © [+0205 | 0.285 [cet ine (©) | 0.008) | ¢eo.ot00) ter tink side) ~o01 | 19.083 | 0.043 Replace (-0.0016) {+0.002)_| (+0.0020) 20 25 YN12B02217P1 ¢ 40.285 | (0.08) | (0.01) | Pests o Bucket cylinder 080 (+0.0110) e (os side) (0.1496) so2a5 | 40.089 {0.010} | (0.0040) 10.089 [40.265 Bucket oyinder (+0.008) | (0.0700) & [Pym | yropozzters 0.088 (+0.0030) et +0.020 [so250 | 0.250 cylinder 285 | (0.0008) | (0.009) | (+0.0100) [Rod side) [*N07B04722P1 | ig 34555] 0.020 | 0.065 | +0.088 (6.0008) |_@0.003) | (0.0020) 0218 | 40.234 ‘Arr foot 990 (40.008) | (+0.0090) 6 omectes pad|ucrasozos¢r1 | |, 24, aera evanar (46.003) | (+0.0020)3. ATTACHMENT DIMENSIONS (2) Clearance of arm and cylinder installing sections in thrust direction SECTION C-0. SECTION E-€ SECTION F-F PL? LPs SECTION B-B SECTION D-D SECTION GG Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction 3-103. ATTACHMENT DIMENSIONS Unit : mm (in) Clearance X adjusted with shim Pin en feed (total of both sides) ee Sec. item Smee Remedy No.| Size | Sandard |Repaitablel vice imi] No,| Length value_| level 326 acm (1279)|1.0(0.04)| 2.0 A |Acm poi Pl eee puke || 228 | orless | (0.08) st : (12.83) 481 18.9) Link side ; Pen ee 2-8 |Buoket link wpe _ 7 PL Bucket ea 323 25 ater ink cc jae am | is | c27 Ave on | 8 |Pvs (eam connection eas - ) Bucket lnk Rod side 7 D-D | (ler tink Lincaise | Lt] 32 aor connection) eta (12.72) (16.8) os-1.0] 20 Shim Rod side 108 | 024-002} (0.08) ne adjust [Bucket link (4.13) bo uw -ment (Rod side) eae 11 (437) 105 exe [Pucketoyincer TPES || v4.13) pis) 28 (Head sice) reat 111 (0.25) «sr | 0620] 30 40 720 | o.oe-a08)) (0.12) | (0.18) R ecg [Armoylinder ease | 1272) pie] 260 |(Rod side) ty 126 (10.2) (4.98) cm ae (1346)| 05 | 1.0 25 505 6.6 Jarmt oe boom | | 8a | 002) | oa | 10) |) e199) (13.66) 3-113. ATTACHMENT DIMENSIONS 3.3 BUCKET 3.3.1. BUCKET DIMENSIONAL DRAWING (1) Hoe bucket Fig. 3-7 Bucket dimensional drawing No. NAME: No. NAME: ‘A [Distance between pin and bracket G [inner width of bucket bottom B [Distance between bucket pin and tooth end H [Bucket outer width of front side C Inner width of bucket top end 1 |Pitch between teeth D [inner width of tug fo |Pitch between teeth E__[lnner width of bracket dt_[Outer dia. of bushing F _ [Outer width of side cutter 02 [Pin dia, 3.3.2 BUCKET DIMENSIONAL TABLE Unit: mm (fin) Tye Hoe bucket (SE. Asia S10) opis) 0.80 m* ee 0.54 me 0.70 m* 0.93 1.08 ewe) | oper) | (OST euya)) | (OS2euyd) | (1.24 cua) Side pin type PartNo | YN61B00272F1 | YN61B0025eF1 | YNeiB002e7F1 | YNOiBOOZSGR1 | YNeTBOOZEErI A Ra30 16.9") © © € © 8 Ri,440 (49°) © = e © ¢ 1,008 (33") © Tie (28°) 925 (364°) 1176 (407) D 399 (15.7") © © © e E 327 12.9") © a © © F 1.187 (8) © 868 (34.2") 7,073 66) 1330 (44°) G 863 (34") < 572 (22.5°) 765 (30.9") 7,036 (95) x 7.087 (36°) < 76 (30.2") 979 (38.5") 7.230 (4) 1 224 (6.82") © 300,(11.8") 203 (7.99") 266 (10.5") 0 224 (6.82") = 300 (17.8°) 203-(7.98") 286 (10.5) at 095 (3.74) © e © © 2 280 (3.15") = © © & 3-123. ATTACHMENT DIMENSIONS 3.3.3 LUG SECTION DIMENSIONAL DRAWING y 8 | Ba i q | | ‘i oo x an a Boss a 1 vyastB01002°1 139) Apply ust prevention o : » / oF} ON go | i a | ; cL \ Boss SEM lveinstateg MSeVtthis pin tush with surface ye61801002P1 ‘at shipping) SECTION X-X DETAIL B Fig. 3-8 Dimension of lug section Unit : mm (ft-in) g 2° g | als gs 2 Cepacty of BES aE ede e/ele/$ ‘Type of —_ PatNoot js }/2]/s | 8/3 )/S] 8/3) 38) 2 puceet | BERL | ket ge ;e;e/e/e]elel sigs ‘cuye) fre;e)2le)s)eie)a)é eis i|2l|Flé isle slai 8 aAlepi[olelri[eo[Hiuluin [SE. Asia STD] bat (nas) | uesa00arar | [Oceania ST] | | Hoe 0,80 (1.05) YN61B00258F1 | ps0 | 25 | 995 | 13 | e180 25 16170 | 36 | 140, bucket | PT LB | oben] Fy SE] FOR) | 1016 | 0 B8ey BE [coy els }o.s1(0.67) — | YNetBooze7F4 | 0.70 (0.92) YN61B00280F1 | o.93(1.21) — |YNetBo0288F1 | | | | L 3-43,3. ATTACHMENT DIMENSIONS 3.3.4 BOSS SECTION DIMENSIONAL DRAWING A go seer) Fig, 3-9 Dimension of boss section Unit : mm (ft-in) Wwe] Comes | oma | pes orf mae | PenMeet | re | on | yp Foc | oof e | F | oo | a T | 1 bucket] m’ (cue) ISE. Asia STO) 25 0.80(1.08) | YNe1B00272F1 [Oceania TD] 0.20 (1.05) | YN61800258F') YestBor602°1 0510.67) | ynexeco287F1 0.70(0.92) | vnereocze6r1 0.93(1.21) _[yne1B00288"+ Hoe bucket a fuss} ss] a | oe | ow | os 319} 4157 | 4399 | sry | (150 | (oes | 5124] (nosey 3-1411. TOOLS TABLE OF CONTENTS 11.1, TIGHTENING TORQUES FOR CAPSCREWS AND NUTS 143 11.2, SCREW SIZE. ange 145 41.2.1 CAPSCREW (BOLT) 115 11.22 CAPSCREW (SOCKET BOLT) ...... att 115 41.23 SOCKET SET SCREW..... enn eB 11.3 TIGHTENING TORQUE FOR HOSE AND FITTING 116 11.3.4 JOINT (O-RING TYPE} oo ene 116 14.32 HYDRAULIC HOSE (30° FLARE TYPE) 116 11.3.3 JOINT (ORS TYPE). edt . 116 11.34 SPLIT FLANGE fae seninnne 1B 11.4 TIGHTENING TORQUES FOR NUTS ANDO SLEEVES. 7 445 PLUG felt 118 11.5.1 PLUG FOR HYDRAULIC PIPE JOINT. 7 118 11.5.2 PLUG FOR HYDRAULIC EQUIPMENT 119 11.6 SPECIAL SPANNER FOR TUBE vn 7 1444 417 SPECIAL TOOLS.....cn ms nme ese AZ 14.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......14-14 11.9 SUCTION STOPPER. a . 5 11-15 14.8.4 COMPONENTS. . sees AB: 119.2 DIMENSION oo 11.8.3 APPLICABLE MODEL 11-15 14.10 COUNTER WEIGHT LIFTING JIG laa aoc 11-16 11.11 UPPER FRAME LIFTING JIG... ent 1-17 11.12 ENGINE MOUNTING PEDESTAL... . 14-18 14.13 TRACK SPRING SET JIG ... #7 7 fs 14-19 Book Code No, S5YN1118E01 14-411. TOOLS Issue “Date of Issue Applicable Machines “Remarks _ First edition August, 2006 SK200-8 : YN17-45001~ ISK210LC-8 : YQ11-06001~ SSYN1118E01 (ASIA, OCE} 11-241.4 11. TOOLS TIGHTENING TORQUES FOR CAPSCREWS AND NUTS Tables Tablet1-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given. Overtightening cf bolts may result in a twist-off and a fracture under load. Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques. Tabie11-1 Tightening torque for metric coarse threads (not plated) Unit : Nem (lbfeft) classification 487 7 10.97 Nominal size |No lubrication| Oil lubrication] No lubrication] Oil lubrication] No lubrication] Oil lubrication ie 7 44x05 | 37404 | gext0 | g1soe | 174s18 | 14.7418 204) | (27403) | (7140.7) | 6.0206) | (12.813) | (10.8#1.1) Me paizg | to7et1 | 9.0209 | 235820 | 19.6120 | 422839 | 25.9239 (7.9208) | (6620.7) | (17.381.5) | (14.681.5) | (31.1229) | (26.082.9) Mio Pets 21.642.0 | 17.9818 | 46.1249 | 39.283.9 | 83.438.8 | 70.626.9 (15.981.4) | (13.2813) | (34.0836) |_(28.942.9) |_61.5%65) | (62.185.1) wiz pays | 96939 | stasze [ 7oae7e [osreb | tasers | 12iei2 (26.822.9) | (23.242.4) |_(68.685.8) | (49.2851) |_(10511) | _(69.288.9) an 87.9259 | 49.0949 | 126818 106210 | 226820 | 191319 __| 42.7244) | (36.1836) | (92.980.6) | (78.227.4) | (167218) | (141814) Naaeeeet 86.386 | 74.5469 | 191820 veisté | 343eg9 | 284820 | (05.146.5) | (55.086.1) |_(1ate15)_|_(119#42) | (253429) | (209821) Mis 122412 103210 285429 226420 461448 402239 (90.038.9) | (75.887.2) | (195321) | (167215) | (955296) | (297429) ieneeeetpeae test? | tadeta [373239 | 314229 | 667469 | 559559 (ia7s13)_| (voss10) | (275829) | (232421) | (ao2e5t) | (412%44) 22 226220 192420 00849 | 422839 902488 755878 (167215) | (142415) | (@eges6) | (attez) | (esses) | (557258) Meee 204229 | 235129 | 637209 | 620249 | tie0st18 | 941z98 "| rz) | (73s24) | a7oss1y | (a8aes6) | (856887) | (694272) iat agia39 | 363x990 | oats98 | 7e5e78 | 17003167 | 13702137 (318#29) | (260s29) | (eoae72) | (S84#58) | (12508123) (10104101) aot 586259 | 490249 | 12852127 | 107es108 | 23008235 | 19402196 (434244) | (961236) | (948294) | (796280) | (17002173) | (14902145) ron 794s78 | 667869 | ‘17262177 | 14512147 | 31108314 | 26102265 a _ (686258) | (492851) _| (12702131) | (1070#108) | (22908232) | (19302195) seed 7030208 | 863388 | ve6ss186 | a010e402 | 33602333 (7e0e72) | (637465) _| (16408167) | (13708137) | (29604297) | (24808246) 11-311, TOOLS Table11-2 Tightening torques for metric fine threads (not plated) Torque value Unit : Nem (Ib) Classification 487 TT 409 Nominal size _ [No lubrication] Oil ubrication|No lubrication] Oil lubrication| No lubrication] Oil lubrication Me pao | Msett | Obe10 [245220 [ 206120 | 441239 | 97.983.9 (9.3408) | (7.00.7) | (18.121.6) | (15.281.5) | (2522.9) | (27.5#2.9) Mio peta5 | 226820 | 187218 | 4atsa9 | 412439 | a7ce8e | 73.569 (16.7218) | (13.881.4) | (95.543.6) |_(90.942.9) | (64.4265) | (54.225.1) Miz Pei2g | 392839 | 22229 [ e62s88 | 71.0260 | 154216 129813 (28.9429) | (24.6821) | (62.9465) | (52.885.1) | (114812) | (95.280.6) wie parg | 922288 | 775278 | 196820 169817 363239 304829 (68.046.5) | (67.2258) | (145215) | (126813) | (268820) | (224221) hoes 186219 155216 | 402430 333229 | 726269 |” 608269 (i37et4y | (is4et2y | (297820) | (24x21) | (635851) | (448244) toateeeepue 314228 265229 | 686269 s60n59 | 12402118 | 1030298 (22421) | (1gss21) | (606851) | (a20eaay | (e15387) | (760872) heats 627359 saot49 | 13002137 | i167e118 | 25008255 | 20808206 (470244) | (991296) | (10302101) |_ (#53287) | (1840%188) | (15901152) Hegemon 859288 706270 | 1e60st@6 | 18508155 | 3360x934 | 27908275 (ezge65) | (62te52y | (93708137) | (11408114) | (2470#248) | (20608203) Waeeeeipes yo7os108 | 8eze8e | 23308226 | 19402196 | 42002422 | 35008363 (7eoxe0) | (esese5) | (17202167) | (14302145) | (3100#811) | (25804260) 11-441. TOOLS 11.2 SCREW SIZE 41.24 CAPSCREW (BOLT) Nominal [8mm | Nominal [8mm screw size sorew size | 7 Tool size 7 Too! size “Me | 10 "M36 55 MB 13 a2 cy M0 7 Mas 70 Miz 18 Mae 75 (4) 22. MSE 85 M16 27, (M60) 90) (Mia) a7 Med 95 M20 30. (M68) 100) (422) 32 M72 105) M24 36 M76 110 (M27) at M80 115 M30 46 ath 11.2.2 CAPSCREW (SOCKET BOLT) Nominal Simm] Norinal [Bm er 820 en | OS ra ia) 28 | Wao | a (M4) 3 (M22) 7 d {MS) 5 M24 19 M6 5 (M27) 419 MB é M30. 22 Mio | 8 __ M36 27 wiz [40 | wae a2] wig [easy | MiG | 14 M48 36 (wt6) 14 MSZ 36 Sunes 11.2.3 SOCKET SET SCREW Nominal [Bini] Nomnal [Bam seen 6 ogi sae [SCM S2®| ool aze é w25 [127 | wea we [ 48 | Mio 18 we 2 [wig] ws | 28 | te “| 6 5 M6 3 M20 70 | ise Peay 11-511. TOOLS 11.3. TIGHTENING TORQUE FOR HOSE AND FITTING 44.3.1 JOINT (O-RING TYPE) Size Wrench Tightening toraue PA ia Neale o-niNe opine 178 4 4722 (1321.5) / 7 14 19 3642 (2787.5) LL: 2, 7 3/8 22 7a (5524) ae " 5 1g —_| 3/4 36 16220.8 (11927) _ 1 41 25529.8 (18847) HYDRAULIC HOSE (30° FLARE TYPE) Size Tightening torque (PF) Wrench(mm) site A 178 id 7512.0 (1181.5) 14 79 2084.9 (2120.8) 3/8 22 4924.9 (9613.6) 1/2 27 TeE4.9 (5843.6) 3/4 36 11620.8 (6727.2) ace 41 137215 (101211) #4 7 11.3.3 JOINT (ORS TYPE) Tightening Torque Unified screw size | Opposing flats ightening Torqu: CONNECTOR O-RING FITTING Unified screw size | Nem (loft) i y) 6 177216 (131813) 41 206226 (162216) 47116612 UN 46 206: east) NUT i 11.3.4 SPLIT FLANGE ___ Tightening torque Nem (Ibi) FUNGEHEAD | CLAMP HALE size | Standard pressure | 534,| Hipressure | ao ta / series eg series cae f 20.6 MPa 41.2MPa 37a | 35.8856 (2544) [WHO | 90.5256 esa) | wi ny j 7_| 42.4256 (3124) [M10] 62.2856 (4624) | M12 1 « |ASS \ “Viral “55.147.1 (4185) | wo |__93.528.4 (6926) | Mid || ce 11/2] 70684 (6286) | mi2 | 169811 (12528) | M16 I 2 81.948.4 (6086) | M12 | 22411 (20838) | M20 So 1-611. TOOLS 11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES ‘Table11-3 indicates standard tightening torques applicable to cases where no particutar note is given. Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe connections, Always lighten nuts and sleeves to proper torques. Tablet1-3 Working Tube size | Opposing] Tightening torque Manufacturer's name| Pressure OD xthickness | flats Nem (Ibft) i MPa (psi) mm (in) (HEX) mm 10x15 | 9.8 (3627.2) (osesvoose) | 1 49:020.8 (9647-2) 2152.0 | 3212 (8728.7) (0.591x0.079) a ited teed 21825 : ie Nippon A.M.C. 29.4270) | io-r0970.098) 32 1a7e15 (190811) 2223.0 16422 (16081 (0.866%0.118) = beeen ett 226x4.0 275827 (2008: coon at 5427 (200820) 285%5.0 #44 (3308: Ihara Koatu 29.4 (4270) (1.3600.197) 55 saveae (930839) 7 SLEEVE san NUT as| So | WAL. 4 Tube size Paris No. Tube size | Opposing Paris No. ed Thara Koatu | Nippon AMG ed flats thara Koatu_ | Nippon AMC. a (HEX) mm é 293806000 = 8 14 2F93N06000 = a 293808000 = 7 Zr93noeo00 [ 40 ZFS3S10000 | ZA93S10000 19 ZF93N10000 | ZAG3N10000 42 ZF93S12000 = 22 2F93N12000 = 18 2F23815000 | ZAe3S15000 | 27 ZFO3N15000 | ZA93N15000 18 2F93818000 | ZA93S18000 ae ZF9anie000 | ZA9SN18000 22 2F93S22000 | 2A93822000 [ 36 2F93N22000 | _ZA93N22000 28 ZF93S28000 | ZA93S28000 a ZF9aNza000 | ZA93N26000 32__ | zFe3s32000 = 50 2F93N32000 = 38 2F93835000 | ZA93S35000 55 ZF93N95000 | ZAS3N35000 38 7793838 = 60 ZF93N38000 i 1-711. TOOLS 11.5 PLUG 11.5.1 PLUG FOR HYDRAULIC PIPE JOINT (1) Cap nut (Joint plug) (2) Plug (Tube plug) Sleeve Nut Type joint body (3) Nut dscrew i Applicable tube Cap nut parts T sorew lOpposing flats No. BLA ZFe3HO6000 | Mi2x15 14 | 14 ZF83H10000_| M16.x 1.5 3HoBoo0 _| Mt 2F83H12000_| M18 x15 ZF@3H15000_| M22 x 1.5 ZF83H18000_| M26 x 1.5 ZF83H22000_| M30x 1.5 ZF63H28000_| 36x 1.5 ‘Applicable tube | Plug parts No. O.D'A 6 2F63P06000 8 ZF83P08000 40. ZF&3P 10000 2 ZF83P 12000 15__ | _2F83P 15000 18 ‘ZF83P 18000 22 | _ZF83P22000 28 ZF83P28000 ‘Applicable tube | Nutparts No. | d screw |Opposing flats O.D:A | 6 __| 2FOsNO000 | MI2x45] 14 | ZF93Nosooo | Maxis] 17 jo | zFeani0000 [wiex ts] 19 12__| 2F9ani2000 | Mi8x 15] 22 78 | 2Fosnis000 | Me2xis| 27 78__| Zroaniao00 | M26xi5| 32 22 ZF93N22000 | M30 x 1.5 6 26__| 2F93N26000 | waex15| 41 32 __| 2FOsNS2000 [WAZ x15] 50 35__| ZF93N35000 | masx15| 55 ~~36__ | 2F93n36000 [M48 x15] 60 11-811. TOOLS 11.5.2. PLUG FOR HYDRAULIC EQUIPMENT (1) PF screw Plug paris No. |2 mm] O-ring paris No. | Nominal O-ring E72x04000 | 19 | Z012P07100 | 18 Pit E72x06000 | 22 | Z2D12P01400 18 Pia ‘2E72x08000 | 27 | ZD12P01800 4B P18 2E72x12000 | 36 | Z2D12P02400 1B P24 PF screw Ze72x16000 |_41 | 2D12P02900 18 P29 (2) PT screw B PT screw PT screw| Plug parts No. Bmm rie | Zee2To2000 | _5 pri | Ze82T04000 | 6 PT3/8. 2E82T06000 8 pri | zee2toso00 | 10 praia_| Ze82T12000 | 14 pti | ze62T16000_|_17 PT114 | ZE82T20000 22 prise | zee2t24000 | 22 (3) Plug for (F) flare hose PF screw PF screw] Plug parts No. [8mm pra | 2442272001 | 24442272602 PR _| 24047272603, . Praia _| 2444z272004 Opposing flats B PFt 24442272805 PF screw) Plug parts No. | E mm | F mm. PFi4 | 244az2720D1 | 14 | 19 praie_| 24a4z272002 | 17 | 22 pet2 | 2aaaza72903 | 23 | 27 pra4 | 2aaqz2720D4 [27 | 36 “Opposing pe1_| 2asazzr2005 | 36_| 41 fats E Prt ia | 2agaz272006_| 40 | 50 11-914. TOOLS {4) Plug for ORS joints Male ‘Sorew size | Applicable ‘Opposing | O-ring [Nominal A hose 0.0 | PUG ParSNO. pus iex| parts No._| O-ring 114UNS | 021.7 |YNOTHO1001P1, 27 _|ZD12A01600| 1BAt6 13/16-12UN| 927.2 |YNO1HO1002P1) 36 |ZD12A01800| 1B A18 17/16-12UN| 634.0 |YNO1HO1003P1) 41 | ZD12A02100) 1B A21 Female Screw size | Applicable’ Opposing A | tube 0.0 | Plug parts No. inate (HEX) st A 1-14UNS 921.7 |YNO1HO1004P1} 32 13/16-12UN| 027.2 [YNO1HO1005P1) 36 1 7/6-12UN| 934.0 [YNO1HO1006P1} 41 (6) Pig for hal clamp 40H For standard pressure : 20.6 MPa (2990 psi) Plug O-ring Size} parte, [CMM] D mm mm |Hmm part No. sre |zer2008000| 38.10 | 1748 S59 | aszoi02 314 |Z£12012000| 47.63 | 22.23 | 188°} 11 jzD12P02600 + |ze12@18000| 52.37 | 26.19 |88:75°| 11 212P03400 4114 2€12020000] 58.72 | 30.18 |“.58") 11 'z012P03800 For high pressure : 41.2 MPa (5970 psi) Plug T ‘O-ring Size | partno, [ORm|Dmm| Emm Hmm) anno 112 |ze13008000] 4.49 | 10.24 |*857"| 9 [2aaszeato1 314 |2€13012000| 50.80 | 23.80 |S.) 11 |z12P0z600 1 |2E13Q16000] 57.15 | 27.76 | Se/e> | 13. [zD12P02400 1114 2613020000) 66.68 | 31.75 |“4,5&| 15 |zp12Pcse00 14-1011. TOOLS 11.6 SPECIAL SPANNER FOR TUBE Applicable tube diameter Part No HEX (mm) Drawing of a special spanner mm (in) mm (in) 182781, 2 16 (0.881) | 24217160 ar oe0) anit sr) 127 (0800332) 701210 gt 18 (0.709) | 2421T138 32 Pane, woe Boo) ee = ox OE ago) 2F SO 800335) 702.76) 420.9) TA ges oH 22 (0.866) 24217130 36 (0.908), eran NEEL [Bessy ne 12740500332) 7091429) Seopa 28 (1.10) 2421715 at dl ne ae Ne. HEX 2043.15), 10014.29) gest] 28 (4.10) 24217234 46 ok Or} parteno. FAH sa) a 19.08% (07603) 80(3.18) , 1004.20) Fe5(0 045) | 32 (1.26) 24217232 50 od [Poe nee" 119.087 (0.76038) 816,19), 9003.58 35 (1.38) 24217314 55 ad exes 11-1111. TOOLS 11.7. SPECIAL TOOLS Tablot1-4 No.| Tools name [Tools No ‘Shape Applicable % [E Allen wrench | zrooq10000 | 5 x Pump 1 Nominal oe eee B:10,C:11.3 vas. L Commercial oo angth (Lt) - ut ength = Requied length 40 (1.87°) - 10 (0.98") = 30 (1.18°) ‘Spanner or 2 socket |General toots Heh Nominal 8 : 17 3 | Spanner | 2712A36000 Swing motor Nominal $ : 36 AB port 81 (3.19°) - 16 (0.63") = 65 (2.56") ‘Addiional M10 X22 forti0 Bye bot 7 Plug 2€72X12000 Jor M10 eye bol For slinging the PRS/4 swing motor Pron ‘O-ring 410 Eve bot Eye bot | 2891C01000 : For slinging the One. or swing motor commercial & equivatent : Flare hose ¢ t Fm T ! iB Eye bolt Pl i 2F83P22000 (Nominal wed 22 aeinrant | Fare tose Eye tor | 2897000800 ve 2F93N22000 ¢ iasie: Nut ' CAdationas i treading for Me Eye bot 11-12Tablet1-4 11. TOOLS Me Eye bolt 8X 18 Plug YNOTHO10011 Esko + reading Norninal \ 7 | 4414UNs | Flare nose Eye bot | 2891C00800 | _AAAUNS a MB Eye bolt | | MB x18 ‘Aadtiona Plug | YNotHot002e1 threding NX Nominal 8 | taner2un | y Flare hose Eye bot | 2S91C00800 ee Piug 2E25F 08000 i‘ PrI2 For slinging the Coupling swivel joint halt TORX driver seems For instrument 10 proof) — | Point shape renal eevee 730 | \ (For M6) 11-1311. TOOLS 11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND (1) For general use ue Manufacturer ae Loctite | Three-Bona | Fou tow #242 1 300K | strongth Screw locki crew locking aa ia Middle compound strength High ial 1908 | strength Sealing commons | #585 te15 | Sealing (2) For specific location No. |__Use | Manufacturer] Name Equivalent Aoplicable (Manufacturer; Loctite) #1904 |Anti-seizure loyiinder Three-Bond |#1218 gray #8609 Swing motor #1211 white #52011 | wing motor fe r3038 leon [Main pump (Manufacturer; Theee- Bond) Beate #222 # 134an Main purnp 1 & #277 [#1907 Pilot valve adhesive (Manufacturer; Three- Bond) Loctite Parmatexosd |v 1121 Hydraulic ol tank Sumitomo Chemical Co., {cyano Bond PO-t Hose Ls Shel Shell Alvenia EP2 |New Molyknock Grease 2 |Swing bearing grease bath petroleum 11-1411. TOOLS 11.9 SUCTION STOPPER 41.9.4 COMPONENTS No. | NAME PARTS No. [QTY — SUCTION STOPPER ASSY [24100P076F2| 4 [ROD 24207486001] 1 Sines 2_[NUT zn16co8007 | 1 — 3 [COVER lataTat2302| 1 It 4 [O-RING |4579106 1 | 2Nut 7 3 cover 4 O-1ing Fig. 11-1 Components of suction stopper 11.9.2 DIMENSION 20 cal eet T *e 113 (4.45") M8 NUT 7 _Iil os 0.3155 dl ; g a Ty & fags e og s| ge, es e & 3 @ Bel Sl 8) | Grsacn et “| RRO. Sorry | “ie (4.25") COVER Fig. 11-2 Dimension of suction stopper 4193 APPLICABLE MODEL NN Applicable xclale wl model slzlele/S)S\/8le/#l Ble ~ S18) S/S /S/8/2/28/8/ 818/818) [roto 9-1 515 | 5151515151551 81515 | 8 | | 2a100Po7er2 e[olofofofofolofolofofolo] 11-15,11. TOOLS 11.10 COUNTER WEIGHT LIFTING JIG (1). Standard eye boit Fig. 11-3 Eye bolt 11-16 Size] Vera MB [mao (ate 18 18 PartNo. | atin | j ant | Meta | Z5eiG00800| 80(176) | 2891001000] 150 (331) | M12 22. 2891001200 220 (486) Mi6 27 2891001600| 450 (982) [zo 30 2391602000 | 630 (1390), 24 38 891602400 950 (2080) [so 45 2891603000 | 1500 (3310) use| 55. 2391603600 |2300 (5070) aa] [maa 2400 (7480) [4500 (9820)|41. TOOLS 11.11 UPPER FRAME LIFTING JIG aa ra 7) | | 130(8.12°) 65 (0.748")19 80 B15) Qty :2 sets Material : Mild steel Fig. 11-4 Uppor frame lifting jig 1-1711. TOOLS 11.12 ENGINE MOUNTING PEDESTAL 245 (2.65) Material : Wood Unit ; mm (inch) 6 4 ar Als =H g TT] alts z z é ® 744 (29.3) 409 taf 945 (97.2) 5 °. 1 6 215 500 toa Tay 2X 1 piece 4X1 piece 1X tpiece 400 (157) 570 26.4) EE 430 (185) +s dig ayer a | boca a a tT a Es ras q ‘150 \) 3 @ als 2 leo 3 124(0.95) a" | 2 124,098) 5X1 piece 3X1 plece “670 (26.8). foo e572) 2 | 6X8 ples Sl ect fe 4049.93) Ee Tao OY 0.30, Fig, 11-5 Engine stand 11-1811. TOOLS 11.13 TRACK SPRING SET JIG M30 _ Retainer nut S~ Retainer plate 700 380 Base Fig, 14-6 Track spring set jig 11-1911. TOOLS [MEMO] 11-2012. STANDARD MAINTENANCE TIME TABLE q ‘TABLE OF CONTENTS 12.1. STANDARO WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4 12.2. ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) cnn . vanes AB: 12.2.4 MEASURING METHOD 7 ne 1246 12.2.2 WORKING CONDITION... ene 2A 42.2.3 STANDARD TIME CONSTITUENT. Fl 12-48 12.24 MEANING OF WORDS IN USE 1247 Book Code No, SSYN1218E01 12412, STANDARD MAINTENANCE TIME TABLE Issue “Date of Issue Applicable Machines [_____ Remarks [SK200-8 YN11-45001~ SBYN1218E01 First edit ju eee August, 2006 SK210LC—8 : YQ11-06001~ (ASIA, OCE) 12-212, STANDARD MAINTENANCE TIME TABLE PREFACE, (1) Working Conditions 1) Workers More than one worker shall be ‘st class service technician (having five years or more of field experience and having received training in the operation). 2) Equipment Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The ‘maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for specific self inspection activities. 3) Place ‘Aflat land where work may be performed and to which a service car or a truck crane is accessible. (2) Range of standard maintenance time i 1) Standard maintenance time=Direct maintenance timexPreparation time 2) Direct maintenance time : Net time actually spent for maintenance 3). Spare time ‘Time needed to move machines for service, prepare safety operations, discuss work, and process the needs of the body. (8) Extra time (not included in the standard service time) 1). Repair time Machining, sheet metal, welding, melt cutting, folding and extracting tolls, servicing parts, and painting. 2) Items excluded from service time because of uncertainty in time Receiving 2 vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults, diagnosis, and inspection. 3) Indirect time Time for; field work, preparation of necessary paris before leaving for work, return for field work, waiting time because of user's convenience in the field, paper work after returning to shop, and preparation of bills. 4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately. 5), Separate calculation : The operating time for service cars, trucks with a crane and erane trucks. (4) Applicable machine for estimation of standard maintenance time 1) Standard machine 2) A.well maintained and controlled machine with a standard combination of attachments which is used in a general environment. 12-312, STANDARD MAINTENANCE TIME TABLE 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR (1) Standard maintenance time table 1) 2) 4) 5) Units of working time : 6 minutes = 0.1 hour Calculating method of standard maintenance time Maintenance time=Working timexNumber of workers (Working time=Maintenance time+Number of workers) When more than one operation is going on ‘Add each standard service time. A pure time (readily started) is given exceptcovers easily removed by hand. Assy works include the following works marked with black dot « OIH : The removing and attaching time is not included ‘Abbreviations in the table. AIC Air conditioner cv Control valve on Over haul ASSY — : Assembly cyl Cylinder SOL: Solenoid ATT —: Attachment BIG Engine sw Switch BRG Bearing Fhose : Flexible hose v Valve (2) Classification of working code No. Group Remarks Ee 01 [Attachment Indicates installing, removing, replacement anc overhaul 7 02 |cab & Guard 03 [Swing frame 04 [Travel system 95 [Etestie Indicaies the instaling, removing and replacer ent of single items lequipments i 09 (|E/Grelation Indicates overhaul of the single engine. ot |(Materiais prepared by manufacturer ) (8) Conditions for standard service time of the engine 1) 2) 3) Tools designated by B/G maker are used Genuine parts are changed Correct working procedures are observed. + The time required for works specified in this Chapter shows the total time for maintenance. 12-412. STANDARD MAINTENANCE TIME TABLE croup Location MORO yi Remarks is (00 [Bucket relation ‘See 3212 PEE IEEE 01 [Bucket ASSY Deizenvatacn| 1 pe. [Include adjustment. 06 02 |+ Bucket ataching and detaching postion | Preparation} 1 pc. on 03 |+ Bucket attaching pin Betachiatacn| 1 Include stopper pin. on 04 |+ Bucket drive pin Detachiatach| 1 on 05 |+ Bucket sling and movement Preparation] 1 pe. 02 06 | Bucket (single) OI | 4 pc. | Notinclude attaching and detaching | 2.4 07 |+ Tooth Replace | 1pc. | 06 08 |+ Side cutter Replace | 1 pe. 12 09 |+ Bushing Replace | 1 po. 06 10 [Arm relation [See 92.1.3 11 [arm ASSY SESE Detachiatech| 1 po. 5 12 12 |+ Bucket cylinder attaching and | Preparation} 1 po. | 04 detaching position and piping 13. |+ Bucket cylinder rod pin Detachattach | 1 pc. {Include stopper pin on 14 |+ Bucket cylinder head pin Detachiatch | 1 pc. |include stopper pin on 18 |+ Bucket cylinder assy Detactiatach | 1 pe. on 46 |+ Arm cylinder rod pin etaeriatacn] 1 pe. |Include stopper pin ot 47 |+ Boom top pin Detzchiatiacn| 1 po. [Include wire stop pin. o4 i 48 |+ Arm sting and movement etacniatach) 1 pe. 02 2 [30 [Boom relation [Seoda.1.4 5 [31 [Boom ASSY T Betcnatacn| 1 pe 14a 32 |+ Boom attaching and detaching posiion| Preparation] 1 pe. on 33 |+ Boom cylinder temporary slinging Preparation} 2 pes 02 34 [+ Boom cylinder rad pin Detachiatiach | 2 Include two stopper pins. | 02 35 |+ Boom cylinder piping Detactvaticn| 2 pc. 02 26 |+ Arm & bucket piping Detachiatacn| 1 pe. 02 37 |+ Boom assy temporary slinging | Betachvatacn | 4 po. | o1 38 |+ Boom foot pin Betachitiacn| 1 [Include stopper pin. 02 39 |+ Boom assy slinging Detachiatacn| 1 po oz 40 |/Arm cylinder attaching and detaching | Detacnatach | 1 pc. 04 41. |+ Arm cylinder piping Detechisticn| 4 pe. 02 42 |» Arm cylinder head pin Detactvatach | 1 pc. |Include stopper pin on 43 |+ Arm cylinder slinging Cetachatacn | 1 pe. on 50 |Boom oyinder attaching and detaching | Detactattach| 2 pes. 07 51 |+ Boom cylinder piping Detachatach | 2 03 52 |+ Boom cylinder head pin Detachiatisch | 2 pes 02 53 |+ Boom cylinder slinging Detechiattacn| 2 02 60 |Bucket cylinder oir 1 36 61 |+ Pin bushing Replace | 1 _ | include seal. 12 70_|arm cyindar om 1 36 12-512, STANDARD MAINTENANCE TIME TABLE Group Location Moree) Unit Remarks a 71 |» Pin bushing Replace | 1 set include seal 12 ~ | 80 (Boom cylinder ort 2 70 © | a1 |+ Pin bushing Replace | + set include seal 42 10. |Cab relation See 38.12 11 [ca assy Datechetacn| 7 po. 14 12 |+ Front lower glass, floor mat Detzcnetact| 4 po, each oa 18 |+ Seat rear cover top, bottom Detacniatac | 4 places| 02 14 |+ seat rear cover top, bottom Detachiataeh 4 pe. each 02 46 |+ Right side panel (include NC duct) | Oetechatach| 3 03 16 |+ Cable and hamess (electric) | ewenattach) 6 02 17 |+ Cab mounting bott Detacattaeh | 8 pes. 02 18 |+ Cab slinging Detaciattach |3 places! 02 20 [Guard relation See 33.14 21 [Bonnet assy (11) Deiachitacn| 1 pe. 02 22 [Guard (5) Dstachiatacn| 1 pe 02 23. |Guard (6) Detachatacn| 4 pe 02 24 |Guard assy (3) Detaciatacs] 4 pe. 02 25 |Stay (7) etaratacn| 4 pe. 02 B] 25 [ouars2) outaowatach | 1 po 02 G | 27 |Panel assy (21) Dotachvattach | 1 pe. 0.2 |) 26 [Panel assy (23) Detecnatach) 1 pe 02 8 | 29 |Panet assy (22) Detachiatacn] 4 pe 02 | 30 [Guard assy (18) etacwataen] 1 pe. 02 31 [Guard (14) Detachatacn| 1 po 02 92. |Guard (15) etaevatacn| + po 02 38. [Guard (17) Detacatacn| 1 pe 02 34 |Pllir (14) etacvatacn| 1 po. 02 35 [Beam (4) etachitaen] 1 pe 02 36 [Pillar (10) Detachatacn| 1 pe 02 37 [Pillar (12) Detactvateen| 1 pe. 02 38. |Guard assy (18) Detacvatisen} 1 po 02 39 [Guard assy (13) Detaciataen | 1 pe 02 40 | Guard (19) Detachiatacn| 1 pe 02 41. Cover (2) Detach} 4 pe. 02 42 |Guard assy (1) etachatacn| 1 pe 02 43 |cuard assy (3) atachsttacn| 4 pe 02 44 {Plate (20) Detachatiacn | pe 02 45 | Cover assy (1) etacnanacn| 1 po 02 Note: The numbers the peronthesis ike guard (14) match the guard numbers on the upper structure, 12-612, STANDARD MAINTENANCE TIME TABLE Group Location busibadead fet Remarks ee done Hour 80 [Under cover relation See 33.1.8 61 [Cover (1) Deieenatacn | 4 po. oA 52 |Cover (2) ataciatach | 1 po o4 53 [cover (3) Detechlatach| 1 po oa 84 [cover (4) Detachiatach| 1 po oA 85 [Cover (5) Detaciatacn| 1 po. on Z| 56 |cover (6) Delacistach | 4 po ot | 87 (Cover (7) Detactten | 4 po o4 | 58 |cover (8) Datacivataen| 4 pe ot é 3 [[o0" [counterweight retafion e035 1 |Counterweight ASSY Deachiatech| 1 po 06 62 |+ Counterweight iting eye bot | Detaavarach| 1 get oA 63 |+ Counterweight temporary singing |Preperation| 1 pe. 02 84 |+ Counterweight mounting bolt | oetentataen} 1 pe. 02 65 |+ Counterweight slinging Detnetattien| 1 pe ot 70 [intake relation See 33.1.9 11 |Aircleaner ASSY Derschiataen| 7 pe. 04 12 |+ Hose (3) Detachotecn| 4 of 48 [+ Air cleaner mounting bolt Detacvntach| 1 sat 02 14 |» Element Replace | 1 01 20 [Exhaust relation fs0033.1.10 24 [Muifier ASSY Deacniatacn| 1 pe 04 22 |+ Ubolt otachianaen| 1 pe. 02 9 | 23 | Clamp ASSY etaevataen| 1 pe 02 a ‘© |_30 [Radiator relation S00 33.1.12 3 | 31 [Radiator ASSY Deaciatech| 1 pe. 40 & | 32 [+ Cootant (Luc) Replace | 1 pe 03 33 |++ Concentration of coolant Measuring | 1 pe 02 aa |+ arc condenser betactiatach| 1 pe. 03 a8 |+ Stay Delachatach] 1 po. 01 38 |+ Bracket ewctatacn | 4 63 37 |+ Sub tank hose Detachatacn] 4 po. oa 38 |+ Fan guard Detaciataen| 1 pe. 03 39 |+ Water hose (radiator~£/G) | oetecvatacn) 2 08 40 |+ Radiator mounting bolts removing | Detachatiacn| 1 set 02 41 |+ Under cover etacnaieen| 1 pe. oa 42 |+ Hydraulic oi tank suction stopper | Detacivatacn| 1 pe 02 43. |+ Hydraulic oll piping Detachietacn| 1 pe os. "Note: The aumnbers in he parenthesis ike cover (2) maich the guard numbers on the upper stuciure 12-712. STANDARD MAINTENANCE TIME TABLE croup Location WIRE ya romans el 44 |* Inter cooler hose & tube Detachiatiach | 2 pos. 05 {EIG to inter cooler) 45 | Radiator titing or hoisting Detacrvatacn| 1 pe. 02 46 |- Radiator inter cooler core & oil cooler | Cleaning | 1 pe. 4.0 50_[Fuel relation See 33.16 51 [Fuel tank ASSY Detachiatiacn| 1 po. 18 52 |+ Fuel Replace | 1 pc. 03 53 |+ Hose (water separator side) Detechitiach) 2 on 84 |+ Water separator Detechiatach | + po. O41 85 |+ Tube (tank side) Detachiattach| 1 o4 57 [+ Fuel tank installing bolts Detzchiattach| 1 pe. 03 68 |+ Tank slinging Detachiatiach| 1 pe. oa [Other necessary works Betechiatich} 1 po. [Removing and installing guard | 0.4 60_|Hydrauic oil tank relation [See 33.17 61 [Hydraulic oil tank ASSY Detacnvatach | 1 po. 30 © | 85 f+ Cover Detechiatach | 4 po. 02 5 + Hydraulic oil Replace | 1 pc. 05 a | 68 |+ Pilot drain hose Detechiatach | 1p. 02 3 + Pump suction hose Detachattach | 1 po. 08 © | 70 [+ Mounting dott Dotaciatach | 1 pe. 02 © | 71 |+ Hydraulic oil tank slinging Delaoniattach | 1 po. 03 72 |e Return fiter Replace | 1 02 73 |+ Suction fter Cleaning | 1 02 80_|Pump relation See 33.18 @1 [Pump ASSY Detachvatach | 4 pec 32 82 |+ Hydraulic oll tank cover Detachiattach | 1 pe. 02 83 |+ Strainer & stopper Dotachattach| 1 po. 03 84 |+ Piping Detzchiatach| 1 set 1.0 85 |+ Guard Detachlatach| 5 pcs. 10 86 [+ Pump slinging Detachiatach | 1 pe. 05 87 |+ Cleaning Cleaning | 1 pe ot 88 |+ Vent air Adjust. | 1 po ot 89. |Pump ASSY on | 1 pe 40 90_| Swing motor unit relation [See 33.14.19 91 | Swing motor ASSY Detachiatach| 1 pe. 24 92 |+ Piping Detachatach| 1 set 10 93 |+ Mounting bot Detachattach | 1 pe. 07 94 |+ Unit singing Detechvatach | 1p. 05 95_|+ Cleaning and sealant Cleaning |_1 set 02 12-842, STANDARD MAINTENANCE TIME TABLE Group Location Merete Pe Unit Remarks oe 96 [Swing motor om | te. 36 97 | Swing reduction gear om | 4 pe. 42 700 [Swivel oint relation See $3.1.20 701 [Swivel joint ASSY Detachiatacn | 1 26 102 |+ Piping (Top part only) Detachiaiacn| 1 set os 103 |+ Whirl stop bolt Detachiatacn | 4 02 104 |+ Cover Dotachiatiacn| 1 04 405 |+ Joint & elbow Detacriatach| 1 set 04 406 |+ Mounting bott Detachiatach| 1 sot 04 107 |+ Swivel joint slinging Detachiatach| 4 04 108 |+ Cleaning Cleaning | 1 set 03 109 | Swivel joint OM | set |Removing and installing guard] 3.6 other necessary works Cetachiatach| 1 set |Lower piping 06 10 | Mull control valve (For Oceania) See 33.115 1H [+ Mull CIV ASSY Detachiatach| 1 (Alter removing guard 17 g | 112 Joie hose name on muni Cv comecting nose] Oetaciatach] 1 set 03 | 113 |+ Piping Detachiatach| 1 set 0s | 114 [+ Mounting bott Detachiatach| 1 set 03 Z| 215 |+ cleaning Cleaning | 4 set 02 8 JOther necessary works Detechiatiach| 1 set |Guerd 04 1120 [Main control valve See 35.116 121 [Main control valve ASSY Detactiattach| 1 pc 26 122 |+ Attach tag to port name of pipe | Preparation! 1 pe. 06 123 |+ Piping Detachiatach| 1 set 17 12d |+ Bracket mounting bolt Detacniatach| 1 pe. on 425 |+ Valve slinging Detachiatach| 1 pe oa 4126 |Main control valve ASSY Detachiatach| 1 set 60 Jother necessary works Detacvatach| 1 set [Guard 04 190 [Valve relation OPT 131 [Solenoid valve ASSY Detacwatach| 1 10 192 |+ Attach tag to port name of pipe [Preperation] 1 02 133 |+ Piping Detachiatach| 1 sot 08 14 |+ Mounting bolt Detactvatacn| 4 03 140 [Engine (ES) mounting relation see 33.113 141 [Engine ASSY Detacwatacn| 1 pe. [Alte removing pump & radiator | 1.8 142 |+ Hames connector & grounding & | Detastvatech| 1 po. 03 cable connection 143 |+ Fuel hose Detachiatech| 1 pe oA 12-912. STANDARD MAINTENANCE TIME TABLE Group Location Peat Unit Remarks fae 144 [+ Others Detaewatacn| 1 set 05 145 |+ Mounting bott Detachiatach| 4 pe. 08 146 |+ Engine stinging Cetgcrianach| 1 set 02 147 |+ Cleaning Cleaning | 1 pe. 03 148 | Engine OH | set Reference for engine (Chapter 51) Other necessary works Detachlotsch| 1 set |Removing and instaling guard | 0.6 Cetacratech| 1 set {Removing an stating Counterweignt | 0.6 Detacratach| 1 set |Removing and installing pump | 3.2 Detachiatach) 1 set_ [Removing and installing aircleaner| 0.4 2 DetacWatach| 1 set [Removing and installing muffler | 0.4 = Detachiatiacn| 1 set |Removing and installing radiator | 4.0 5 ® 1780 [upper trame [See 8.1.21 8 1751 lUpper frame ASSY Deiechatach| 1 pe. [After removing swivel joint 13 182 |+ Mounting bolt Detachiataen| 1 set 04 188 |+ Upper frame slinging Detacwatiacn| 1 pec 04 184+ Cleaning Cleaning | 4 pe. 03 185 |+ Sealant Apply | 1 pe. 02 Other necessary works Detachiatach| 1 set [Cab 14 Deizevatacn| 1 set [Guard oa Cotechatacn| 4 aet_|Counterweight 00 Detachiatiach| 1 set [Boom 14 00 [Travel relation See 34.12 01 [Track link ASSY Detachatiach |One sidelinclude adjustment of tension | 4.5 02 |+ Track ink staching end detaching ostion | Preparation One side| of 03 |+ Master pin Detachattacn [One side| 0s 04 |+ Track link extending and winding | detachiataen One side! 0s 05 Shoe plate Replace | 1 pc o4 g & [10 [Upper rotter relation See 34.13 3 A [Upper rotor ASSY Oeiachiatach| 1 [After removing track link 02 3 | 12 |Upperrotter on 1 10 © [20 [Lower roller relation [See 34.14 21 [Lower roller ASSY Detachiatach| 1 02 22 |Lower roller on 1 15 30. [Front idler relation See 34.1.5 31 [Front idler ASSY Detactvatach [One side|Atter removing track tink 06 32 |Front idler ASSY stinging Detachatach |One side| 02 33 | Front idler ASSY Detaching |One side 03 34 [idler ASSY of _ [one sice| 10 12-10412. STANDARD MAINTENANCE TIME TABLE Group Location wort Pe nit Remarks ae 36 [idler adjuster ASSY OI One side| Replace spring 24 36 |+ Grease cylinder OI One side| 08 40 [Sprocket see 34.1.6 41 [Sprocket Replace [One sidel After removing track link 06 50_ [Travel motor relation See 34.1.7 51 [Travel motor ASSY Detachiatiach [One side Afier removing track link 17 52 |+ Motor cover Detachiatach |One side| ot 53 |+ Hydraulic piping Detachiatiach |One side| 0.9 ¢ | 54 [+ Motor mounting bok Detachiatach |One side! 08 5 | 55 |+ Motor stinging Detachiatiach |One side} ot 2 | 56 [Motor cleaning Cleaning |One side| O41 & | 57 [Travel motor OHH |One side| 36 5 58. | Travel reduction gear Ol [One side! 36 {80_[Swivel joint relation 81 [Pipe on ewival joint travel side Deiachianach| 1 pe. [nce tomar aay ova evden | 08 62 | Swivel joint OH} 1pc. |See33.2.6 36 70 [Swing bearing jsee04.1.0 71 [Swing bearing ASSY Detachvatacn| 1 pe. After removing upper frame 07 72. | Swing bearing mounting bolt Detachatiacn | 1 po. 0s 73. |Swing bearing slinging etacratiacn| 1 pe. 03 [Controller 6-1 |Conirolier (KPSS) Replace | 1 08 6-2 |Gauge cluster Replace | 1 10 -4 |Air conditioner Amplifier Replace | 1 20 Diode 2 | 0-4 [Diode Replace | 1 08 & | 0-5 |Diode Replace. 1 03 3 | 06 [Diode Replace | 1 03 2 | 0-9 [Diode Replace 1 03 Bono cece asa ap i 8 |D-12|Diode Replace | 4 03 D-13|Diode Replace | 1 03 D-14|Diode Replace | 1 03 0-15 | Diode Replace | 1 03 0-16 | Diode Replace | 1 03 0-17 |Diode Replace | 1 03 12-1112. STANDARD MAINTENANCE TIME TABLE Group Location ote T unit Remarks oe D-16 [Diode Replace | 1 03 D-19 Diode Replace | 4 03 0-20 [Diode Replace | 4 03 Electric equipments Ext [Fuse & relay box Replace | 1 08 &-2 |Alternator Replace | 4 10 €-3 |Hour meter Replace | 1 03 E-5 |Hoxn (High) Replace | 4 03 £-6 [Hom (Low) Replace | 1 03 £-7 [Tuner AM & FM (OPT) Replace | 1 08 E-6 |speaker lett Replace | 1 03 E-9 |Speaker right Replace | 1 03 E-10| Receiver dryer Replece | 1 _|Include gas sealing 40 -11 |air compressor Replace | 1 |eeriecoutereohirrornganciessing. | 1.0, E-12| Battery Replace | 2 04 e | E13 Travel alarm (OPT) Replace | 1 os 5 | E-14| cigarette ignter Replace | 1 03 S | £215 [Fusible tink Replace | 1 02 8 | g-24JoPs antenna Replace | 1 05 % | -25|PDC antenna (IT controller) Replace 1 or 1 |e20z7|Acoo!amergency mode resistance 12 | Replace | ‘pair 08 Light T-1 [Boom work ight iat Replace | 1 [Bub 02 L-2 |Work tight right Replace | 1 02 8 [Swing fusher & work light (lft) Replace | 4 02 L4 [Swing fusher & work light (ight) | Replace | 1 02 LS |Room light Replace | 1 02 L-6 [Boom cylinder work light (right) Replace | 1 02 ‘Motor 1M [Starter motor Replace | 1 [incite Comwatntronovnganéwatairg | 1.0 M3 | Winer motor Replace | 4 08 Mt [Washer motor Replace | 4 08 M8 [Grease motor (OPT) Replace | 4 08 M9 | Skylight wiper motor (OPT) Replace | 4 08 Propotional vaive PSvAlAim variable recreuation propotonalveive | Replace | 4 08 psv.s/P2 bypass cut proportional valve | Replace | 1 rowcenorenouredecrrenanyosesuing | 0.8 Psv-c|Travel straight proportional valve | Replace | 1 08 12-1212, STANDARD MAINTENANCE TIME TABLE Group Location [Work 0 66) ni Remarks ae Psv.0|P1 bypass cut proportional valve | Replace | 1 0s psves]P1 pump proportional valve Replace | 1 0s sve2|P2 pump proportional valve Replace | 1 os Relay Ht Re [Battery relay Replace | 1 03 R-2 [Starter rotay Replace | 1 03 R-3 [Glow relay Replace | 1 03 R-4 [Safety relay Replace | 1 ot R65 |Hom relay Replace | 1 ot R6 [Work light retay Replace | 1 ot R.23| Auto idle stop relay 4 Replace | 1 ot R-24 | Auto idle stop relay 2 Replace | 1 4 | R-25|£/G emergency stop relay Replace | 1 ot | R-26 | Safety lock lever relay Replace | 4 on R-28| Alternator relay Replace | 1 | a4 R-29| Wiper motor relay (Normal rotation) | Replace | 1 o4 |R-30|Wiper motor relay (Reverse rotation) | Replace | 1 of § | R-31|Wiper motor relay arc prevention relay! Replace 1 04 = | R-82|Washer motor relay Replace | 1 on 3 |__|Sensor sania S| | 8 Pressure sensor : Bucket digging | Replace | 1 03 Pressure sensor : Bucket dump Replace | 1 | 03 Pressure sensor : Boom up Replace | 1 03 SE-4) Pressure sensor : Boom down Replace | 4 os SE-5|Pressure sensor : Swing Replac 1 03 ‘SE-7|Pressure sensor : Arm in Replace | 1 03 ‘SE-8 Pressure sensor : Arm out Replace | 1 03 SE-9/Pressure sensor : Travel right Replace | 1 |inclute uncer coverremeving andintating) 0.5 /SE-10) Pressure sensor : Travel left Replace | 1 jinclate undercover removing andinstating! 0.5 SE-11| Pressure sensor : P2 side OPT. Replace | 1 |inclie undercover removing andinstating) 0.5 [se-13] Engine speed sensor Replace | 1 |Inctuse undercover removing ancintating| 0.5 ISE-15)Engine water temperature sensor | Replace | 1 —_|incuse guard emoving nd instating | 0.5 ISE-16| Accel potentio Replace | 1 05 SE.20|Prossure sensor: Pt side :P1 side (OPT}] Replace | 1 |incudeundercover removing andinstling| 0.5 SE-22)Pressure sensor : P1 pump Replace | 1 0s 'SE-23| Pressure sensor : P2 pump Replace | 1 0s Solenoicl | SV-1 | Swing parking SOL T Replace | 1 [imusscronen vive necro aonasing | 0.5 SV-2| Attachment boost pressure SOL Replace | 1 |racovoporiaraitasrencigandnsaing | 0.5 12-13,12. STANDARD MAINTENANCE TIME TABLE Group Local ote Unit Remarks [ents ‘SV-3|2-speed travel SOL "| Replace | 1 (navapemnavanncrnon onic | 0.5 8V-4| Safety lever lock SOL Replace | 1 |rewencroroutvsvenscrreningwaieaivn, | 0.6 a ‘Switch 7 B /swalkey owitch Replace | 1 03 § |Sw-4|Swing parking release switch Replace 1 03 E |we7fenain of pressure teh repace | 41 03 5 |SW-8|Clogged air filter switch Replace 1 03 i | sw-t0 Horn switch (left) Replace 1 03 © | sw-ti|Safety lever lock switch Replace | 1 03 ‘sW-19] Wiper interlock switch Replace | 1 03 sw-20]Attachment power boost switch (right)| Replace | 4 03 sw-27]Engine cooting coolant level switch | Replace | 1 03 eee EEE eee 12-1412, STANDARD MAINTENANCE TIME TABLE, 12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) Preface This standard working time is based on the work time required for service of engine like disassembly, check, adjustment and assembly and so on under a following condition This standard working time is provided under the following conditions. 12.24 MEASURING METHOD (1) The time from the worker beginning working at the regular position of machine to the returning to the reguler position after completion of the work is counted as working time. (2) The measuring unit is in 0.1 minute, and then round up the fractions. (3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two workers is counted 2s the working time. But light work which can be carried out easily by a person and the efficient is higher is counted as a workman 12.2.2. WORKING CONDITION 42.224 TOOLS, INSTRUMENT (1) Hand tool: ‘Tools which are commercially available and each workman usually carries (2) Common tool Tools which are commercially available and each workman do not usually carry but the storing place is specitied (3) Special tool; Tools especially prepared by HINO Motors Lid. and the storing place is specified (4) Machine tool ; ‘When measuring equipment and instrument are used, the time required to move parts lo the specified place is included but the time waiting for tool is not included as a general rule 12.22.2 WORKING PROCEDURE The disassembly and assembly should be carried out according to working procedure prepared by HINO Motor's Ltd. Service Technical Dept. Training Group. 12.2.2.3 STANDARD WORKMAN QUALIFICATION, Workmen shall basically acquire 2~3 years of maintenance experience of HINO 122.3 STANDARD TIME CONSTITUENT 1223.1 STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD ALLOWANCE TIME (1) Net working time The time workman works actually and the time required for measurement, cleaning, and so on is included, but the time required for troubleshooting is not included Standard time Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts and s0 on, and for the work site clean- Standard allowance time Calculate the allowance time directly required for workmen from the following equation 2 2 Net standard time x HINO allowance rate Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position and so on. 12-15