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MAINTENANCE SPECIFICATIONS
SHOP SK250-8
MANUAL model SK260LC-8
(HS Engine)
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 © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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- (21)Do not operate a machine if any rotating 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)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)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- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is 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 to a 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 a 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 falling attachment. Don’t fail 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. Do not bend
or strike high pressure lines 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
a high velocity oil 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 in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
0-4
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SK250-8
ASIA(HS Engine) INDEX SK260LC-8
Book Code No. Index
Title
Distribution Year–Month No.
MAINTENANCE SPECIFICATIONS
S5YN0118E01
2007-05
OUTLINE 1
S5LQ0217E01
2007-05
SPECIFICATIONS 2
S5LQ0317E01
ATTACHMENT DIMENSIONS 3
2007-05
S5LQ1114E01
TOOLS 11
2007-05
S5LQ1217E01 STANDARD MAINTENANCE
2007-05
12
TIME SCHEDULE
S5LQ1314E01 MAINTENANCE STANDARD
2007-05
13
AND TEST PROCEDURE
S5LQ2117E02 MECHATRO CONTROL
2008-10
21
SYSTEM
S5LQ2217E01
2007-05
HYDRAULIC SYSTEM 22
S5LQ2317E01
SYSTEM
2007-05
ELECTRIC SYSTEM 23
S5LQ2417E02
2008-10
COMPONENTS SYSTEM 24
S5LQ2517E01
2007-05
AIR-CONDITIONER SYSTEM 25
_
S5YN3118E01 DISASSEMBLING
DISASSEMBLING
S5LQ4617E01
2007-05
BY ERROR CODES 46
S5YN4718E01
2007-05
BY TROUBLE 47
S5YN4818E01
2007-05
TROUBLE DIAGNOSIS MODE 48
_
S5LQ5117E03
ENGINE 51
2010-07
_
LQ12-06001~
LL12-05001~ APPLICABLE MACHINES
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
1. OUTLINE
TABLE OF CONTENTS
1-1
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1. OUTLINE
1-2
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1. OUTLINE
1.1 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
extinguisher, and also where to make contact
Read Operator's Manual
for emergency measure and ambulance to
before disassembling
1-3
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1. OUTLINE
1-4
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1. OUTLINE
(6) Engine key off before touching terminals of starter (2) Flexible hose (F hose)
and alternator. • Even if the connector and length of hose are the
(7) Remove battery grounding terminal before same, the parts differ according to the
beginning work close to battery and battery relay withstanding pressure. Use proper parts.
with tools. • Tighten it to the specified torque, and check that
(8) Wash machine with care so as not to splash water it is free from twist, over tension, interference,
on electrical equipment and connector. and oil leak.
(9) When water has entered in the waterproofed
1.1.6 WELD REPAIR
connector, the removing of water is not easy. So
(1) The weld repair should be carried out by qualified
check the removed waterproofed connector with
personnel in the specified procedure after
care to protect it from entry of water. If moisture
disconnecting the grounding cable of battery. If the
adheres on it, dry it completely before connecting.
grounding cable is not disconnected, the electrical
equipment may be damaged.
(2) Remove parts which may cause fire due to the
Battery fluid is dangerous. entry of spark beforehand.
The battery fluid is dilute sulfuric acid, and causes (3) Repair attachments which are damaged, giving
scald and loss of eyesight by adhering on eyes, particular attention to the plated section of piston
skin and clothes. When the fluid has adhered on rod to protect it from sparks, and don’t fail to cover
them, take an emergency measure immediately and the section with flame-proof clothes.
see a doctor for medical advice.
• When it has adhered on skin ; 1.1.7 ENVIRONMENTAL ISSUES
Wash with soap and water. (1) Engine should be started and operated in the place
• When it has got in eyes ; where air can be sufficiently ventilated.
Wash in water for 10 minutes or more (2) Waste disposal
immediately. The following parts follows the regulation.
• When it has spilled out in large quantity ; Waste oil, waste container and battery
Use sodium bicarbonate to neutralize, or wash (3) Precautions for handling hydraulic oil
away with water. Hydraulic oil may cause inflammation of eyes.
• When it was swallowed ; Wear goggles to protect eyes on handling it.
Drink milk or water. • When it has got in eyes ;
• When it has adhered on clothes ; Wash eyes with water until the stimulus is gone.
Wash it immediately. • When it was swallowed ;
Don’t force him to vomit it, but immediately
1.1.5 HYDRAULIC PARTS receive medical treatment.
• When it has adhered on skin ;
Wash with soap and water.
(4) Others
(1) O-ring For spare parts, grease and oil, use KOBELCO
• Check that O-ring is free from flaw and has genuine ones.
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.
1-5
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1. OUTLINE
1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations
Introduction Table1-4
Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA
of SI units system is described here. Frequency hertz Hz 1Hz=1/s
Given hereinunder are an excerpt of the units that are Force newton N kg • m/s 2
related to this manual : Pressure and
pascal Pa N/m2
1. Etymology of SI Units Stress
English : International System of units Energy, Work
2. Construction of SI Unit System and Quantity of joule J N•m
heat
Base units Power watt W J/s
Table 1-1
Derived units Quantity of
coulomb C A•s
Supplemen of base units electricity
SI units tary units Table 1-3
SI unit Table 1-2 Electric
system Derived units potential
Derived bearing peculiar
designations difference,
units volt V W/A
Table 1-4 Voltage, and
Electromotive
Prefixes of SI
(n-th power of 10, where n is an integer) force
Table 1- 5 Quantity of
static electricity
(1) Basic Units farad F C/V
and Electric
Table1-1 capacitance
Electric
QUANTITIES DESIGNATION SIGN ohm V/A
resistance
Length Meter m
celcius
Mass Kilogram kg Celcius
degree or C
° (t+273.15)K
Time Second s temperature
degree
Current Ampere A
Thermodynamic Kelvin K Illuminance lux lx l m/m2
temperature
(5) Prefixes of SI
Gram molecule Mol mol
Luminous intensity Candela cd Table1-5
PREFIX
(2) Supplementary Units POWER
DESIGNATION SIGN
Table1-2 Giga G 109
QUANTITIES DESIGNATION SIGN Mega M 106
Plain angle Radian rad Kilo k 103
Solid angle Steradian sr Hecto h 102
Deca da 10
(3) Derived Units of Basic Units
Deci d 10–1
Table1-3 Centi c 10–2
QUANTITIES DESIGNATION SIGN Milli m 10–3
Area Square meter m2 Micro 10–6
Volume Cubic meter m3 Nano n 10–9
Velocity Meter per second m/s Pico p 10–12
Acceleration Meter per second / second m/s2
Density Kilogram per cubic meter kg/m3
1-6
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1. OUTLINE
1-7
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1. OUTLINE
[MEMO]
1-8
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2
2. SPECIFICATIONS
TABLE OF CONTENTS
2-1
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2. SPECIFICATIONS
2-2
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2. SPECIFICATIONS
ARM CYLINDER
ARM
BOOM
FUEL TANK
CONTROL VALVE
BUCKET
MONITOR PANEL
FRONT IDLER
IDLER ADJUST
ENGINE
UPPER ROLLER
COUNTER WEIGHT
AIR CLEANER
TRACK GUIDE
RADIATOR AND OIL COOLER
LOWER ROLLER
2-3
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2. SPECIFICATIONS
2,950 (9'8")
3,0
20
(9'
11
")
10,120 (33'2")
2,970 (9'9")
3,200 (10'6")
3,060 (10'1")
1,090 (3'7")
(18.1")
460
Lower roller Q'ty : 8 pcs or [9 pcs ] 600
4,260 (13'12") [4,640 (15'3")] (23.6") 2,990 (9'10")
5,090 (16'8") [5,280 (17'4")] [3,190 (10'6")]
2.2.2 SK250–8/SK260LC–8 [6.02m (19ft-9in)+2.5m (8ft-2in) Short Arm+1.2m3 (1.57cu•yd) Bucket Shoe]
10,170 (33'4")
4,120 (13'6")
2,970 (9'9")
3,380 (11'1")
1,090 (3'7")
2-4
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2. SPECIFICATIONS
Unit : mm (ft-in)
10,130 (33'3")
4,120 (13'6")
2,970 (9'9")
3,360 (11'3")
1,090 (3'6")
Lower roller Q'ty : 8 pcs. or [9 pcs.]
2-5
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2. SPECIFICATIONS
2-6
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2. SPECIFICATIONS
Unit ; kg (lb)
Model
SK250 - 8 SK260LC - 8
Item
4. Lubricant and water (Assembly of following :) 590 (1,300)
4.1 Hydraulic oil 160 (350)
4.2 Engine oil 20 (44)
4.3 Fuel 380 (840)
4.4 Water 30 (66)
2-7
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2. SPECIFICATIONS
2.4 TRANSPOTATION
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER
(1) 6.02m (19ft-9in) Boom+2.98m (9ft-9in) Arm+1.00m3 (1.3cu•yd) Bucket
Model
SK250-8 SK260LC-8
Item
Width 600mm (23.6in) shoes 2,990 (9ft-10in) 3,190 (10ft-6in)
Weight 24,700kg (54,460 lbs) 25,200kg (55,570 lbs)
Unit : mm (ft-in)
3,200 (10'6")
38(1.5")
3,800 (12'6")
A
SECTION A-A
2-8
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2. SPECIFICATIONS
Type
6.02m (19ft-9in) Boom
Item
LengthHeightWidth 6.25 1.71 0.75
m (ft-in)
LHW (20'6" 5'7" 29.5")
Weight kg (lbs) 2,140 (4,720)
Type 2.5m (8ft-2in) Arm + 2.98m (9ft-9in) Arm + 3.66m (12ft) Arm +
1.2m 3(1.57cu•yd) Bucket 1.0m 3 (1.3cu•yd) Bucket 0.81m 3 (1.06cu•yd) Bucket
Item
LengthHeightWidth 5.00 1.00 1.44 5.47 1.03 1.27 6.14 1.0 1.06
m (ft-in)
LHW (16'5"3'3"4'9") (17'11"3'5"4'2") (20'2"3'3"3'6")
Weight kg (lbs) 2,100 (4,630) 2,170 (4,790) 2,240 (4,940)
(3) Arm
Type
2.5 m (8ft-2in) Arm 2.98 m (9ft-9in) Arm 3.66 m (12ft-0in) Arm
Item
LengthHeightWidth 3.59 0.89 0.55 4.06 0.90 0.55 4.73 090 0.55
m (ft-in)
LHW (11'9"35"22") (13'4"35.4"22") (15'6"35.4"22")
Weight kg (lbs) 1,240 (2,735) 1,340 (2,955) 1,520 (3,350)
2-9
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2. SPECIFICATIONS
(4) Bucket
Hoe bucket
2-10
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2. SPECIFICATIONS
2.5.2 ENGINE
2.5.4 WEIGHT
Unit : kg (lbs)
Fully equipped weight 24,400 (53,800) 24,900 (54,900)
Upper structure 11,380 (25,100)
Lower machinery
7,900 (17,420) 8,400 (18,520)
(600mm grouser shoe)
Attachment
6.02m (19 ft-9in) Boom+2.98m (9ft-9in) Arm 5,120 (11,300)
+1.0m3 (1.3cu•yd) Bucket
2-11
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2. SPECIFICATIONS
Use 600mm (23.6") 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.)
2-12
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2. SPECIFICATIONS
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
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.
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
2-13
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2. SPECIFICATIONS
2-14
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2. SPECIFICATIONS
Condition to be measured: The net value is indicated, measuring with cooling fan ; ø650 (25.6")suction type,
pulley ratio Crank / Fan=0.93
marks show the rated point
SHAFT TORQUE
SHAFT OUTPUT
2-15
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2. SPECIFICATIONS
[MEMO]
2-16
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3
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
3-1
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3. ATTACHMENT DIMENSIONS
3-2
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3. ATTACHMENT DIMENSIONS
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING
Fig. 3-1 Boom dimensional drawing
Unit : mm (ft-in)
STD —
6.02M (19ft-9in) BOOM
LQ02B00251F1 —
No NAME DIMENSION
A Boom length 6,020 (19'9") —
B Boom foot width 752 (29.6") —
C Boom end inner width 380 (15.0") —
D Boom end outer width 528 (20.8") —
E Height of boom cylinder rod pin 1,063 (3'6") —
F Height of arm cylinder (head side) pin 1,305 (4'3") —
G Distance between pins of boss R2,437 (7'12") —
H Distance between pins of bracket R3,009.5 (9'10") —
I Arm cylinder (head side) inner width 136 (5.35") —
J Outer width of bracket on the arm cylinder (rod side) 522 (20.6") —
mounting
d1 Boom foot pin dia. ø 100 (3.94") —
d2 Boom cylinder (rod side) pin dia. ø 90(3.54") —
d3 Pin dia. of boom end. ø 90 (3.54") —
d4 Arm cylinder (head side) pin dia. ø 90(3.54") —
3-3
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3. ATTACHMENT DIMENSIONS
A
C
Unit : mm (in)
Standard value Clearance
Sym- Bushing Repaira
Item Pin part No. Pin dia. Standard Service Remedy
bol Pin dia. i.d. ble
tolerance value limit
tolerance level
+ 0.213 + 0.233
ø 100 (+0.0084) (+0.0092)
A Boom foot LQ02B01395P1
(3.9370) + 0.065 + 0.045
(+0.0026) (+0.0018)
Boom cylinder + 0.020 + 0.238 + 0.258 More
B LQ02B01390P2 Replace
(Head side) (+0.0008) (+0.094) (0.0102) than 2.5
bushing
Boom cylinder - 0.020 + 0.077 + 0.057 2.0 (0.1)
C LQ02B01373P1 or pin
(Rod side) ø 90 (-0.0008) (+0.003) (+0.0022) (0.08)
(3.5433) + 0.25 + 0.270
Arm cylinder (+0.0098) (+0.0106)
D LQ02B01380P1
(Head side) + 0.05 + 0.030
(+0.0020) (+0.0012)
3-4
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3. ATTACHMENT DIMENSIONS
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable Service
No. Size No. Length
value level limit
752
Boom
(29.6) 0.5 (0.02) 921
A-A Boom foot L1 PL1
758 or less (36.3)
Upper frame
(29.8) 2.0 2.5
120 (0.08) (0.10)
Boom cylinder
Boom cylinder (4.7) 0.6~1.0 284
B-B L2 PL2
(Head side) 126 (0.02~0.04) (11.2)
Upper frame Shim
(5.0)
adjust
120
Boom cylinder L3 ment
Boom cylinder (4.7) 0.6~2.0 3.0 4.0 810
C-C PL3
(Rod side) 522 (0.02~0.08) (0.12) (0.16) (31.9)
Boom L3'
(20.6)
130
Arm cylinder
Arm cylinder (5.12) 0.6~1.0 2.0 2.5 274
D-D L4 PL4
(Head side) 136 (0.02~0.04) (0.08) (0.10) (10.8)
Boom
(5.35)
3-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
3. ATTACHMENT DIMENSIONS
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
3-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
3. ATTACHMENT DIMENSIONS
E F
D, D'
B
C
G
Unit : mm (in)
Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.252 +0.312
(+0.0099) (+0.0123)
A Arm point
–0.020 +0.077 +0.097
ø90 (-0.0008) (+0.0030) (+0.0038)
LQ12B01439P1
(3.5433) –0.080 +0.282 +0.342
Bucket link (-0.0031) (+0.0111) (+0.0135)
B
(Bucket side) +0.154 +0.194
(+0.0061) (+0.0076)
+0.241 +0.281
Idler link
ø70 (+0.0095) (+0.0111)
C (Connected part LQ12B01440P1
(2.7559) +0.175 +0.175
of arm) (+0.0069) (+0.0069)
0 +0.228 +0.268
Bucket link (0) (+0.0090) (+0.0106) Replace
D 2.0 2.5
(Idler link side) –0.040 +0.158 +0.158 bushing
(0.08) (0.01)
(-0.0016) (+0.0062) (+0.0062) or pin
LQ12B01441P1
ø80 +0.290
Bucket cylinder (3.1496) (+0.0114)
D'
(Rod side) +0.250 +0.050
(+0.0098) (+0.0020)
Bucket cylinder +0.050 +0.270
E LQ12B01563P1
(Head side) (+0.0020) (+0.0106)
Arm cylinder +0.020 +0.030
F LQ02B01380P1 (+0.0012)
(Rod side) (+0.0008)
ø90 –0.020 +0.278 +0.298
Arm foot (-0.0008)
(3.5433) (+0.0109) (+0.0117)
G (Connected part LQ12B01487P1
+0.148 +0.128
of boom)
(+0.0058) (+0.0050)
3-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
3. ATTACHMENT DIMENSIONS
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X L3 PL5
X L6
X L5
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D
SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction
3-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
3. ATTACHMENT DIMENSIONS
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable
No. Size Service limit No. Length
value level
325
Arm
(12.79) 1.0 (0.04) 2.0
A-A Arm point L1 PL1
326 or less (0.08)
Bucket
(12.83) 472
325 (18.6)
Link side
(12.79)
B-B Bucket link L2 — — PL2
327
Bucket
(12.87)
332 2.5
Idler link Arm 0.5 1.0
C-C L3 (13.07) (0.10) PL3
(Arm connection) (0.02) (0.04)
Link side -
Bucket link Rod side -
D-D (Idler link L4 332 454
Link side
connection) (13.07) (17.9)
0.6~1.0 2.0 Shim
107 PL4
Rod side (0.024~0.04) (0.08) adjust
Bucket link (4.21)
D’-D’ L4’ -ment
(Rod side) 113
Link side
(4.45)
107
Head side
Bucket cylinder (4.21) 247
E-E L5 PL5
(Head side) 113 (9.72)
Arm
(4.45) 0.6~2.0 3.0 4.0
130 (0.024~0.08) (0.12) (0.16)
Rod side
Arm cylinder (5.12) 274
F-F L6 PL6
(Rod side) 136 (10.8)
Arm
(5.35)
375
Arm
(14.76) 0.5 1.0 2.5 552
G-G Arm foot L7 PL7
380 (0.02) (0.04) (0.10) (21.7)
Boom
(14.96)
3-9
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
3. ATTACHMENT DIMENSIONS
3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
Unit : mm (ft-in)
Type Hoe bucket
0.81 m 3 [STD]
1.20 m3 1.40 m3
Capacity (1.06 cu•yd) 1.00 m3
(1.57 cu•yd)) (1.83 cu•yd))
Side pin type (1.31 cu•yd))
Part No. LQ61B00170F1 LQ61B00186F1 LQ61B00125F1 LQ61B00166F1
A R500 (19.7")
B R1,515 (4'12")
C 896 (35.3") 1,115 (3'8") 1,276 (4'2") 1,443 (4'9")
D 399 (15.7")
E 327 (12.9")
F 959 (37.8") 1,274 (4'2") 1,339 (4'5") 1,505 (4'11")
G 746 (29.4") 965 (38") 1,126 (3'8") 1,293 (4'3")
H 896 (35.3") 1,178 (3'10") 1,276 (4'2") 1,443 (4'9")
I 256 (10.1") 247 (9.7") 287 (11.3") 263 (10.4")
IO 256 (10.1") 247 (9.7") 287 (11.3") 263 (10.4")
d1 ø 105 (4.13")
d2 ø 90 (3.54")
3-10
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
3. ATTACHMENT DIMENSIONS
X B
J
A
BOSS
M
28 2416P26834
(1.10) Apply rust prevention oil
19
(0.748)
3-G
B
F
N
D E
H
BOSS
SHIM 1 Insert this pin flush with surface LQ61B01016P1
Five shims are installed
at shipping SECTION X-X
DETAIL B
Unit : mm (ft-in)
Lug plate thickness
Boss width.
Boss width.
Screw dia.
Capacity of
Hole dia.
A B D E F G H J M N
0.81 (1.06) LQ61B00170F1
[STD]
Hoe 90 25 105 13 190 25 180 36 150
bucket 1.00 (1.31) LQ61B00186F1 (3.45") (0.984") (4.13") (0.512") (7.48") M16 (0.984") (7.09") (1.42") (5.91")
1.20 (1.57) LQ61B00125F1
1.40 (1.83) LQ61B00166F1
3-11
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3. ATTACHMENT DIMENSIONS
H 5
(0.197")
oG
oC
oD
oA
oB
15 (0.591")
Unit : mm (ft-in)
Type Capacity of
Part No. of Part No.
of bucket øA øB øC øD E F øG H I
bucket of boss
bucket m3 (cu•yd)
0.81 (1.06) LQ61B00170F1
[STD] 127 94 118.5 124.5 15 30 17 13 3.0
LQ61B01016P1
Hoe 1.00 (1.31) LQ61B00186F1 (5.00") (3.7") (4.67") (4.9") (0.59") (1.18") (0.669") (0.512") (0.12")
bucket 1.20 (1.57) LQ61B00125F1
19 34
1.40 (1.83) LQ61B00166F1 2418P26834
(0.75") (1.34")
3-12
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
11
TABLE OF CONTENTS
11-1
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
11-2
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
11-3
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
11-4
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 M36 55
M8 13 M42 65 d
M10 17 M45 70
M12 19 M48 75
(M14) 22 M56 85
M16 27 (M60) 90 B
(M18) 27 M64 95
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
(M3) 2.5 M20 17
(M4) 3 (M22) 17 @
(M5) 5 M24 19
M6 5 (M27) 19
M8 6 M30 22
M10 8 M36 27
*
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
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
11-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
11-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
SLEEVE NUT
B
d
d
11-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)
Applicable
tube Plug parts No.
O. D : A
A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000
(3) Nut
Applicable
A
11-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal 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
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29
(2) PT screw
B
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
PF screw
PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36
screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E
11-9
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11. TOOLS
$ % & ) * - "
.,/01
'$ +,) #
( ' +,) ! # !
( ' +,) #
Female
11-10
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
70(2.76)
16 22
15 (0.591) 2421T160 27 (0.630) (0.315) (0.866)
70(2.76)
42(1.65)
19 22
18 (0.709) 2421T138 32 (0.748) (0.866)
12.7 (0.500 )
22(0.866)
70(2.76)
48(1.89) 11.5(0.453)
23 22
22 (0.866) 2421T130 36 (0.906) (0.866)
12.7 (0.500 )
109(4.29)
60(2.36)
14.5(0.571)
29 22
28 (1.10) 2421T115 41 (1.142) (0.866)
12.7 (0.500 )
28 (1.10) 2421T231 46
32 (1.26) 2421T232 50
81(3.19) 90(3.54)
20.5(0.807)
11-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
Allen wrench
ZT22A10000 Pump
1 Nominal
suction
B : 10, C : 11.3
Additional M10 X 22
threading
for M10 eye bolt
Plug ZE72X16000 For slinging the
4
PF1 swing motor
O-ring
PF1
M12
M8 Eye bolt
Plug
ZF83P22000
(Nominal
tube dia. 22)
6 Reference nut Flare hose
Reference
ZS91C00800
Eye bolt
ZF93N22000 M8 X 18
Nut Addtional
threading for
M8 Eye bolt
11-12
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
Table11-4
M8 Eye bolt
M8 X 18
Plug YN01H01001P1
Additional
threading
Nominal
7 1-14UNS HEX 27 Flare hose
M8 Eye bolt
M8 X 18
Additional
Plug YN01H01002P1 threading
Nominal
8 1 3/16-12UN HEX 36 Flare hose
Plug ZE25F08000
PF1/2 For slinging the
9 Weld
Coupling swivel joint
half Coupling half
PF 1/2
11-13
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle
#262 1374
compound strength
High
#271 1305
strength
Sealing
#515 1215 Sealing
compound
11-14
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
2 Nut
3 Cover
4 O-ring
11.9.2 DIMENSION
50
(1.97")
R
(1 8 O113 (4.45")
.3
15" 2
) M8 NUT (0.08")
O8 (1.315")
600 (23.6")
M8 O100 +0.5
0
(0.787")
(3.94 +0.0197
0 )
O108
20
(4.25")
ROD COVER
Fig. 11-2 Dimension of suction stopper
Applicable
SK115SR
SK135SR
SK235SR
SK200-6E
SK100-2
SK120-2
SK100-3
SK120-3
SK200-6
SK200-8
SK250-8
model
SK100
SK120
Part No.
24100P978F2
11-15
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
Size Vertical
Part No. lifting load
d L kg (lbs)
M8 15 ZS91C00800 80 (176)
M10 18 ZS91C01000 150 (331)
M12 22 ZS91C01200 220 (485)
M16 27 ZS91C01600 450 (992)
M20 30 ZS91C02000 630 (1390)
M24 38 ZS91C02400 950 (2090)
L
d
M30 45 ZS91C03000 1500 (3310)
M36 55 ZS91C03600 2300 (5070)
M42 65 ZS91C04200 3400 (7490)
M48 70 ZS91C04800 4500 (9920)
11-16
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
11-17
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
6 1
175(6.89)
375 (14.8)
2
400 (15.7)
(4.72) (4.72)
240 (9.45)
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)
11-18
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
M30
Retainer nut
Retainer plate
)
.6"
(12
(27.6")
Stand
(15.0")
Hydraulic jack
Base
Fig. 11-6 Track spring set jig
11-19
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11. TOOLS
[MEMO]
11-20
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
12. STANDARD MAINTENANCE
TIME TABLE
12
TABLE OF CONTENTS
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST
(TEMPORARY EDITION) ................................................................................................12-14
12.2.1 MEASURING METHOD .........................................................................................12-14
12.2.2 WORKING CONDITION .........................................................................................12-14
12.2.3 STANDARD TIME CONSTITUENT ........................................................................12-14
12.2.4 MEANING OF WORDS IN USE .............................................................................12-16
12-1
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
12. STANDARD MAINTENANCE TIME TABLE
12-2
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
12. STANDARD MAINTENANCE TIME TABLE
PREFACE
(1) Working Conditions
1) 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).
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 :
A flat land where work may be performed and to which a service car or a truck crane is accessible.
(2) Range of standard maintenance time
1) Standard maintenance time=Direct maintenance timePreparation 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.
(3) Extra time (not included in the standard service time)
1) Repair time :
Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting.
2) Items excluded from service time because of uncertainty in time :
Receiving a 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 parts 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 crane 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
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12. STANDARD MAINTENANCE TIME TABLE
12-4
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.6
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.2
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 2.4
07 • Tooth Replace 1 pc. 0.6
08 • Side cutter Replace 1 pc. 1.2
09 • Bushing Replace 1 pc. 0.6
12-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
71 • Pin bushing Replace 1 set Include seal. 1.2
80 Boom cylinder O/H 2 7.0
01
Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.
12-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
50 Under cover relation See 33.1.5
51 Cover (1) Detach/attach 1 pc. 0.1
52 Cover (2) Detach/attach 1 pc. 0.1
53 Cover (3) Detach/attach 1 pc. 0.1
54 Cover (4) Detach/attach 1 pc. 0.1
55 Cover (5) Detach/attach 1 pc. 0.1
02 Cab & Guard
12-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
44 • Inter cooler hose & tube Detach/attach 2 pcs. 0.5
(E/G to inter cooler)
45 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.0
12-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
96 Swing motor O/H 1 pc. 3.6
97 Swing reduction gear O/H 1 pc. 4.2
12-9
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12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
Detach/attach 1 set Removing and installing air cleaner 0.4
Detach/attach 1 set Removing and installing muffler 0.4
Detach/attach 1 set Removing and installing radiator 4.0
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.3
152 • Mounting bolt Detach/attach 1 set 0.4
153 • Upper frame slinging Detach/attach 1 pc. 0.4
154 • Cleaning Cleaning 1 pc. 0.3
155 • Sealant Apply 1 pc. 0.2
Other necessary works Detach/attach 1 set Cab 1.4
Detach/attach 1 set Guard 0.4
Detach/attach 1 set Counterweight 0.6
Detach/attach 1 set Boom 1.4
12-10
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12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
52 • Motor cover Detach/attach One side 0.1
53 • Hydraulic piping Detach/attach One side 0.9
54 • Motor mounting bolt Detach/attach One side 0.5
55 • Motor slinging Detach/attach One side 0.1
56 Motor cleaning Cleaning One side 0.1
57 Travel motor O/H One side 3.6
04 Travel system
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0
Diode
D-4 Diode Replace 1 0.3
D-5 Diode Replace 1 0.3
D-6 Diode Replace 1 0.3
D-9 Diode Replace 1 0.3
06 Electric equipments
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
12-11
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12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air compressor Replace 1 Include Counterweight removing and installing. 1.0
E-12 Battery Replace 2 0.4
E-14 Cigarette lighter Replace 1 0.3
E-15 Fusible link Replace 1 0.2
E-27 Accel emergency mode volume Replace 1pair 0.5
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-3 Swing flusher & work light (left) Replace 1 0.2
L-4 Swing flusher & work light (right) Replace 1 0.2
L-5 Room light Replace 1 0.2
L-6 Boom cylinder work light (right) Replace 1 0.2
Motor
06 Electric equipments
M-1 Starter motor Replace 1 Include Counterweight removing and installing. 1.0
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-8 Grease motor (OPT) Replace 1 0.5
M-9 Skylight wiper motor (OPT) Replace 1 0.5
Proportional valve
PSV-A Arm variable recirculation proportional valve Replace 1 0.5
PSV-B P2 bypass cut proportional valve Replace 1 Include proportional valve block removing and installing. 0.5
PSV-C Travel straight proportional valve Replace 1 0.5
PSV-D P1 bypass cut proportional valve Replace 1 0.5
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
12-12
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12. STANDARD MAINTENANCE TIME TABLE
Work to be Unit :
Group Location Unit Remarks
done Hour
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
R-31 Wiper motor relay arc prevention relay Replace 1 0.1
R-32 Washer motor relay Replace 1 0.1
Sensor
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
SE-9 Pressure sensor : Travel right Replace 1 Include under cover removing and installing 0.5
SE-10 Pressure sensor : Travel left Replace 1 Include under cover removing and installing 0.5
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover removing and installing 0.5
06 Electric equipments
SE-13 Engine speed sensor Replace 1 Include under cover removing and installing 0.5
SE-15 Engine water temperature sensor Replace 1 Include guard removing and installing 0.5
SE-16 Accel potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side : P1 side (OPT.) Replace 1 Include under cover removing and installing 0.5
SE-22 Pressure sensor : P1 pump Replace 1 0.5
SE-23 Pressure sensor : P2 pump Replace 1 0.5
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-2 Attachment boost pressure SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-3 2-speed travel SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-4 Safety lever lock SOL Replace 1 Include proportional valve block removing and installing. 0.5
Switch
SW-1 Key switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3
SW-7 Engine oil pressure switch Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lever lock switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-20 Attachment power boost switch (right) Replace 1 0.3
SW-27 Engine cooling coolant level switch Replace 1 0.3
12-13
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12. STANDARD MAINTENANCE TIME TABLE
12.2.3.1 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
(2) Standard time
Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts
and so on, and for the work site clean-up.
(3) Standard allowance time
Calculate the allowance time directly required for workmen from the following equation.
Net standard time 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.
12-14
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12. STANDARD MAINTENANCE TIME TABLE
12-15
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12. STANDARD MAINTENANCE TIME TABLE
12-16
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12. STANDARD MAINTENANCE TIME TABLE
12-17
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12. STANDARD MAINTENANCE TIME TABLE
12-18
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12. STANDARD MAINTENANCE TIME TABLE
119 00552 Replacing crank shaft rear oil seal Single unit From fly wheel is removed condition 0.2 0.2
131 00613 Replacing intake manifold One set Include; Applying liquid gasket 2.0 2.3
132 00614 Replacing intake manifold gasket One set Include; Applying liquid gasket 2.0 2.3
Removal and installing intake pipe
133 00636 One set 1.3 1.6
(manifold side)
134 00637 Replacing intake pipe (manifold side) One set 1.3 1.6
135 00622 Replacing air intake hose One set 0.4 0.2 0.4 0.2
136 00623 Replacing air intake pipe One set 0.4 0.2 0.4 0.2
137 00626 Replacing air intake pipe One set Turbo charger to inter cooler 0.4 0.4
138 00627 Replacing air intake pipe One set Air cleaner to turbo charger 0.4 0.2 0.4 0.2
Completed
139 00675 Replacing silencer body 0.3 0.2 0.3 0.2
machine
Completed
142 00641 Tightening exhaust manifold 0.9 1.3
machine
Removal and installing exhaust Completed
143 00643 With insulator and stud bolt 2.8 3.2
manifold machine
12-19
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12. STANDARD MAINTENANCE TIME TABLE
12-20
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12. STANDARD MAINTENANCE TIME TABLE
12-21
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12. STANDARD MAINTENANCE TIME TABLE
471 01901 Replacing main engine speed sensor One set Include; Function check 1.2 1.2
472 01902 Replacing sub engine speed sensor One set Include; Function check 1.2 1.2
Replacing coolant temperature
473 01903 One set Include; Function check 1.2 1.2
sensor
474 01904 Replacing accel sensor One set Include; Function check 1.5 1.5
475 01908 Removal and installing EGR valve One set Include; Function check 2.1 2.5
476 01909 Replacing EGR valve One set Include; Function check 2.1 2.5
479 01916 Removal and installing EGR cooler One set 1.8 1.8
480 01917 Replacing EGR cooler One set 1.8 1.8
Removal and installing closed
481 01918 One set 0.3 0.3
ventilator
482 01919 Replacing closed ventilator One set 0.3 0.3
12-22
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13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ...13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE .....................................................13-4
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6
13.3.1 MEASUREMENT OF ENGINE SPEED ..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.3 PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12
13.5.1 TRAVEL SPEED.....................................................................................................13-12
13.5.2 DEVIATION OF TRAVEL .......................................................................................13-12
13.5.3 PERFORMANCES OF PARKING BRAKE .............................................................13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR.......................................................................13-14
13.6 MEASURING SWING PERFORMANCES.......................................................................13-15
13.6.1 SWING SPEED ......................................................................................................13-15
13.6.2 PERFORMANCE OF SWING BRAKE ...................................................................13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ..................................................13-16
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18
13.7.1 OPERATING TIME OF CYLINDERS .....................................................................13-18
13.7.2 OIL TIGHTNESS OF CYLINDERS .........................................................................13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20
13.9 MECHATRO CONTROLLER...........................................................................................13-21
13.9.1 ENGINE CONTROL INPUT / OUTPUT ..................................................................13-21
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) ...13-21
13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO
CONTROLLER .......................................................................................................13-27
13-1
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-2
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-3
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition
Class
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23)
°C
— Atmospheric temp
50°C~-10°C
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — (122°F~14°F)
H mode Lo idle 1000 + 30 - 30 LOW throttle
Engine speed
not required
Adjustment
Measure the engine
B mode Hi idle 2100 + 30 - 30 Perform all
speed at multi display on min-1
A mode Hi idle 2100 + 30 - 30 measurement with
the gauge cluster.
Decel 1050 + 30 - 30 the air-conditioner
S mode Hi idle 1900 + 30 - 30 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure
P1 a1
Main relief
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.5 (-650) (psi) OR2 Bucket dump
Bucket a1
H 39.7 (5760) 0 - 5.9 (-855) OR1 Bucket digging
RH 28.5 (4130) + 4.0 (+580) + 1.0 (+145) OR6 Swing RH
Swing a2
LH 28.5 (4130) + 4.0 (+580) + 1.0 (+145) OR5 Swing LH
FW —
RH a1 34.3 (4970) + 0.7 (+100) - 0.5 (-73) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 34.3 (4970) + 0.7 (+100) - 0.5 (-73) RH and LH
RV —
13-4
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
Standard
Inspection item Unit
value
Sprocket revolution 1st speed 32.7 ~ 29.5
min-1
(RH,LH) 2nd speed 52.9 ~ 47.9
Up 2.8 ~ 3.4
Boom
Down 2.3 ~ 2.9
Operating speed
55 ~ 75 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 95
ATT amount of drift Boom cylinder 7 mm / 5min (At no load)
Arm cylinder 6
Amount of horizontal play at the bucket tooth 30 ~ 50 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out
13-5
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13. 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 OF
F
MODE HM
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V
13-6
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
B1
After releasing air in the hydraulic oil tank, open the
cover and sample oil in the hydraulic tank, and a1 a2
measure with the instrument for analysis. If the
Fig. 13-3 Gauge port on main pump
measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.
13-7
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
PLUG FOR
OR8 : ARM (R) OPTIONAL RELIEF
MACHINE
FRONT
MACHINE
FRONT
13-8
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
A3
a5
Dr3
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
13-9
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)
: 6 mm
: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 6 mm
: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 6 mm 0-:
Fig. 13-9 Over load relief valve
No. of turns of adjust screw Pressure change MPa (psi) (Boom, bucket, arm sections)
13-10
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
: 19 mm
: 6 mm
13-11
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-12
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
(3) Preparation
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket
is lifted by about 30cm (1ft). A
(4) Measurement 20m (66ft)
1) Measure the max. deviation distance of the
circular arc in the 20m (66ft) length, excluding
Fig. 13-15 Measuring method
the preliminary run of 3~5m (10~16ft).
2) Operate the travel lever at the same time. Travel deviation Unit : mm (in) / 20m (66ft)
Measuring Reference value
position Standard value for remedy Service limit
A 240 (9.45) or less 480 (18.9) 720 (28.4)
C
GUIDE FRAME
Fig. 13-17 Method of measurement
13-13
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-14
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-15
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-16
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-17
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-18
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-19
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-20
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
E-27:
C-8: EMERGENCY
ACCEL
ENGINE CONTROLLER
INJECTOR
E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
13-21
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.9.2.3 PREPARATION
(1) Raise the oil temperature to about 50°C (122°F) to warm up the engine.
(2) Turn the air-con OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the adjustment data
is not entered.
A215, A225, A015, A025, 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.
For machines equipped with lifting magnet, turn the generator OFF.
13-22
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
MULTI DISPLAY
WASHER SWITCH
WIPER SWITCH
SELECT SWITCH
4) After starting engine, press selector switch on gauge cluster, and "MEMORY
ENG" is displayed, the engine speed is automatically increased, and the
adjustment of engine is performed.
(When trying to limit engine speed, press selector switch on gauge cluster at
the speed as it is, and the adjustment of engine is terminated. The torque
adjustment and unloading adjustment required later are not performed, and
default value is written.)
5) When normal HIGH idling speed is detected, the adjustment is completed. And
FINISH ENG
"FINISH ENG" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared, PUMP PRESSURE
C-1 2.0M C-2 2.0M
and the adjustment of engine is completed. The torque adjustment and STEP
400
unloading adjustment required later are not performed, and default value is
written.)
13-23
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
2) When the unloading valve operates to the specified value, the adjustment of
unloading proportional valve is automatically terminated. And "FINISH
UNLOAD" is displayed.
The speed is shifted to the speed corresponding to acceleration potentiometer.
(4) Corrective actions taken when the adjustment can not be performed;
ERROR ENG.
1) In cases where the adjustment of engine can not be performed; And ERROR ENGINE SPEED
2000rpm
PUMP PRESSURE
ENG" is displayed. C-1 2.0M C-2 2.0M
STEP
Judging condition: The read engine speed is 50rpm lower than the last value. 400
It is conceived that the error is caused by the speed read error, pump load
applied to the engine and unusual acceleration command voltage applied to
the engine controller in the course of adjustment.
a. Checking speed sensor: Check that it is free from wrong reading of speed
due to engine vibration.
b. Checking load applied to pump: Check that it is free from abnormal
increase of pump pressure during adjustment of engine through
adjustment screen.
c. Checking acceleration command voltage: Measure the acceleration
command voltage output from mechatro controller to engine controller.
Check that signal is regularly input to the engine controller by actual
measurement of voltage or with failure diagnosis tool of engine controller.
13-24
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
2) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
P1 and P2 average pump pressure at the time when the adjustment is E-1 300mA E-2 300mA
completed is 25MPa or less.
Judging condition 2:
The adjustment does not complete although the pump proportional valve
current reaches to the specified value.
For machines equipped with lifting magnet, turn the generator OFF.
13-25
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13. MAINTENANCE STANDARD AND TEST PROCEDURE
(6) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are
replaced, perform the adjustment of unloading valve only.
Procedure
1) Turn starter switch ON keeping the work mode selector switch on the gauge
cluster pressed, and hold it for 5~10 seconds, and then release it.
(If the engine is started, the following indication is not displayed. Therefore do
not start the engine.)
2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release
it and the screen for selection of adjustment type is displayed. And "ADJUST"
ADJUST
READY
is displayed. FEED
When adjustment data is not entered in mechatro controller, "READY" is
indicated. If the adjustment operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Change the adjusting items with washer switch ( ) and wiper switch ( ), and
select "ADJUST UNLOAD". (See Fig. 13-35)
Like the output adjustment, when adjustment data is not entered in mechatro
controller, "READY" is indicated. If the adjustment operation is once
performed, "FIN" is indicated.
4) Press selector switch on gauge cluster to display "START ENG".
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration
command voltage) are indicated.
5) After starting engine, press selector switch on gauge cluster and "MEMORY
MEMORY UNLOAD
UNLOAD" is indicated, the engine speed is automatically increased and the ENGINE SPEED
2000rpm
adjustment of unloading valve is performed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" PROPO-VALVE
D-1 300mA D-2 300mA
6) When the unloading proportional valve operates to the specified value, the
adjustment of unloading proportional valve automatically completes. "FINISH
UNLOAD" is indicated.
The speed is shifted to the speed corresponding to acceleration potentiometer.
13-26
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Operating procedure:
1) Set the emergency acceleration to NORMAL position.
2) Start engine.
3) Turn the emergency acceleration to HI side and control the engine speed.
4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping.
Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed does not increase.
When the machine does not operate, set the emergency acceleration to NORMAL position.
The emergency mode should be used in only case of emergency. We recommend that the defective section is
repaired by troubleshooting as early as possible.
13-27
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
13. MAINTENANCE STANDARD AND TEST PROCEDURE
[MEMO]
13-28
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21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
21-1
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21. MECHATRO CONTROL SYSTEM
21-2
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21. MECHATRO CONTROL SYSTEM
PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the
conditions before and after each conversion, refer to the hydraulic system and the electric system.
21-3
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21. MECHATRO CONTROL SYSTEM
%
% %
% % %%
%
% %
% %
%
% %
%%
(
)
% % *+
%
%
% %
$%
%
!"#
$% %
21-4
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21. MECHATRO CONTROL SYSTEM
SE-29
P1 UNLOAD
ATTACHMENT BOOST
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
PL1
SOL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3
L4
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
L5
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
21-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective
low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by
mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the
pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
21-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
21-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also
with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and
consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
21-9
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
21-10
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
21-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low
pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot
signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2
unload proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve
for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump
delivery rate is low due to low engine speed.
21-12
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is
input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valves.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
21-13
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and
P2 unload proportional valves and travel straight proportional valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of the control valve.
(4) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
21-14
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-15
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
(1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches bucket spool and
is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and
P2 unload proportional valves and travel straight proportional valve.
(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of control valve.
(5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary
pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump
delivery rate is low.
(7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the
pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the
stroke limit of bucket spool.
21-16
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
VALVE
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure
sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot
secondary pressure switches swing spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2
unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel
straight spool, arm 2 spool.
(4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched
enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil
on arm cylinder rod side is recirculated into arm cylinder head side.
(5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate
is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum
speed drop possible.
21-17
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTIONAL
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C
21-18
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
21-19
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
SE-23 SE-22
ENGINE
PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER SECONDARY PRESSURE
(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot,
accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum
tilt angle.
2) Outputs command of pressure release and outputs command of pressure release control to ECU and fixes
engine speed to pressure release control speed.
3) Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes P1 and
P2 unload valves to the maximum opening.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to
be released by operating each control lever and switching spool with the unload valve opened.
21-20
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SE-29
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
21-21
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
PILOT VALVE
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
21-22
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)
21-23
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25 For the work with breaker, select "B mode" without fail.
A mode
10:25 For the work with crusher (nibbler), select "A mode".
21-24
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 246L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.
10:25 Flow
rate 130 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 130 L/m rate 130 L/m
A B
(b) (c)
21-25
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 2,000 Hr
• The display automatically changes to the main screen, if switch is not operated for 30 seconds.
• For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.
21-26
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
MACHINE CONDITION
H
MULTI DISPLAY INDICATIONS
1) Display function for operator ......... Screen usually displayed during operation
1.1 Clock display function ......... Current time is displayed.
1.2 Self-diagnosis display ......... When abnormality is detected on mechatro system like sensor, proportional
valve, etc., this displays error code.
1.3 Warning display ......... When machine was thrown into dangerous state, or was failed, displays warning
contents with the symbol and statement. (For warning contents, see items
shown below.)
1.4 Machine condition display ......... Displays machine operating condition.
2) Display function for maintenance ......... Displays remaining time up to replacement/change of following
items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3) Failure history display function ......... Stores abnormality occurred on mechatro system in the past and
displays in order of recent occurrence.
4) Mechatro adjustment display ......... Displays procedure for adjustment of mechatro system like output
adjustment and unload adjustment, etc.
5) Service diagnosis display ......... Displays information like pressure sensor sensed value, proportional valve
command, etc. output by mechatro controller
6) Failure diagnosis mode display function ......... Specifies failed section automatically for failures which are
not detected by self diagnosis and displays the results.
HIGH ENG
AUTO IDLE STOP WATER TEMP.
W006 CHARGE ERROR
WARM FINISH WARM-UP DRAIN WATER SEPA W010 WARM AUTO WARMING UP
DATA
CPU COMMUNICATION CLOGGED AIR FLTR W008 CHANGE ENG OIL
ERROR
SWING BRAKE
ENGINE STOP
DISENGAGED
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
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21. MECHATRO CONTROL SYSTEM
CONTROL
Pressure sensor, Engine controller SERIAL COMMUNICATION
INPUT Proportional valve, Battery relay Gauge cluster
Selector valve (SOL) (Buzzer sound)
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21. MECHATRO CONTROL SYSTEM
Note)
The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.
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21. MECHATRO CONTROL SYSTEM
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21. MECHATRO CONTROL SYSTEM
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 2205 No load setting rpm B-1 BOOM RAISE
MEAS1 2201 Actual rpm 1 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS2 2201 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 2.6M Sensor voltage / Pressure converted value
WATER TEMP 100 OFF Coolant temperaturre sensor B-3 ARM OUT
MODE HM Work mode 3.5V 2.6M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage B-4 ARM IN
POS. 100% Voltage % indication 3.5V 2.6M Sensor voltage / Pressure converted value
ECU OUTPUT 0.5V Accel output voltage to engine B-5 BUCKET DIG
controller 3.5V 2.6M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
3.5V 2.6M Sensor voltage / Pressure converted value
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL(R)
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL(L)
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
B-19 DOZER 2
3.5V 2.6M Sensor voltage / Pressure converted value
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21. MECHATRO CONTROL SYSTEM
7 16
NO.7 P.SENSOR PROPO-V NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-3 BOOM-HEAD B-13
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-4 BOOM-ROD B-14
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
PROPO-VALVE B-15
E-3 OPT RELIEF 1 Set value in computer / Converted value from pressure 3.5V 12.6M Sensor voltage / Pressure converted value
COMP. 600mA 14.5M Measured value / Converted value from pressure B-20
MEAS. 600mA 14.5M 3.5V 12.6M Sensor voltage / Pressure converted value
E-4 OPT RELIEF 2 Set value in computer / Converted value from pressure
COMP. 600mA 14.5M Measured value / Converted value from pressure
8 NO.8 PROPO-VALVE
18
NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI2 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI6 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI9 OFF ON/OFF indication
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI11 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI12 OFF ON/OFF indication
DI13 OFF ON/OFF indication
DI14 OFF ON/OFF indication
9 19 NO.19 DIGITAL INPUT
NO.9 PROPO-VALVE
E-1 P1 PUMP DI15 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI16 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI17 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI21 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI22 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 OFF ON/OFF indication
DI26 OFF ON/OFF indication
DI27 OFF ON/OFF indication
DI28 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
4.5V 90 Fuel level DI30 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI31 OFF ON/OFF indication
4.5V 30 Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW OFF Glow switch DI33 OFF ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 OFF ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 OFF ON/OFF indication
ENG OIL FILTER LIVE Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 OFF ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI39 OFF ON/OFF indication
HEATER OFF Command from air heater DI40 OFF ON/OFF indication
ENG OIL LEVEL LIVE Engine oil level DI41 OFF ON/OFF indication
COOLANT LEVEL LIVE Coolant level DI42 OFF ON/OFF indication
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value DO5 COMP. OFF Set value in computer
F-6 MEAS. OFF Measured value
COMP. OFF Set value in computer DO6 COMP. OFF Set value in computer
MEAS. OFF Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
12 22
NO.12 POTENTIO. NO.22 DIGITAL OUTPUT
H-2 BOOM DO8 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
H-3 ARM DO9 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
DO10 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO11 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO12 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO13 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO14 COMP. OFF Set value in computer
MEAS. OFF Measured value
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21. MECHATRO CONTROL SYSTEM
31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
B-1 BOOM RAISE 1.9M Boom up pressure sensor D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL(R) 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVEL(L) 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot pressure at travel straight (P1 side)
Pi-P2 13.9M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
D-3 S-TRAVEL 600mA Command current D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARM OUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B-4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux/ Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current
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21. MECHATRO CONTROL SYSTEM
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
15mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 2040 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 600mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 137 137 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 137 137 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 137 137 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 137 137 Angle adjustment
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21. MECHATRO CONTROL SYSTEM
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
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21. MECHATRO CONTROL SYSTEM
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 12.5~16.5 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 12.5~16.5 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 550~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 550~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 400 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 2100~2190 G-3 ENG SPEED 2100~2190
POWER SHIFT 0 mA POWER SHIFT 0 mA
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21. MECHATRO CONTROL SYSTEM
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21. MECHATRO CONTROL SYSTEM
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21. MECHATRO CONTROL SYSTEM
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21. MECHATRO CONTROL SYSTEM
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
All the stored items are erased. It is impossible to erase data partially.
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21. MECHATRO CONTROL SYSTEM
For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
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21. MECHATRO CONTROL SYSTEM
time is stored. H
1. After displaying the display for setting by pressing the display change switch, set the respective maintenance
time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not
sound.
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21. MECHATRO CONTROL SYSTEM
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
AUTO IDLING STOP
(d)
AUTO WARM-UP AUTO IDLE STOP AUTO IDLE STOP
OFF OFF ON
(c)
(e)
AUTO IDLE STOP AUTO IDLE STOP
OFF ON
OFF ON OFF ON
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST"
select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
3. In operation of FEED (4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
4. In operation of FEED (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
(e) is displayed.
5. Switch from "OFF" to "ON" in operation of FEED (4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
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21. MECHATRO CONTROL SYSTEM
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).
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21. MECHATRO CONTROL SYSTEM
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555)
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH
STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5. Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) 99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).
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21. MECHATRO CONTROL SYSTEM
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option Does left rotation pedal use?
attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Optional flow rate limitation, relief pressure limitation, combination of return
Setting of optional equipment
selector adjustment)
Engine speed ON/OFF of engine rpm display
Adjustment the type of the engine speed of auto deceleration runs up
Auto acceleration
abruptly.
Change of starter mode Change of start mode
Low temperature mode forcible
Low temperature mode release
release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
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21. MECHATRO CONTROL SYSTEM
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
24 RXD3 Reception RS232C communication
25 DL EARTH / OPEN(5V
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Rotary light (yellow) Output EARTH/OPEN
33 DO 24 Rotary light (green) Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
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21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A28 Spare Input 0.5~4.5V
21 +5VA Power output 5V
22 D1 37 Spare Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
15 +5VA Power output 5V
16 Reserved
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21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A18 Boom rod Input 0.5 4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A20 Spare Input 0.5~4.5V
12 GA 0V
13 A21 Spare Input 0.5~4.5V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
17 A23 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
21 +5VA Power output 5V
22 +5VA Power output 5V
23 A25 Spare Input 0.5~4.5V
24 GA 0V
25 GA 0V
26 A26 Spare Input 0.5~4.5V
27 +5VA Power output 5V
28 DI 1 Cab slow up and down Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN105 1 +24V Battery relay output side 20~32V
2 +24V Battery relay output side 20~32V
(sensor analog output)
3 +24V Battery relay output side 20~32V
4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 Travel 1,2 speed select valve Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
9 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
21 GND Battery (-) 0V
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ Cab slow stop valve Output +0~800mA
26 D7- -0~800mA
27 D8+ Boom cushion Output +0~800mA
28 D8- -0~800mA
29 D9+ Arm cushion Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
21-49
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase (spare) Output +24V 1.5A
4 F1- Accel motor A phase (spare) Output +24V 1.5A
5 F2+ Accel motor B phase (spare) Output +24V 1.5A
6 F2- Accel motor B phase (spare) Output +24V 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
13 D13+ Spare Output +0~800mA
14 D13- -0~800mA
15 D14+ Spare Output +0~800mA
16 D14- -0~800mA
17 GND Battery (-) 0V
18 D12+ Spare Output +0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication
Connector No. Pin No. Port name Function Input/putput Signal level
CN107 1 DI 3 Key switch (GLOW) Input +24V/OPEN
2 DI 8 Water separetor Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Stroke end check Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
8 DI 14 Spare Input EARTH / OPEN
9 DI 15 Spare Input EARTH / OPEN
10 DI 20 ECU main relay Input EARTH / OPEN
11 DI 28 Spare Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Extra pressure Input EARTH / OPEN
15 DI 40 Spare Input EARTH / OPEN
16 DI 41 Spare Input EARTH / OPEN
17 Reserved
21-50
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Spare Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 High reach hoisting at fixed position Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Nibbler open check SW Input GND / OPEN
10 DI 21 Elevator cab up check Input +24V / OPEN
11 DI 22 Spare Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation / Input
clamp open or close GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Hand control breaker Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 High reach (hoist at travel) Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
22 DI 34 Spare Input +24V / OPEN
23 DI 35 Spare Input +24V / OPEN
24 Reserved Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Accel signal 2 0~5V
28 H2- 0V
Connector No. Pin No. Port name Function Input/putput Signal level
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Bucket move limitation Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Rotary light (RH) Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Extra pressure release Output GND / OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Tranmission RS232C communication
18 RXD2 Reception RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shiled GND
22 DO 10 Cab up and down switching valve SV 24V/OPEN
21-51
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
No. Item name Wire color No. Item name Wire color
Gauge cluster Mechatro
GND source (+24V Battery Yellow /
1 controller (RS232C White 5
direct connection) Black
communication)
Mechatro controller Gauge
2 cluster (RS232C Red 6 GND Black
communication)
Source (+24V starter switch
3 Reserved — 7 White
ON)
GND (RS232C
4 Reserved — 8 Black
communication)
3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
21-52
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
21-53
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21. MECHATRO CONTROL SYSTEM
2) Circuit diagram
21-54
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21. MECHATRO CONTROL SYSTEM
21-55
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
21-56
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
Vcc GND
SPECIFICATION :
PRESSURE RANGE : 0 3.0 MPa
RATED VOLTAGE : 5.0+0.5V DC
OUTPUT CHARACTERISTIC INSURANCE RESISTANCE : 50M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)
21-57
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
21. MECHATRO CONTROL SYSTEM
[MEMO]
21-58
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
TABLE OF CONTENTS
22.1 SUMMARY.......................................................................................................................22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS ...............................................................22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS........................................22-8
22.4 NEUTRAL CIRCUIT.........................................................................................................22-8 22
22.5 TRAVEL CIRCUIT ...........................................................................................................22-10
22.6 BUCKET CIRCUIT...........................................................................................................22-12
22.7 BOOM CIRCUIT ..............................................................................................................22-14
22.8 SWING CIRCUIT .............................................................................................................22-18
22.9 ARM CIRCUIT .................................................................................................................22-20
22.10 COMBINED CIRCUIT ......................................................................................................22-26
22.11 PRESSURE DRAINING (RELEASING) CIRCUIT ...........................................................22-30
22-1
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22-2
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22. HYDRAULIC SYSTEM
22.1 SUMMARY operability, safety, mass volume handling and low fuel
consumption.
The hydraulic circuits are built up with the following
functions and features in order to achieve easy
Table22-1
Perfor- Device
mance Function Features
Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever
Attachment
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Holding valve for boom (Option) Prevention of boom falling when boom head side piping breaks
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others
Positive flow rate control Flow control by positive pilot control pressure
Hydraulics backup control Backup control by hydraulic when the electric flow controlled
variable displacement pump fails.
Boom up conflux circuit Speed up of boom up operation
Attachment
Micro
22-3
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22-4
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22. HYDRAULIC SYSTEM
22.2.1 STANDARD
R/G
P2 P
PSV-P1 PSV-P2
Av
P2
R/G
P1
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
LCb LCs Pss
BOOM SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
22-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
NOTE:
PTb 1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT.
TRAVEL 2. SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR BREAKER IN SERVICE.
P1 UNLOAD PRIORITY
PCb
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
SELECTION
(W: , W/O: )
M CONFLUX / SINGLE FLOW ELECTROMAGNETIC COMMAND SIGNAL P1 P2 TRAVEL
P2 UNLOAD CHANGEOVER SWITCH OF SELECTOR VALVE (ITEM 50)(W:O,W/O:-) PUMP PUMP STRAIGHT P1 UNLOAD P2 UNLOAD
51
LEFT
NIBBLER
NOTE 4
HYD.TANK 53 RIGHT
BREAKER
PBo 52
OPTION
PAo NIBBLER & BREAKER
PILOT VALVE
24.5MPa Ao
Bo T
P
24.5MPa
B C1 C2 A
SOL/V BLOCK LEVER
A1 LOCK P
SE-11
50 SV-13
Ps C PL
P
SE-29
YN01Z00162P1 01
22-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT 22.4.3 PUMP POSITIVE FLOW CONTROL resulting in the reduction of tilt angle. Similarly,
FOR HYDRAULIC CIRCUITS (1) Type : when the servo piston moves rightward, the
This section describes the following.
Electric flow controlled variable displacement spool (652) is moved leftward by the feedback
Blue (1) Bypass cut valve and unload valve control
pump. lever.
Feed, drain circuit (2) Safety lock lever and pilot circuit The operation is maintained until the opening of
less than 0.44 MPa (64 psi) (2) Principle :
(3) Pump positive flow control spool sleeve is closed.
Green The current command I to the pump’s solenoid
(4) Pump P-Q (Pressure-Quantity) curve control proportional valve controls the delivery rate of the
Return, make up circuit, 22.4.4 PUMP P-Q CURVE CONTROL
0.44~0.59 MPa (64~86 psi) pump. OPERATION
22.4.1 OPERATION OF BY-PASS CUT VALVE
Purple AND UNLOADING VALVE HOUSED IN (3) Operation : (1) Type :
Secondary pilot pressure, CONTROL VALVE 1) Flow rate rise operation (Eg. P1 pump) Electrical flow control type variable pump
(including proportional vlave) By operating any of control levers, the
(1) By-pass cut valve (2) Principle :
0.59~5 MPa (86~725 psi) operating secondary pressure of pilot valve
On starting engine, P1 and P2 unloading Perform an operation of the value from pump high
Red rises, and the rising pressure is transformed to
proportional valves (PSV-D, PSV-B) output pressure sensor to P-Q curve control value, and
Primary pilot pressure, the rise of output voltage corresponding to the
secondary pressure according to the command send a command to the pump solenoid proportional
(including proportional vlave) pressure input by the low pressure sensor.
output by mechatro controller, and this pressure valve.
5 MPa (725 psi) Mechatro controller signal-processes this
exerts on PBp1 and PBp2 ports, and consequently (3) Operation :
Orange change of voltage, resulting in rise of command
the by-pass cut spool is switched to CLOSE side. The pump high pressure sensor converts the
Main pump drive pressure, current value I to the pump proportional
The by-pass cut spool is usually held on CLOSE pressure to the output voltage corresponding to the
5~34.3 MPa (725~4970 psi) solenoid valve and consequently the pump flow
side after the engine started. And it is switched to pump delivery pressure.
Blue tone rate rises. This is called "Positive Control
OPEN side only when failure occurred on pump The mechatro controller converts the voltage output
At valve operation System".
proportional valve and mechatro controller. by the high pressure sensor to the P-Q curve
Red valve As the pump command current value rises, the
(2) Unloading valve control value. On the other hand, select the pump
When solenoid proportional valve (reducing) secondary pressure of proportional solenoid
On starting engine, like by-pass cut valve, the positive control command current value from the
is operating valve also rises. On the regulator attached on
secondary pressures output by P1 and P2 low pressure sensor in lower order, and the values
Red solenoid the pump, the spool (652) through piston (643)
unloading proportional valves (PSV-D, PSV-B) are output to respective pump proportional valve as
In active and exciting is pushed leftward, and stops at the position
exert on PCb and PCa ports, consequently the P1 a command current.
Displaying the flow circuit and standby circuit when where being in proportion to the force of pilot
and P2 unloading valves are switched to OPEN With this operation, the pump power is controlled so
operating. spring (646).
side. as not to be exceed the engine power, therefore
Regarding the electrical symbols in this manual, refer to The tank port connected to the large bore of
engine dose not stall.
the electric circuit diagram. 22.4.2 SAFETY LOCK LEVER AND PILOT servo piston (532) opens, and the piston
CIRCUIT moves leftward by delivery pressure P1 of the
(1) Purpose : small bore resulting in the increase of tilt angle
To protect attachment from unexpected movement ( ).
for safety. The servo piston and spool (652) are
connected to feedback lever (611). Therefore
(2) Principle :
when servo piston moves leftward, the spool
Cut pressure source of pilot valve for operation.
(652) also moves rightward by means of
(3) Operation :
feedback lever. With this movement, the
If the safety lock lever (red) is pushed forward after
opening of spool sleeve closes gradually, and
the engine starts, the limit switch (SW-11) is turned
the servo piston stops at the position the
on. The timer relay is actuated one second later
opening closed completely.
which causes the solenoid (SV-4) of the solenoid
2) Flow rate reduction operation
valve block (13) to be energized and makes the
As the current value I of mechtro controller
pilot operating circuit to stand by.
reduces, the secondary pressure of solenoid
proportional valve reduces, and spool (652) is
moved rightward by the force of pilot spring
(646). With the movement of spool, the delivery
pressure P1 usually flows into the large bore of
piston through the spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of area,
22-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
651
652
643 532 8 B Mv A
a3 646 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2
SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
22-9
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22-10
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.
22-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22.6 BUCKET CIRCUIT 5) The secondary pressure delivered in travel 3) With the function of pilot circuit, the oil flow is
straight proportional valve (PSV-C) is led to switched from bucket spool, and is fed into
This section describes the following.
PTb port provided in control valve (2) and shifts bucket cylinder head side through AC port of C/
(1) Bucket digging pilot circuit
the travel straight valve one stage. V (2). On the other hand, the return oil from
(2) Auto accel operation cylinder rod (R) side is throttled by bucket spool
22.6.2 AUTO ACCELERATION OPERATION
(3) Flow control in the work mode and returns to tank circuit from BC port of C/V
(1) Principle : (2).
(4) Bucket digging travel straight main circuit
Auto acceleration actuates according to signals
(5) Bucket spool stroke limiter References :
from low pressure sensor.
• In bucket dumping operation, the travel straight
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING (2) Operation :
valve also switches like digging operation,
(1) Mechatronics : <When lever is set to neutral position>
resulting in confluence with travel straight.
In the event where the sensor does not receive
1) When the operation for bucket digging is • When the bucket operation and other operation
signal for 4 seconds or more even though the
performed, the pilot proportional secondary are simultaneously performed, the travel straight
acceleration dial is set to MAX position, the engine
pressure is delivered through port 1 of the right valve does not actuate, resulting in single flow of
speed should be raised to 1000rpm.
pilot V (9), flows to PAc port, and acts on the low bucket circuit.
<When lever is operated>
pressure sensor (SE-1), and at the same time
When the pressure 0.6MPa (87psi) is input to low 22.6.5 BUCKET SPOOL STROKE LIMITER
the bucket spool is switched.
pressure sensor in STD specification (travel,
2) The voltage output by low pressure sensor (1) Purpose :
bucket, swing, arm), proportional voltage from low
inputs in mechatro controller. The mechatro To secure simultaneous operability of boom and
pressure sensor inputs in mechatro controller, and
controller performs signal processing and arm on boosting up attachment pressure (Pump
then the engine speed returns to the dial set
outputs current corresponding to the increase flow rate decreases.) and to prevent cavitations at
position corresponding to the lever operation.
of pump flow rate to pump proportional valves low engine speed
(PSV-P1) and (PSV-P2) on the P1 and P2 22.6.3 STAND-BY CURRENT CONSTANT (2) Operation :
pump sides, and at the same time the CONTROL On boosting up attachment pressure, pilot primary
command current is output to P1 unloading (1) Principle : pressure exerts on PCc port of C/V(2) through
valve (PSV-D), P2 unloading valve (PSV-B) and When the engine speed is intermediate speed or attachment booster solenoid valve, operates stroke
travel straight proportional valve (PSV-C). lower, command current value to have the pump limiter of bucket spool, and throttle oil path of spool.
In the following pages, the relation of operation delivery rate constant is output. As a result, P1 pump pressure increases, making
of low pressure sensor to both the increase of the simultaneous operation of boom up and bucket
(2) Operation :
pump flow rate and unloading proportional digging possible.
Even if the engine speed specified by acceleration
valve is the same. Therefore the explanation is Even though the engine speed is low, similarly the
potentiometer is low speed, as the delivery rate
omitted. cavitations can be prevented by actuating the
corresponds to the intermediate speed, the
3) The secondary pressure output by P1 pump stroke limiter.
actuator moves earlier than the movement
proportional valve (PSV-P1) and P2 pump equivalent to the control lever angle rate in light
proportional valve (PSV-P2) exerts on pump load operation.
regulator, actuating the pump onto the delivery
flow increase side. 22.6.4 BUCKET DIGGING AND TRAVEL
STRAIGHT CONFLUENCE (CONFLUX)
4) The secondary pressure delivered in P1
MAIN CIRCUIT
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is led to PBp1, PCb, PBp2 and (1) Operation :
PCa ports provided in control valve (2). 1) The oil delivered through A1 port of P1 pump
The secondary pressure from proportional goes into P1 port of C/V (2), opens load check
valve which has exerted on PBp1 and PBp2 valve LCc through parallel circuit and enters in
ports holds the by-pass cut spool on CLOSE bucket spool.
side, like the operation in the lever neutral 2) On the other hand, the oil delivered through P2
position. port of P2 pump goes into P2 port of C/V (2),
The secondary pressure from proportional confluences with oil from P1 pump through
valve which has exerted on PCb and PCa ports travel straight valve, and goes into bucket
switches the unloading spool in CLOSE side. spool. (Confluence of oil from 2 pumps)
22-12
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Travel straight conflux), Auto-accelation and Standby flow rate constant control
22-13
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22-14
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function.
22-15
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION
(1) Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
(2) Prevention of natural fall by lock valve and (1) Purpose :
actuation at lowering Prevention of cavitation during boom
lowering motion.
(3) Constant recirculation function of boom down main
circuit (2) Principle :
The oil returning from the boom cylinder head (H) is
22.7.3 BOOM DOWN PILOT CIRCUIT recirculated to the rod (R).
(1) Operation : (3) Operation :
1) If the boom down operation is performed, the When the oil is supplied to the boom cylinder rod
secondary pilot proportional pressure comes (R) side during boom down operation, the boom
out of portáC of the right pilot valve (9) and acts moves faster than it should do in some cases by the
upon the low pressure sensor (SE-4). self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod (R)
PBb port of C/V (2). side is on the negative side.
2) The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R) flows
(SE-4) enters the mechatro controller and into the A1 port of the P1 pump and the P1 port of
processed in it. C/V. The oil then passes through the boom spool
and goes out of the Bb port.
3) Then, the proportionl secondary pressure fed
On that occasion, the oil returning from the head
into C/V (2) PBb port and branches off in two
(H) goes through the recirculation path in the boom
lines and switches boom spool and releases
spool, pushes the check valve in the spool open, is
boom lock valve.
recirculated to the Bb port and is supplied to the rod
22.7.4 PREVENTION OF NATURAL FALL BY (R). When the (R) pressure is larger than the head
LOCK VALVE AND ACTUATION AT (H) pressure, the check valve in spool closes.
LOWERING Thereupon, the recirculation is stopped.
(1) Purpose :
Prevention of natural fall when the lever is neutral
(2) Principle :
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation :
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from making a
natural fall.
22-16
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.
22-17
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22-18
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
22-19
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22.9 ARM CIRCUIT with P2 pump delivery oil in the valve section,
and then is flowed into arm cylinder head (H)
This section describes the following operations.
side through Aa port of C/V (2).
(1) Arm in, light-load operating pilot circuit
3) The return oil from arm cylinder (R) side flows
(2) Arm in, light-load variable normal recirculation main
in Ba port of C/V (2) and passes through the Ba
circuit / internal conflux main circuit
port because the arm lock valve CRar is open,
22.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT and is flowed into arm 2 spool through arm 1
CIRCUIT spool.
(1) Purpose : 4) Because arm 2 spool is switched to normal
Speed-up and Anticavitation when the arm is at recirculation position, causing restriction of
light loaded. passage to tank, the return oil from arm cylinder
(R) side flows into arm cylinder (H) side.
(2) Principle :
The oil returning from the arm cylinder rod (R) is • Because, at light load, the pressure in
recirculated variably to the head (H) at arm 2 spool cylinder rod (R) side is higher than that in
in C/V. the head (H) side, it opens the check valve
housed-in arm 2 spool and is recirculated in
(3) Operation :
the head (H) side, resulting in the speed up
1) When the arm in operation is performed, the
of arm-in operation at light load.
secondary pilot proportional pressure gets out
5) Cavitations prevention control in arm-in
of port 7 of the left pilot valve (9) and acts upon
operation
the low pressure sensor (SE-7).
Command current is output to arm 2 solenoid
At the same time, the pressure is branched off
proportional valve by signal processing of E/G
in two flows, acts upon the Paa1 port and the
speed and arm-in pilot pressure, accordingly
PLc2 port, changes over the arm spool and the
the arm 2 spool is switched to neutral
arm lock valve CRar. releases.
(cavitations prevention) position, resulting in
2) The output voltage by the low pressure sensor
cavitations prevention.
is input into mechatro controller, and is pilot
signal-processed, and is output to P1, P2 pump
Position of arm 2 spool
proportional valve (PSV-P1), (PSV-P2) and arm
2 inverse proportional valve (PSV-A). Neutral position
(Anticavitation position)
3) The secondary pressure from pilot proportional Normal recirculation position
valve, which is reduced by arm 2 inverse Recirculation
proportional valve (PSV-A) switches arm 2
spool.
From arm out
P/V
22.9.2 ARM-IN, LIGHT-LOAD VARIABLE
From arm 2 inverse
NORMAL RECIRCULATION, INTERNAL proportional valve
CONFLUX MAIN CIRCUIT
Reference :
(1) Operation : In light-load arm-in operation (normal recirculation,
1) The P2 pump delivery oil flows in travel left conflux), when the attachment to which the circuit in
section through P2 port of C/V (2) and is P1 pump side is applied is operated, the meter-in
branched off in by-pass circuit and parallel path of arm 2 spool is closed, resulting in single flow
circuit, but because arm 1 spool is switched, the operation.
delivery oil which goes through parallel circuit
opens load check valve LCa and is flowed into Spool position at arm in,
light load and combined operation
arm 1 spool. (This position is not shown in hydraulic diagram)
2) On the other hand, P1 pump delivery oil flows in Neutral position Meter-in passage
P1 port of C/V (2), and the flows in travel (Close)
22-20
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
22-21
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
This section describes the following operations. 4) The return oil returns directly into tank circuit
(3) Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
(4) Arm in, heavy load operating sequence confluxed
Position of arm 2 spool
main circuit
Neutral position Recirculation cut position
22.9.3 ARM IN, HEAVY LOAD OPERATING
PILOT CIRCUIT
From arm out
(1) Operation :
P/V
1) In arm-in operation, when the heavy loading is
From arm 2 inverse
applied to arm and the P2 pump pressure proportional valve
increases to the set pressure, the voltage
output by P2 pump pressure sensor (SE-23) is
converted to signal (signal processing) by
mechatro controller, consequently the current
of arm 2 solenoid proportional valve is
controlled according to the load pressure and
the arm variable recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light load
operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.
22-22
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function
22-23
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
This section describes the following operations. 22.9.7 NATURAL FALL PROTECTION WITH ARM
(5) Arm out pilot circuit LOCK VALVE
(6) Arm out 2 pumps conflux main circuit (1) Purpose :
To prevent the arm from falling naturally by the
(7) Natural fall protection with arm lock valve
weight of the arm and bucket.
22.9.5 ARM OUT PILOT CIRCUIT (2) Principle :
(1) Operation : Complete seat of the return circuit against the arm
1) When the arm out operation is performed, the spool of the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out (3) Operation :
of port 8 of the left pilot valve (9), and acts upon 1) When the secondary pressure for arm
the low pressure sensor (SE-8). At the same operation disappears and the arm cylinder
time, the oil is branched off in two flows and act stops, the pressure on the rod (R) side passes
upon the PBa1 and Pba2 ports of C/V (2). through the selector of the lock valve from the
2) The operating proportional secondary pressure Ba port of C/V, acts the back pressure on the
flowed in Pba1 port of C/V (2) switches the arm lock valve CRar and seats the lock valve.
1 spool. 2) Since the oil flow into the arm spool from the
3) Then, the operating secondary pressure flowed lock valve is shut off completely, natural fall of
in PBa2 port of C/V (2) switches the arm 2 spool the arm due to oil leaks through the arm spool
valve. is prevented.
22-24
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
BOOST
15 14 PL
CMR1
CHECK ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-9 ARM CIRCUIT : Arm out operation, Confluence function
22-25
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
22-26
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.
22-27
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
In this section, the independent operation is omitted 22.10.4 SWING / ARM IN, SWING PRIORITY MAIN
and describes difference in combined operation. CIRCUIT
(3) Swing / Arm in light load, pilot circuit (1) Purpose :
(4) Swing / Arm in, swing priority main circuit Stable swing speed.
(2) Principle :
22.10.3 SWING / ARM IN LIGHT LOAD, PILOT
Raise the oil pressure flowing to arm cylinder, and
CIRCUIT
give a priority of the delivery of P2 pump to swing
(1) Operation : operation.
1) On operating swing (left) and arm in motions (3) Operation :
simultaneously, mechatro controller outputs
1) The swing main circuit operates with P2 pump
command current to travel straight solenoid
flow. But on P2 pump circuit side, the flow goes
proportional valve (PSV-C) and arm 2 solenoid
to the swing circuit and arm circuit
inverse proportional valve according to signal
simultaneously because the swing circuit and
processing, and this proportional valve outputs
arm circuit are parallel. Then since the return oil
secondary pressure, which acts on PTb port
from arm cylinder rod (R) side is restricted in
and PAa2 port of C/V(2).
the arm 2 spool because the arm 2 spool is
2) PTb port pressure switches the travel straight switched to forced recirculation position, the
spool 2 steps, and the PAa2 port pressure pressure of return oil is raised, causing the rise
switches the arm 2 spool to the forced of circuit pressure on the arm cylinder head (H)
recirculation position. side.
2) At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.
This operation is called "Swing Priority Circuit".
22-28
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
LCAP2
SV-2 PBa2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function
22-29
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
This section describes the following operations. 22.11.2 PRESSURE RELEASE MAIN CIRCUIT
(1) Pressure drain (releasing) pilot circuit (1) Operation :
(2) Pressure drain (releasing) main circuit
22-30
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
R/G
PSV-P1 PSV-P2 P2
Av
P2
R/G
P1
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 LEVER CYLINDER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.
22-31
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
22. HYDRAULIC SYSTEM
[MEMO]
22-32
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
TABLE OF CONTENTS
23-1
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
23-2
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
DC-DC CONVERTER,
ROOM LIGHT TUNER
CIGARETTE LIGHTER
HORN, HORN RELAY
GAUGE CLUSTER
IT CONTROLLER
MACHINE No. YQ11-06001-
AUTO GREASE
CONTROLLER
CONTROLLER
CONTROLLER
LEVER LOCK
LC10-07001-
BATTERY RELAY
MECHATRO
MECHATRO
C-8 : ENGINE CONTROLLER ENG. HARNESS
YC10-03501-
BACK UP
BACK UP
SUPPLY
TUNER
LQ12-06001-
LL12-05001- ENG. SPEED SENSOR
FOR ECU
SH7 SHIELD
E-1 : FUSE & RELAY BOX
R-26 :
LEVER LOCK RELAY
SOLENOID,
HIGH REACH,
LMN/BH
AIR CON.
AIR CON.
RADIATOR COOLANT
LEVEL CONTROLLER,
FLASHER, REAR WORK
LIGHT, TRAVEL ALARM,
ONE WAY CALL
DC-DC CONVERTER
WORK LIGHT
GAUGE CLUSTER
WIPER, WASHER
ROOF WIPER
OPT. 1
OPT. 3
OPT. HAND CONTROL
INJECTOR 2
E-12 : E-12 :
BATTERY BATTERY SH2 SHIELD
STARTER CABLE
INJECTOR 3
SH3 SHIELD
E27 :
R-1 : ACCEL REDUNDANT
E-15 : BATTERY RELAY VOLUME INJECTOR 4
FUSIBLE LINK
SH4 SHIELD
R-23 :
AUTO IDLE STOP RELAY 1 R-24 : R-25 : INJECTOR 5
AUTO IDLE ENG. EMERGENCY
STOP RELAY 2 STOP RELAY SH5 SHIELD
KEY ON
POSITION
INJECTOR 6
PREHEATING
SH6 SHIELD
START
TERMINAL
ENGINE START
ACC
OFF
ON
IN THE CASE OF
R-3 : SK330-8, SK350LC-8
GLOW RELAY GLOW
CYLINDER
DISCRIMINATION
G SENSOR
C-5 :
CONTROL : (SENSOR POWER RADIATOR COOLANT SW-27 :
SOURCE, CPU) LEVEL CONTROLLER RADIATOR COOLANT LEVEL SW.
OUT SOURCE :
(PSV, SOL. MOTOR)
R-28 : ALTERNATOR RELAY
23-3
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SE-3 : BOOM UP
POSITION
INJECTOR 1
SE-4 : BOOM DOWN
RELEASE
NORMAL
SW-4 :
TERMINAL SWING PARKING BRAKE RELEASE SW.
INJECTOR 2 SE-7 : ARM IN SV-1 :
SWING PARKING BRAKE SOL.
SE-8 : ARM UP
INJECTOR 3 SV-3 : TWO SPEED SELECT SOL.
SE-5 : SWING
SV-2 : POWER BOOST SOL.
IN CASE OF
INJECTOR 4 SK200-8, SE-9 : TRAVEL RIGHT PSV-B : P2 UNLOAD
SK210LC-8 PROPORTIONAL SOL.
SK250-8,
SK260LC-8
SE-10 : TRAVEL LEFT PSV-C : TRAVEL PRIORITY
PROPORTIONAL SOL.
SE-22 : PUMP P1
PSV-D : P1 UNLOAD
PROPORTIONAL SOL.
SE-23 : PUMP P2
PSV-A : ARM TWO-SPEED INVERSE
PROPORTIONAL SOL.
SE-11 : P2 OPT.
PSV-P2 : PUMP P2
PROPORTIONAL SOL.
OPT
SW-20 : POWER BOOST SW. RIGHT
SHIELD
(2/4)
LC03Z00036P1 02
23-4
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SW-15 : R-31 :
CONFLUX/SINGLE SELECT SW. PREVENT SPARK RELAY
R-29 :
WIPER MOTOR RELAY L-5 : ROOM LIGHT
OPT
M-3 : WIPER MOTOR
R-30 :
WIPER MOTOR REVERSING RELAY
GROUND
OUTPUT AIR CON.
AMP.
SW-19 : WIPER INTERLOCK SW.
COOLING
UNIT
SE-29 :
OPT. SELECTOR DETECT SENSOR
OPT
TO 4/4
(3/4)
LC03Z00036P1 02
23-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
FROM 3/4
E-2 :
ALTERNATOR
SV-7 :
SW-34: REVOLUTION
R-13 : REVOLUTION LEFT SOL
REVOLUTION LEFT SW.
OPT. LEFT RELAY
AUTO GREASE
REVOLUTION N&B
L-3 :
R-19 : FLASHER RELAY SWING FLASHER LEFT & WORKING LIGHT
SV-10 :
SW-30 : NIBBLER CLOSE
R-16 : NIBBLER CLOSE SOL
NIBBLER CLOSE SW.
RELAY
L-4 :
SWING FLASHER RIGHT & WORKING LIGHT 9P CONNECTOR
SWING FLASHER & WORKING LIGHT
DOWNLOAD
(4/4)
LC03Z00036P1 02
23-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
C-2 GAUGE CLUSTER YN59S00021F1 SWING FLASHER (LH) & REAR PRESSURE SENSOR :
L-3 YM80S00001F1 SE-2
AIR-CON CONTROLLER WORK LIGHT BUCKET DUMP
C-4 AIR CON ACCESSORY
(L) LIGHT
(INCLUDING PANEL) SWING FLASHER (RH) & REAR SE-3 PRESSURE SENSOR : BOOM UP
L-4 YM80S00001F2
ENGINE COOLANT LEVEL WORK LIGHT PRESSURE SENSOR :
C-5 ENGINE ACCESSORY SE-4
(SE) SENSOR
CONTROLLER L-5 ROOM LIGHT YT80S00001P1 BOOM DOWN
C-8 ENGINE CONTROLLER ENGINE ACCESSORY L-6 BOOM WORK LIGHT (RH) YW80S00001F1 SE-5 PRESSURE SENSOR : SWING
L-7 CAB WORK LIGHT YT80S00002F2 SE-7 PRESSURE SENSOR : ARM IN
D-4 DIODE HARNESS ACCESSORY L-9 BOOM CYL. WORK LIGHT SE-8 PRESSURE SENSOR : ARM OUT
D-5 DIODE ACCESSORY OF RELAY BOX SE-9 PRESSURE SENSOR : TRAVEL RH
D-6 DIODE M-1 STARTER MOTOR ENGINE ACCESSORY SE-10 PRESSURE SENSOR : TRAVEL LH
(M) MOTOR
D-9 DIODE M-3 WIPER MOTOR YN53C00012F2 SE-11 (PRESSURE SENSOR : P2 OPT.)
D-10 DIODE M-4 WASHER MOTOR YN54C00001F1 SE-13 E/G SPEED SENSOR ENGINE ACCESSORY
(D) DIODE
(P) PROPORTIONAL
SV-1 YN35V00051F1
SOLENOID VALVE
P2 UNLOAD (YN35V00047F1) BRAKE SOL.
(SV) SOLENOID
PSV-B YN35V00048F1 POWER BOOST
PROPO.VALVE SOLENOID
SV-2 (YN35V00047F1) YN35V00050F1
TRAVEL STRAIGHT VALVE ASSY SOL
PSV-C SOLENOID
E-1 FUSE AND RELAY BOX YN24E00016F1 PROPO.VALVE TWO SPEED
SV-3 VALVE ASSY
E-2 ALTERNATOR ENGINE ACCESSORY P1 UNLOAD SELECT SOL
PSV-D SAFETY LOCK
E-3 HOUR METER YT58S00006P1 PROPO.VALVE
SV-4
E-5 HORN HIGH LC53S00001D1 P1 PUMP LEVER SOL
PSV-P1 PROPO.VALVE YN35V00052F1 KEY SWITCH
E-6 HORN LOW LC53S00001D2 SW-1 YN50S00026F1
PUMP ACCESORY
E-10 RECEIVER DRYER YN54S00041P1 P2 PUMP SWING PARKING BRAKE RELEASE
PSV-P2 SW-4 YN50S00047P1
E-11 AIR-CON COMPRESSOR YX91V00001F1 PROPO.VALVE SWITCH
E-12 BATTERY YN72S00014P1 R-1 BATTERY RELAY YN24S00008F1 SW-5 HORN SWITCH (RH) YN50E00017P1
E-14 CIGARETTE LIGHTER YN81S00003P1 R-2 STARTER RELAY ENGINE ACCESSORY SW-7 E/G OIL PRESSURE SWITCH ENGINE ACCESSORY
E-15 FUSIBLE LINK LQ13E01143S002 R-3 GLOW RELAY ENGINE ACCESSORY SW-8 AIR FILTER CLOGGING SWITCH YR11P00008S005
E-27 ACCEL REDUNDANT VOLUME YN52S00052P1 R-4 SAFETY RELAY YN24S00010P1 SW-10 HORN SWITCH (LH) YN50E00017P1
(E) ELECTRIC FITTINGS
(SW) SWITCH
R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1 SW-19 WIPER INTERLOCK SWITCH YT50S00004P1
R-24 AUTO IDLE STOP RELAY 2 SW-20 POWER BOOST SWITCH (RH) YN50E00017P1
(R) RELAY
R-25 ENGINE EMERGENCY STOP RELAY SW-21 POWER BOOST SWITCH (LH)
R-26 LEVER LOCK RELAY SW-26 CAB WORK LIGHT SWITCH YN50S00040D4
R-28 ALTERNATOR RELAY SW-27 COOLANT LEVEL SWITCH ENGINE ACCESSORY
WIPER MOTOR RELAY SW-28 WATER SEPARATOR SWITCH ENGINE ACCESSORY
R-29 YN24S00012P2
(NORMAL ROTATION) SW-55 BOOM WORK LIGHT SWITCH YN50S00040D1
WIPER MOTOR RELAY
R-30 (REVERSE ROTATION)
WIPER MOTOR RELAY
R-31 (ARC PREVENTION)
R-32 WASHER MOTOR RELAY
R-45 BOOM CYL. WORKING LIGHT RELAY YN24S00010P1
NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. LC03Z00036P1 02
23-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
23.3 HARNESS
23.3.1 HARNESS LIST
3.11 BOOM CYL. LIGHT HARNESS (A) ASSY YN15E00012F1 1 HARNESS YN15E01018P1
BOOM CYL. LIGHT
3.12 BOOM CYL. LIGHT HARNESS (B) ASSY LC11E00028F1 1 HARNESS LC11E01065P2
3.13 BOOM LIGHT INSTALL YN80E00011F1 BOOM LIGHT
3.14 DECK LIGHT INSTALL YN80E00049F1 DECK LIGHT
LIGHT
The parts number may be changed due to the improvement of machine, so use the number for reference only.
23-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
TIGHTENING TORQUE
INSTRUMENT PANEL ASSY YN17M00053F1 (10) 1.5N.m (1.1lbf.ft)
TIGHTENING TORQUE SEMS BOLT TIGHTENING TORQUE
ITEM PART NAME PART No. Q'TY REMARKS 5.2N.m (3.8lbf.ft) 5.2N.m (3.8lbf.ft)
3-2 POTENTIO METER YN52S00032P1 1 2 PLACES INSTALL TO CAB
TAPPING SCREW
TAPPING
3-4 KEY SWITCH YN50S00026F1 1 K250 DUCT ASSY SCREW
SEMS BOLT
4-2 CIGARETTE LIGHTER YN81S00003P1 1 2 PLACES
TIGHTENING TORQUE TAPPING SCREW
5-2 HOUR METER YT58S00006P1 1 2.8N.m (2.1lbf.ft) TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
10 GAUGE CLUSTER YN59S00021F1 1
SECTION BB SECTION DD SECTION EE
TIGHTENING TORQUE
4.1N.m (3.0lbf.ft)
SECTION AA
VIEW
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
TIGHTENING TORQUE
TIGHTENING TORQUE TIGHTENING TORQUE 8.5N.m (6.3lbf.ft)
5.0N.m (3.7lbf.ft) TIGHTENING TORQUE
5.0N.m (3.7lbf.ft) 4.9N.m (3.6lbf.ft) SEMS BOLT
SEMS BOLT TIGHTENING TORQUE
SEMS BOLT
12.0N.m (8.9lbf.ft)
INSTALL
SEMS BOLT
TO CAB
SEMS BOLT
4 PLACES
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SECTION CC
TIGHTENING TORQUE
SEMS BOLT
5.2N.m (3.8lbf.ft)
INSTALL TAPPING SCREW TIGHTENING TORQUE
TO A/C 5.0N.m (3.7lbf.ft)
23-9
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
UPPER
HEXAGON NUT
TOOTHED LOWER
HEXAGON NUT
LOCK WASHER
HORN WASHER
SECTION AA
SEMS BOLT
TIGHTENING
TORQUE
2.8N.m (2.1lbf.ft)
VIEW
TIGHTENING TORQUE
2.8N.m (2.1lbf.ft)
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SEMS BOLT
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
23-10
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
GLOW RELAY
HORN (LOW)
BRACKET
STARTER RELAY
B TERMINAL
BATTERY RELAY BOX C TERMINAL
NUT
TIGHTENING TORQUE
17.5N.m (12.9 lbf.ft) 2 PLACES
SEMS BOLT
TIGHTENING
TORQUE
10.7N.m (7.9 lbf.ft)
TIGHTENING TORQUE
10.7N.m
CONNECT SEMS BOLT
AFTER CHECKING CONNECT HARNESS AS SHOWN
GROUND
NO PAINT IS HERE TO AVOID SHORT CIRCUIT ON
SEMS BOLT HORN (HIGH)
POWER SOURCE WIRING
CONNECT HARNESS AS SHOWN HORN (LOW)
TO AVOID SHORT CIRCUIT ON SEMS BOLT
INSTALL BOLT FROM POWER SOURCE WIRING TIGHTENING TORQUE
FRONT SIDE 11.7N.m
MAX
(BLACK) (BLACK)
VIEW VIEW
23-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
CLIP : NOTES:
UPPER HARNESS ASSY LQ13E00042F1 (08) FIX WHITE TAPING POSITION CLIP (1) TIGHTENING TORQUE OF
ITEM PART NAME PART No. Q'TY REMARKS BATTERY TERMINALS ARE 3.4N.m (2.5 lbf.ft).
(2) TIGHTENING TORQUE OF
1 HARNESS LQ13E01144P4 1 UPPER GROUNDING CABLES ARE 10.7N.m (7.9 lbf.ft).
(3) UNLESS OTHERWISE SPECIFIED
2 HARNESS LQ13E01137P1 1 ECU HARNESS TIGHTENING TORQUE IS SHOWN BELOW.
M8 : 23.5N.m (17.3 lbf.ft)
3 CABLE LC13E01144P1 1 BATTERY-GROUND M10 : 46.1N.m (34.0 lbf.ft)
(4) ATTACHMENT OF WELDING CLIP WIHOUT
4 CABLE LQ13E01100P1 1 ENGINE-GROUND TO PRESS DIRECTIONS IS MADE INTO THE FOLLOWING.
SENSOR:SWING TO ENG.
5 CABLE YN13E01441P2 1 BATTERY-BATTERY CLIP 2 : ECU HARNESS CLIP
1: FIX WHITE
CLIP : TAPING
UPPER HARNESS CLIP
FIX WHITE POSITION
TAPING POSITION SEMS BOLT
CLIP :
UPP HARNESS
FIX WHITE TAPING
CLIP POSITION
DETAIL cc
ECU HARNESS GROUND DETAIL bb
ECU,UPP HARNESS GROUND 10 : TO RADIATOR COOLANT
UPP HARNESS GROUND FLOOR GROUND CABLE
ECU HARNESS LEVEL SW.
SEMS BOLT :
UPPER HARNESS GROUND
TIGHTEN AFTER TO ENG ROOM LIGHT
UPP HARNESS CHECKING MECHATRO CONTROLLER
NO PAINT UPPER HARNESS GROUND FLOOR HARNESS GROUND
NOTE 2
FUEL PUMP ATTACHMENT BOOST SW.(RH) CLIP TO AIR FILTER E-10 : BATTERY RELAY BOX
HORN SW.(RH) SEMS BOLT: CLOGGING SW. RECEIVER DRIER
NIBBLER CLOSE SW.(OPT) TIGHTEN AFTER CLIP
RADIATOR COOLANT
LEVEL CONTROLLER HORN SW.(LH) CHECKING
UPPER HARNESS GROUND ATTACHMENT BOOST SW.(LH) NO PAINT
UPPER HARNESS GROUND UPPER HARNESS GROUND OPT SELECT CHANGE SWITCH WASHER MOTOR NOTE 2 TO EXTRA PRESS SOL.(OPT) TO ENG.REVDLUTION SENSOR
CAB HARNESS (GROUND) DECK WORK LIGHT (RH) NIBBLER OPEN PRESS.SW.(OPT)
LEVER LOCK SOLENOID
ENGINE ROOM LIGHT NIBBLER OPEN SW.(OPT)
ATT. BOOST SOLENOID
SWING FLASHER (LH) (OPT) & REAR WORK LIGHT
TRAVEL 2 SPEEDS SOLENOID
LMN
WATER SEPARATOR SWITCH SWING PARKING SOLENOID
SWING FLASHER (RH) (OPT) & REAR WORK LIGHT
RADIATOR COOLANT LEVEL SWITCH
AIR FILTER CLOGGING SWITCH
FUSE & RELAY BOX
FLASHER RELAY (OPT) BATTERY RELAY (COIL)
DIODE (GLOW RELAY) CLIP CLIP
GLOW RELAY (COIL)
SECTION BB
FIX WHITE TAPING POSITION
23-12
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SE-15 :
UPP FRAME
FUEL SENSOR
CONNECT A HARNESS
WITH IN A CAP.
VIEW
TIGHTENING TORQUE
25.5N.m(18.8lbf.ft)
CLIP
SEMS BOLT
PSV-P1 : PSV-P2 :
PUMP P1 PROPORTIONAL SOL. PUMP P2
PROPORTIONAL SOL.
SIDE OF ENG.
CLIP
FIX A HARNESS PART OF CDULGATED
TO PRESS SENSOR WITH A CLIP
CLIP CLIP CLIP TO WATER SEPARATOR SW.
VIEW SEMS BOLT SEMS BOLT FIX TO THE GUARD
FIX RED TAPING
(DETAIL OF PUMP P1,P2 PROPORTIONAL SOL. INSTALL) POSITION
(DETAIL OF PUMP PRESS SENSOR : SOL. INSTALL) VIEW
23-13
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
E-1 :
34P CONNECTOR 35P(A) CONNECTOR 32P CONNECTOR 35P(B) CONNECTOR 31P CONNECTOR FUSE & RELAY BOX
WITH "CN-1F"TAG WITH "CN-2F"TAG WITH "CN-3F"TAG WITH "CN-4F"TAG WITH "CN-5F"TAG
C-1 :
VIEW MECHATRO
CONTROLLER CONNECT CONNECTOR
C-1 : MECHATRO CONTROLLER WITH "CNT-2" TAG TO
FLOOR HARNESS
C-8 :
ENG. CONTROLLER
REFERENCE DRAWING OF ASSEMBLING
16P CONNECTOR 24P CONNECTOR 17P
28P CONNECTOR 31P CONNECTOR CONNECTOR
FLOOR HARNESS
ECU HARNESS
VIEW
SECTION CC
23-14
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SW.-8 :
SV-4 : SV-1 : AIR FILTER RESTRICTION SW. FIX A HARNESS PART
SV-3 :
OPERATING SW.ING PARKING TWO-SPEED SV-2 : OF COULGATED OF
POWER BOOST SOL.
LEVER LOCK SOL.BRAKE SOL. SELECT SOL. CLIP CLIP TO SW.
PSV-B : CLIP
P2 UNLOAD FIX A HARNESS PART 8
PROPORTIONAL SOL. OF CORRUGATED
PSV-C : OF CLIP TO SW. CONNECT HARNESS OF
TRAVEL PRIORITY AIR FILTER RESTRICTION SW.
CLIP PROPORTIONAL SOL.
PSV-D :
E-10 :
P1 UNLOAD
RECEIVER DRIER
PROPORTIONAL SOL.
PSV-A :
ARM TWO-SPEED INVERSE
PROPORTIONAL SOL.
CLIP
FIX WHITE TAPING POSITION
CLIP
FIX A HARNESS TO
THE GUARD WITH A CLIP
TO AIR FILTER
CLIP RESTRICTION SW.
FIX WHITE TAPING
POSITION
BRACKET
ENG. GROUND CABLE
SEMS BOLT
23-15
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
TIGHTENING TORQUE
F TERMINAL 3.43N.m (2.53 lbf.ft)
S TERMINAL USE NUT OF ATTACHED
GROW RELAY
GLOW RELAY CONNECT WHITE TAPING
HARNESS
CONNECT TO 2P CONNECTOR 9 GLOW RELAY - STARTER RELAY UPP
FOR HARNESS OF ATTACHED HARNESS
TIGHTENING TORQUE
SE-27 : GLOW RELAY C TERMINAL 3.8N.m (2.8 lbf.ft)
RADIATOR COOLANT LEVEL SW. FIX CONNECTOR
SW-16 : USE NUT OF ATTACHED
B TERMINAL TO THE BRACKET
ENG ROOM RIGHT STARTER RELAY
FIX A CONNECTOR SW-16 : TRIM
FIX WHITE TAPING POSITION
ON BRACKET ENG. ROOM RIGHT
CLIP STARTER RELAY
3P
FIX FUSE
2P 1P
CLIP
VIEW
CLIP CONNECT RED TAPING
FIX A HARNESS PART OF CLIP HARNESS
CORRUGATED TO SW.
ADJUST THE LOCK OF THE FUSE
WITH A CLIP FIX FUSE BOX
CLIP BOX COVER TO THE UPPER SIDE
WITH THE BRACKET
BRACKET
SEMS BOLT BATTERY RELAY
UPP HARNESS
STARTER CABLE
BATTERY RELAY CABLE
CLIP
UPP HARNESS SEMS BOLT
SEMS BOLT, CLIP
FIX A STARTER CABLE
UPWARDS AND
FIX UPP HARNESS FIX WHITE TAPING
DOWNWARDS POSITION
VIEW
DETAIL OF RADIATOR COOLANT LEVEL SW. INST.
23-16
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
TO HARNESS OF
ATTACHED ENG.
ALTERNATOR(B)
TIGHTENING TORQUE
ALTERNATOR (B)
3.3~4.4N.m(2.4~3.2lbf.ft)
GLOW
CLIP
FIX WITH ENG. ENG. SUB HARNESS
SUB HARNESS
CLIP
SEAMS BOLT
FIX WITH TAPING POSITION
STARTER CABLE
A CLIP TURN INSIDE FOLLOWING A FIGURE.
FIX UPP HARNESS AND ENG. SUB HARNESS UPP HARNESS
TO THE PLATE
ECU HARNESS
DETAIL OF ALTERNATOR
VIEW
GLOW
SE-13:
TO GLOW ENG. REVOLUTION SENSOR
FIX A CONNECTOR ON BRACKET
INSTALL THE RUBBER CAP
ON UPPER SIDE CLIP
FIX A WHITE TAPING PART
OF HARNESS TO
TIGHTENING TORQUE THE BRACKET WITH CLIP
51.9N.m(38.3lbf.ft)
TIGHTENING TORQUE
SEMS BOLT
23.5N.m(17.3lbf.ft)
NUT CLIP
WASHER NUT
TIGHTENING TORQUE
12~15N.m(8.9~11.1lbf.ft)
4 M-1 :
ENG. GROUND CABLE STARTER MOTOR
CLIP TIGHTENING TORQUE
3.5~5.5N.m(2.9~4.1lbf.ft)
WASHER
C TERMINAL TO GLOW
CLIP CLIP
SEMS BOLT CLIP DETAIL OF ENGINE REVOLUTION SENSOR INST.
NUT
UPP HARNESS FIX WHITE TAPING POSITION COLLAR
WASHER
STARTER CABLE SEMS BOLT
FIX WHITE TAPING POSITION FIX WHITE TAPING POSITION
M-1 : UPP HARNESS TIGHTENING TORQUE
STARTER MOTOR 25.5N.m(18.8lbf.ft)
DETAIL dd
DETAIL ee
23-17
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
2
SEALING PLUG TO BE SEALING PLUG TO BE
SE-15 : INSERTED IN TO ALL
INSERTED IN TO ALL
FUEL SENSOR
TO BE INSTALLED SUPPLY SUPPLY
ITEM 2 CAP WITH WITH
E-6 :
SV-5 : HORN LOW
SV-11 :
BACKET DUMP EXTRA DIS-PRESS SOL
CUT SOL
L-2 :
FRAME
WORK LIGHT
RIGHT
SW-56 :
SEALING PLUG TO BE FUEL SUPPLY
INSERTED IN TO ALL AUTO STOP SW
SEALING PLUG TO BE
E-5 :
TAPING INSERTED IN TO ALL
HORN HIGH
TAPING
SUPPLY M-11 :
WITH FUEL SUPPLY
PUMP
SUPPLY SE-13 :
WITH ENG REVOLUTION SENSOR
WHITE TAPING
L-1 :
BOOM WORKING LIGHT
DOUBLE
SPLICE
TAPING
WHITE TAPING
SUPPLY
WITH
WHITE TAPING
PSV-1 : AMP 1565123-1
PSV-E :
OPT, RELIEF ADJUSTMENT
OPT, RELIEF ADJUSTMENT
PROPORTIONAL SOL. 2
PROPORTIONAL SOL. 1 SUPPLY
SUPPLY SUPPLY
WITH WITH
SEALING PLUG TO BE WITH
INSERTED IN TO ALL SEALING PLUG TO BE SEALING PLUG TO BE
INSERTED IN TO ALL INSERTED IN TO ALL
CORRUGATE TUBE
SECTION AA SEALING PLUG TO BE
SV-13 : INSERTED IN TO ALL
OPT SELECTOR SOL
23-18
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SV-4 : R-2 :
OPERATING STARTER RELAY (COIL)
LEVER LOCK SOL. PSV-P1 :
SUPPLY PUMP P1 PROPORTIONAL SOL.
WITH STARTER
TERMINAL C
CAP TO BE INSTALLED
PSV-H : 7034-1279
SV-1 : ARM CUSHION
SWING PARKING PROPORTIONAL SOL.
BRAKE SOL. SUPPLY
SEALING PLUG TO BE WITH
INSERTED IN TO ALL
R-1 :
BATTERY RELAY
SV-3 : SE-22 : (COIL)
TWO-SPEED PRESS SENSOR ;
SELECT SOL. SEALING PLUG TO BE PUMP P1 L-3 :
SW-8 : R-1 : SWING FLASHER
INSERTED IN TO ALL
AIR FILTER BATTERY RELAY LEFT & REAR
RESTRICTION SW. WORKING LIGHT
WHITE TAPING
TAPING
WHITE TAPING
SV-2 : SEALING PLUG TO BE SUPPLY
POWER BOOST SOL. INSERTED IN TO ALL WITH
SUPPLY TAPING
WITH
PSV-B :
P2 UNLOAD L-4 : SE-23 :
PROPORTIONAL SOL. SWING FLASHER RIGHT PRESS SENSOR ; PUMP P2
INSTAL CTB-3 INSTAL CTB-3 (2 PIECE)
& REAR WORKING LIGHT SEALING PLUG TO BE TAPING
INSERTED IN TO ALL SW-16 : SEALING PLUG TO BE
SEALING PLUG TO BE ENG ROOM LIGHT INSERTED IN TO ALL
WHITE TAPING
INSERTED IN TO ALL
PSV-C : SUPPLY SW-28 : SUPPLY
TRAVEL PRIORITY WITH WATER SEPARATOR SW. WITH
PROPORTIONAL SOL.
SUPPLY
WITH
PSV-D :
P1 UNLOAD
PROPORTIONAL SOL.
SEALING PLUG TO BE
INSERTED IN TO ALL
TAPING AFTER
BUNDLED WHITE TAPING WHITE TAPING
E-13 :
TRAVEL ALARM
SUPPLY
WITH WHITE TAPING
L-10 :
HIGH REACH
ROTARY LIGHT
SUPPLY
WITH
23-19
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
WHITE TAPING
WHITE TAPING
R-19 :
FLASHER RELAY
DOUBLE
SPLICE TO HARNESS
(CAB)
TO HARNESS
(CAB SUB)
DOUBLE
SPLICE SUPPLY WITH
SUMITOMO 6409-0075
DOUBLE
SPLICE C-5 :
RADIATOR COOLANT
TAPING LEVEL CONTROLLER
DOUBLE
SPLICE
TAPING
C-1 :
DOUBLE FLAME GND OF OPT. (HAND CONTROL) MECHATRO CONTROLLER
SPLICE UNDER FLOOR
WHITE TAPING
TAPING
RED TAPING
TAPING
DOUBLE CONNECTOR
DOUBLE TAPING PART
SPLICE TO FLOOR HARNESS
SPLICE CONNECTOR
PART
DOUBLE
SPLICE
23-20
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SHIELDED
CABLE
(2 CORE)
23-21
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SEALING PLUG
DOUBLE DOUBLE DOUBLE
SPLICE SPLICE SPLICE
SEALING
TAPING
CONNECTOR PLUG
SUPPLY WITH
SUMITOMO 6409-0075
SEALING
PLUG
WHITE TAPING
WHITE TAPING
SHIELD UN-CONNECTED
23-22
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
23.3.5-2 ECU HARNESS (2/2) : LQ13E01137P1 23.3.5-3 BATTERY GROUNDING CABLE : LC13E01144P1
WIRE WIRE
WIRE NO COLOR WIRE SIZE FROM CONNECTION TO WIRE NO COLOR WIRE SIZE FROM CONNECTION TO
SHIELDED
CABLE
(2 CORE)
SHIELDED
CABLE
(2 CORE)
TERMINAL
TERMINAL
SHIELDED CAP
CABLE
(2 CORE) TAPED IN TWO TURNS
TERMINAL TERMINAL
SHIELDED
CABLE
(2 CORE)
CORRUGATED TUBE TO BE INSTALLED
(PART. NUMBER)
23.3.5-5 BATTERY CABLE : YN13E01441P2
CONNECTOR
NAME MANUFUC.
(PIN NUM.) HOUSING TERMINAL
SHIELDED
CABLE CORRUGATE TUBE
(2 CORE) TO BE INSTALLED CAP
TERMINAL TERMINAL
CAP
23-23
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
TERMINAL
INSTALL DOUBLE CORRUGATE
SW-8 :
AIR FILTER CLOGGING
TERMINAL SWITCH
WHITE TAPING
CAP
YAZAKI 7034-1283 WHITE TAPING INSTALL
CORRUGATE TUBE
CAP TO BE
INSTALLED
TERMINAL SUPPLY
CAP
WIRE No.35 WITH YAZAKI 7034-1283
TAPING
TAPED DOUBLY
180 (7.09")
TWO TERMINALS ARE IN TOUCH WITH
EACH OTHER TO THEIR BACK AND
BUNDLED BY TAPING, CAP TO BE INSTALLED CAP TO BE INSTALLED
CAP
DETAIL A YAZAKI 7034-1280
TERMINAL TERMINAL
HEAT SHRINKAGE TUBE TO BE INSTALLED
100 (3.94")
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010
TERMINAL
TERMINAL CAP
CAP
YAZAKI 7034-1283
TAPED IN TWO TURNS
23-24
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
TIGHTENING TORQUE
23.5N.m (17.3 lbf. ft)
SEMS BOLT
B TERMINAL
M-1 :
STARTER MOTOR HARNESS (UPPER)
REMOVE AND CANCEL THE HARNESS OF
ATTACHMENT FOR SC TERMINAL
TIGHTENING TORQUE
23.5N.m (17.3 lbf. ft)
SEMS BOLT DETAIL A
STARTER CABLE
HARNESS (UPP)
ALTERNATOR (L, R)
TIGHTENING TORQUE
TIGHTENING TORQUE 9.6N.m (7.1 lbf. ft)
3.3~4.4N.m (2.4~3.3 lbf. ft) CLIP
FIX A HARNESS WITH CLIP ALTERNATOR (B) SEMS BOLT
ON BRACKET OF
ENGINE ACCESSORY
CLIP
HARNESS (ENGINE SUB)
FIX A WHITE TAPING
SW-7 : HARNESS (UPP) TIGHTENING TORQUE
SEMS BOLT 3.3~4.4N.m (2.4~3.3 lbf. ft)
FIX THE PLATE TO ENGINE OIL PRESS SW
CLIP
ENGINE BRACKET SEMS BOLT
TIGHTENING TORQUE
25.5N.m (18.8 lbf. ft)
DETAIL OF ALTERNATOR
23-25
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
E-2 : ALTERNATOR
SW-7 :
ENGINE OIL PRESS. SW.
SEALING PLUG
ENGINE COOLANT
THERMO SENSOR (FOR ECU)
WHITE TAPING
SEALING PLUG
TO UPP HARNESS
23-26
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SE-3 :
UPPER HARNESS ASSY LC13E00032F1 (10)
PRESS SENSOR :
NOTE : 1. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS
SE-4 :
PRESS SENSOR : BOOM RAISING
MADE INTO THE FOLLOWING.
ITEM NAME PARTS No. Q'TY REMARKS
BOOM LOWERING CLIP
1 HARNESS YN13E01449P3 1 FLOOR
SE-1 : HARNESS
4 HARNESS LC13E01186P1 1 CAB SUB HARNESS TO WASHER MOTOR PRESS SENSOR :
BUCKET DIGGING
9 CABLE LE13E01005P1 1 FLOOR HARNESS GROUND SE-2 :
PRESS SENSOR : SE-7 : SW-1 :
BUCKET DUMP PRESS SENSOR : KEY SW.
ARM IN
SE-8 : SW-16 :
PRESS SENSOR : ACCEL POTENTIO
E-1 : FUSE & RELAY BOX ARM OUT
SW-1 : KEY SWITCH
CLIP
USE THE HOLE OF SEAT FASTEN HARNESS BY CLIP CAB HARNESS
SE-16 : WITH BRACKET OF MULTI CLIP
STAND AND FIX HARNESS BUNDLE AFTER
ACCEL POTENTIO NOT USE CLIP CASE BY MULTI
WITH CLIP * CLIP HARNESS DIVERGES
FIX WHITE TAPING
DETAIL A : A CASE OF MULTI
POSITION
(For Oceania)
TO WASHER MOTOR
FIX A HARNESS ON SENSOR
BLOCK WITH CLIP
TO WASHER MOTOR
FIX A HARNESS TO CLIP OF
CLIP CAB SIDE COVER
VIEW
PUSH CONTROL LEVER MOST FRONTWARD
AND FIX THIS SLACK HARNESS WITH CLIP
SE-1 :
SW-12 :
PRESS SENSOR :
SW-35 : OVER LOAD ALARM SELECT SW.
BUCKET DIGGING
HEAVY LIFT SW. CONNECT SWITCH TO TAGGED
SE-8 : SE-2 : CONNECT SWITCH "OVER L" CONNECTOR
PRESS SENSOR : PRESS SENSOR : TO TAGGED "HEAVY"
ARM OUT SW-13 : CONNECTOR
SE-7 : SE-3 : BUCKET DUMP
PRESS SENSOR : PRESS SENSOR : TRAVEL ALARM SW.
BOOM RAISING IN CASE OF TRAVEL SW-40 :
ARM IN SE-4 :
FIX A CORRUGATERD ALARM SPEC., ROTARY LIGHT SW.
PRESS SENSOR : CONNECT SWITCH TO CONNECT SWITCH TO TAGGED "ROTARY"
TUBE NOT CONTACT
M-CONNECTOR BOOM LOWERING TAGGED "ALARM" CONNECTOR
LOCK OF CONNECTOR
DETAIL A : A CASE OF SENSOR TOWER CONNECTOR
SENSOR CLIP
(For SE. Asia) FIX A HARNESS
OF SW. SIDE
CLIP CLIP
FIX A HARNESS PART OF CLIP
SE-20 : PRESS SENSOR : P1 OPT WHITE TAPING WITH CLIP FIX A CLIP ON HOLE
OF STAND SIDE
TIGHTENING TORQUE 10.7N.m (7.9lbf.ft)
TIGHTEN AFTER CHECKING NO PAINT HERE CLIP
FIX A CLIP ON HOLE SW-20 :
NUT
FLOOR HARNESS GROUND OF STAND SIDE POWER BOOST SW. RIGHT
TO PRESS SENSOR, FASTEN FLOOR HARNESS
TUNER CONNECT WITH EARTH MULTI, (YELLOW TAPING)
CABLE OF UPPER WITH LEVER SW.
OVER LOAD ALARM SW. WASHER MOTOR SW-33 :
FRAME HARNESS
HEAVY LIFT SW. REVOLUTION RIGHT SW. (OPT)
TOGETHER
(RED TAPING)
TRAVEL INDEPENDENT CHANGE SW.
SE-10 : SW-5 :
ATT BOOST SW. (RH)
PRESS SENSOR : HORN SW. RIGHT (OPT) (BLUE TAPING)
HORN SW. (RH)
TRAVEL LEFT
ATT BOOST SW. (LH)
SE-9 :
HORN SW. (LH) PRESS SENSOR :
DC-DC CONVERTER TRAVEL RIGHT E-7 :
WASHER MOTOR TUNER CLIP
SE-11 : CLIP FIX WHITE TAPING
PRESS SENSOR : FIX WHITE TAPING POSITION
P2 OPT CLIP FIX A CLIP ON HOLE
POSITION
FIX WHITE TAPING OF SEAT SIDE
THROUGH THE HARNESS
POSITION
AT SEAT SIDE OF BRACKET
CLIP
FIX WHITE TAPING POSITION TO THE FRONT SIDE OF FLOOR PLATE
23-27
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SW-10 : E-1 :
HORN SW. LEFT (OPT) (BLUE TAPING) FUSE & RELAY
SW-21 : BOX C-1 :
POWER BOOST SW. LEFT (OPT)
MECHATRO CONNECT THE "CNT-2" TAGGED
(YELLOW TAPING) C-8 : ENG. CONTROLLER CONTROLLER CONNECTOR WITH "UPPER HARNESS"
SW-34 :
REVOLUTION LEFT SW. (OPT)
(RED TAPING) CONNECT TO SWING
PARKING RELEASE SW.
CONNECT TO SWING
DETAIL OF FUSE & RELAY BOX CONNECTION PARKING RELEASE SW.
23-28
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
SE-9 :
PRESS SENSOR :
TRAVEL RIGHT
SW-1 :
KEY SW.
SE-20 :
PRESS SENSOR : SE-16 :
P1 OPT ACCEL POTENTIO
TAPING AFTER
BUNDLED TO ECU HARNESS
WHITE TAPING
TAPING
WHITE TAPING WHITE TAPING
WHITE TAPING TAPING
SUPPLY WITH
WHITE TAPING
SUPPLY WITH DOUBLE TO UPPER HARNESS
SPLICE
AMP 1565123-1 WHITE TAPING
DOUBLE
SPLICE
SW-43 :
JIB PRESS SW.
TO FRAME GND. M-4 :
WASHER MOTOR
TAPING
SEALING PLUG TO BE
INSERTED IN TO ALL
SW-4 :
SWING RELEASE SW.
SE-8 : SE-1 :
PRESS SENSOR : PRESS SENSOR :
ARM OUT BUCKET DIGGING
SE-4 : SE-3 :
PRESS SENSOR : PRESS SENSOR :
BOOM LOWERING BOOM RAISING
23-29
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
#
!
%
$
"
#!"#
23-30
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23. ELECTRIC SYSTEM
23-31
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
TO HARNESS (UPPER)
E-1 :
FUSE & RELAY BOX
TO CAB HARNESS
100 (3.94")
1PAF
YAZAKI 7123-3010
23-32
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
E-23 :
12V SOCKET
E-9 : CONNECT TO
SPEAKER RIGHT FLOOR HARNESS
CONNECT TO
CAB SUB HARNESS
TIGHTENING TORQUE 4.4N.m (3.2 lbf.ft)
FIX WHITE CONNECT WITH CAB WORK LIGHT
TIGHTEN SEMS BOLT AFTER
TAPING CLIP
CHECKING NO PAINT IS HERE FIX WHITE CONNECT WITH ROOM LIGHT
POSITION
SEMS BOLT TAPING
CLIP CONNECT WITH WIPER INTERLOCK SW.
CAB HARNESS GROUND E-14 : POSITION
CAB HARNESS
GAUGE CLUSTER CIGARETTE FIX TO CLIP ON THE DUCT
CAB WORK LIGHT SW. LIGHTER
AIR-CON UNIT
UPPER HARNESS (GND) CLIP
BOOM DECK WORK LIGHT SW. FIX WHITE TAPING
CAB WORK LIGHT FRONT POSITION
WIPER INTERLOCK SW.
HOUR METER SW-15 : E-8 :
CONFLUX / SINGLE FLOOR HARNESS
WIPER MOTOR SPEAKER LEFT
CIGARETTE LIGHTER SELECT SW.
CONNECT TO
12V POWER SOURCE SOCKET SW-55 : UPPER HARNESS
SKY ROOF WIPER (OPT) BOOM , DECK
CONFLUX / SINGLE CHANGE SW. WORKING CAB SUB TO AIR
CAB WORK LIGHT LIGHT SW. HARNESS CONDITIONER UNIT
SW-1 : CONNECT WITH
FLOOR HARNESS KEY SW.
CAB WORK LIGHT
UPPER HARNESS
C-2 : DETAIL A
GAUGE CLUSTER SW-41 :
HIGH REACH CRANE SW.
CONNECT THE SWITCH
CLIP
WITH "CRANE" TAGGED
BLACK CONNECTOR
CLIP SW-15 :
SW-17 : SW-26 :
CONFLUX / SINGLE SELECT SW.
ROOF WIPER SW. CAB WORK LIGHT SW.
CONNECT THE SWITCH WITH "CONFLUX"
E-3 : CONNECT THE SWITCH CONNECT THE SWITCH WITH "CAB LIGHT"
TAGGED GREEN CONNECTOR
HOUR METER WITH "WIPER" TAGGED TAGGED NATURAL COLOR CONNECTOR
SW-55 :
NATURAL COLOR
BOOM , DECK WORKING LIGHT SW.
CONNECTOR E-4 :
CONNECT THE SWITCH WITH "BOOM, DECK"
M-3 : CIGARETTE LIGHTER
TAGGED BLUE CONNECTOR
WIPER MOTOR
E-4 :
CIGARETTE LIGHTER
WR B DETAIL B
VIEW II
VIEW I
23-33
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23. ELECTRIC SYSTEM
DOUBLE
WHITE TAPING SPLICE
DOUBLE
TAPING AFTER SPLICE
BUNDLED
TO CAB WORKING LIGHT
TO CAB WORKING LIGHT
DOUBLE
SPLICE E-9 :
DOUBLE
SPLICE SPEAKER RIGHT
WHITE TAPING
TO ROOF WIPER
E-23 : SHIELD UN-CONNECTED
12V SOCKET
TAPING TAPING C-2 :
GAUGE CLUSTER
DOUBLE
SW-19 : SPLICE
WIPER INTERLOCK SW. E-3 :
DOUBLE SW-17 : HOUR METER
TO CAB GND. SPLICE ROOF WIPER
SW-41 : SW-15 :
SW.
HIGH REACH CONFLUX / SINGLE
CRANE SW. SELECT SW.
TO ROTALY LIGHT C-4 : E-14 :
TO HARNESS (FLOOR) CIGARETTE LIGHTER
AIR CONDITIONER UNIT WHITE TAPING SW-55 :
TO HARNESS (UPP)
DOUBLE BOOM, DECK
SPLICE
WORKING LIGHT SW.
SW-26 :
CAB WORK LIGHT
SW.
DOUBLE
SPLICE
WHITE TAPING
TAPING TAPING AFTER TAPING AFTER
BUNDLED BUNDLED
TAPING
TO CAB HARNESS
23-34
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
23.3.8-1 CAB HARNESS (2/2) : YN14E01102P3 23.3.8-2 KEY SWITCH EARTH HARNESS : YN14E01106P1
23-35
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
23.3.9 BOOM HARNESS ASSY 23.3.10 BOOM CYL. LIGHT HARNESS (A) ASSY
BOOM HARNESS ASSY LQ15E00012F3 (01) BOOM CYL. LIGHT HARNESS (A) ASSY YN15E00012F1 (01)
ITEM PART NAME PART No. Q'TY REMARKS ITEM PART NAME PART No. Q'TY REMARKS
4 HARNESS LQ15E01005D1 1 BOOM LIGHT 1 HARNESS YN15E01018D1 1
CLIP
CLAMP TO THE TUBE
FOR GREASE AT WHITE
TAPING POSITION OF
HARNESS
TO UPPER
HARNESS
4750
1050
CB104
TO LIGHT 1MA-CNA
T-AV0. 85sq WHITE TAPING
(GREEN)
23.3.10-1 BOOM CYL. LIGHT HARNESS (A) : YN15E01018D1
1600
23-36
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23. ELECTRIC SYSTEM
23-37
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23. ELECTRIC SYSTEM
23.3.11-1 BOOM CYL. LIGHT HARNESS (B) : LC11E01065P2 23.3.12 INSTALLING BOOM LIGHT
SECTION AA
23-38
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
INSTALLING UPPER LIGHT YN80E00049F1 (01) INSTALLING CAB LIGHT YN80E00058F1 (02)
ITEM PART NAME PART No. Q'TY REMARKS ITEM PART NAME PART No. Q'TY REMARKS
1 LIGHT YT80S00002F2 1 1 LIGHT YT80S00002F2 1
6 HARNESS YN02C01760P1 2
7 SWITCH YN50S00040D4 1
NOTE :
ITEM 1, TIGHTENING TORQUE 18.6N.m (13.7 lbf.ft)
MAIN HARNESS
23-39
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
23.3.14-6 CAB LIGHT HARNESS : YN02C01760P1 23.3.15 INSTALLING BOOM CYL. LIGHT
23-40
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
23-41
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
23. ELECTRIC SYSTEM
[MEMO]
23-42
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
24-1
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24. COMPONENTS SYSTEM
24-2
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24. COMPONENTS SYSTEM
24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port
5
EYE BOLT (M10)
a3 PSV2
Dr
A3 2X4-M12
Depth 22
A1 A2
B3
a4 VIEW
PSV1
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2
4 PSV1 4
PSV2 PSV2
Dr3 a5
A1 A2 5
1 A2
Dr3
Hydraulic ports
Code Ports name Size
No. Parts Q'TY
A1,2 Delivery port SAE 6000psi 1"
1 Main pump assy 1 B1 Suction port SAE 2500psi 2 1/2"
2 Regulator assy 2 Dr Drain port PF3/4-20
3 Gear pump assy(for pilot) 1 PSV1,2 Servo assist port PF1/4-13
4 Solenoid proportional reducing valve 2 PH1,2 Pressure sensor port PF3/8-17
5 PTO unit (OPT) 1 a1~a4 Gauge port PF1/4-15
a5 Gauge port PF1/4-14
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15
24-3
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
Regulator Regulator
a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3
24-4
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.1.2.1 CONSTRUCTION
(1) Main pump
953 806 789 532 Apply adhesive (Three Bond No.1305N) 724 901 808 954 717 151 152 211
886 214 548 531 702 792 534 A
535 732
717
261
406
824
774
111
B B
127
123
710 04
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
Tightening torque 05
Tightening torque
Item number Thread size
N.m (lbf.ft) 546
401 M20 430 (317) 414 326
406 M8 29 (21) 725
407 M6 12 (8.9) 727
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 3/4 170 (125)
490 NPTF1/16 8.8 (6.5)
531,532 M24X2 240 (177) 407 325
806 M16 130 (96) SECTION B-B SECTION B-B
VIEW A
808 M20 240 (177) OPT.
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 314 Valve plate (L) 1 724 O-ring ; 1B P8 16
113 Drive shaft (R) 1 325 Sensor block 1 725 O-ring ; 1B P11 9
116 Gear #1 1 326 Cover 1 727 O-ring ; 1B P14 3
123 Roller bearing 2 401 Socket bolt ; M20X210 8 728 O-ring ; 1B P24 4
124 Needle bearing 2 406 Socket bolt ; M8X20 4 732 O-ring ; 1B P18 2
127 Bearing spacer 4 407 Socket bolt ; M6X55 3 774 Oil seal 1
141 Cylinder block 2 414 Socket bolt ; M10X20 4 789 Back up ring ; P18 2
151 Piston 18 466 VP plug ; PF1/4 2 792 Back up ring ; G35 2
152 Shoe 18 467 VP plug ; PF3/8 2 806 Nut ; M16 2
153 Retainer plate 2 468 VP plug ; PF3/4 4 808 Nut ; M20 2
156 Spherical bushing 2 490 Plug ; NPTF1/16 4 824 Snap ring 2
157 Cylinder spring 18 531 Tilting pin ; M24X2 32 885 Valve plate pin 2
211 Shoe plate 2 532 Servo piston ; M24X2 2 886 Spring pin 4
212 Swash plate 2 534 Stopper(L) 2 901 Eye bolt ; M10 2
214 Tilting bushing 2 535 Stopper(S) 2 953 Socket screw ; M16X35 2
251 Swash plate support 2 546 Spacer 2 954 Set screw ; M20 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing 2 702 O-ring ; 1B G35 2 05 PTO unit 1
312 Valve block 1 710 O-ring ; 1B G95 2
313 Valve plate (R) 1 717 O-ring ; 1B G145 4
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3
24-5
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24. COMPONENTS SYSTEM
434
311
312
434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)
24-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
125
711 468
118 825 710 728
117
126
326 262
115
128
826
414
435
886
885
24-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.1.2.2 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 REGULATOR
gear trains on a 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 111
swash plate group that changes the delivery rate;
the valve block group that selects between oil
suction and delivery ; and the PTO group (OPT)
that transmits the drive power to the auxiliary pump.
(1) Rotary group
PTO GEAR CASE
The rotary group consists of shaft(111), cylinder
(OPT)
block (141), piston (151), shoe (152), plate (153), AUXILIARY PUMP
spherical bushing (156), and cylinder spring (157). (OPT)
The shaft is supported by bearings (123) and (124) Fig. 24-4 Construction of hydraulic pump
at its both ends. The shoe, which is caulked to the
piston, forms a 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).
313
124
312
111
116
124
314
141
157
156
151
. 153
152
211
24-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-9
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.1.3 REGULATOR
24.1.1.3.1 CONSTRUCTION
725
730
a3
656 643
438 924
D
801
722 543 755 545 541 724 B 466, 755 708 644 646 645 728
VIEW C SECTION B-B
733
756
622 621 623 625 626 887 763
SECTION A-A
At start and
emergency mode
Tightening torque
662 642 Tightening torque
Item No. Thread size
N.m (lbf.ft)
543 545 541
466 412,413 M8 29 (21.4)
At normal
438,439 M6 12 (8.9)
755 E 418 M5 6.9 (5.1)
466 PF 1/4 36 (26.6)
496 NPTF1/16 8.8 (6.5)
496 630 M30X1.5 160 (118)
755 E
801 M8 16 (11.8)
802 M10 19 (14)
SECTION E-E SECTION D-D
Fig. 24-9
24-10
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24. COMPONENTS SYSTEM
24-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.1.3.2 OPERATION
(1) Control function
Control function …… Electric flow control.
•Positive flow control.
•Total horsepower control.
Emergency mode control.
•Hydraulic positive control.
•Hydraulic total horsepower control
(2) Summary
The regulator KR3G-YTOK for the in-line type axial piston pump K3V series is composed of the control
mechanism as mentioned below:
1) Electric flow control and positive flow control
The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the
solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional
reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to
attain optimum power according to the operating condition. Also, since the pump delivers only the necessary
oil flow, the machine does not consume excessive power.
Command current I
Fig. 24-10
24-12
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
feed back lever rotates at (F) fulcrums with the Hydraulic circuit diagram
B
movement of the servo piston towards (E),
consequently the spool is returned to the original Fig. 24-11
position. With this movement, the opening of
spool sleeve gradually closes, and the servo
piston stops at the position the opening closes
completely.
24-13
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-14
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
consequently the flow rate is also reduced. Since ")* *
1
the feed back lever is connected with servo
piston and spool, the feed back lever rotates at Fig. 24-14
(R) fulcrum with the movement of the servo
piston towards (Q), consequently the spool is
returned to the original position. With this
movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
24-15
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
rate is raised. Since the feed back lever is Hydraulic circuit daigram
connected to servo piston and spool, the feed B
24-16
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-17
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-18
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-19
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
250 Q 2100min-1:
300mA (H mode) [1] 136kW E/G horse power
[3] 126kW H mode at traveling or optional working
1900min-1:
[4] 98kW H mode at operating attachment
S mode [5] 89kW S mode at operating attachment
[1]
200
[4] [3] Input revolution ;2100 min-1
Input horse power ;136 kW
[5] Input torque ;618 N.m
Delivery flow rate Q [ L/min ]
150
Reference value in ( )
Two pumps are loaded
at the same time
100
50
Min.Flow(at 2100min-1)
0 5 10 15 20 25 30 35 40
Delivery pressure Pd [MPa]
250
Q 2100min-1 [2] 105kW : At emergency mode
300mA Input revolution ;2100 min-1
700mA
245L Input horse power ;136 kW
8.8MPa
245L Input torque ;618 N.m
(P
at Q
Delivery flow rate Q [ L/min ]
At f=4
150 em .9M 1471
a
er Pa
7.8 e
MP
Pd= Curv
ge )
nc [2]
y
m
I-Q
od
e
100 981
21.8MPa
110L
37.8MPa
54L
490
50
Input torque
Min.Flow(at 2100min-1)
Tin N.m
Tin 400mA
30L
0 5 10 15 20 25 30 35 40
Delivery pressure Pd [MPa]
0 1 2 3 4 [MPa]
Pilot pressure Pi
24-20
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.2.1 SPECIFICATIONS
PBL
P2 CT2
CP2
CT1
P1
Pcb PAL
CT1 T1
PTb T2
P1 unload CT2
PCb PAL
Travel PL PCb PAL Travel left PBL
AL BL
straight P2 unload
CMR1 CMR2 Ar CP2
USE FOR YN30V00101
Br PAr PCa
Travel PB1 Boom
F1
(P3) (P2)
PBa2 PAo
PBp1 PBp2
PAa2
Arm 2 Option
PBo
PAc PAa1
Bucket Arm 1
(P4) PAa
(P3) PAb
Boom Swing
PBr PCa
Travel right P2 unload
(T3)
PTb
Travel PBL Travel left
straight
PAa2 PBo
A
VIEW A
24-21
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.2.1.2 PORTS
24-22
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.2.1.3 SPECIFICATIONS
Item Specifications
Model KMX15YD/B44011
Maximum flow rate [L/min (gal/min)] 246 (65)2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 852L/min (22.52gal/min)]
When power boost pressure 37.8 (5480) [at 752L/min (19.82gal/min)]
Overload relief valve set pressure
39.7 (5760) [at 30L/min (8gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5480) [at 30L/min (8gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
24-23
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.2.2.1 CONSTRUCTION
(1) Control valve
!
!" !"
!" !"
!"
!" !"
!" !"
!"
!
24-24
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket
Arm 1
F F
PBa2 PAo
PA
Arm 2 MU Option
G G
K PBp1 PBp2
K
(P3) B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10
24-25
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
%"$.
Fig. 24-25 Section (3/6)
24-26
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
Swing
204
203 PBs
Boom
333 PBb 333
331 Pss
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb 162
Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
164 551
Bucket
209
PCc
216 201
333 Arm 1 333
PBa1
331 331
PBc
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRa
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac
162 Aa
161
264 302
603 PAc PAa1 264
205 AcR SECTION F-F 205
AaR 602
Fig. 24-26 Section (4/6)
24-27
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24. COMPONENTS SYSTEM
201
333 Arm 2 Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao
521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
SECTION G-G
205
205
T2
161
P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164
SECTION H-H
24-28
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24. COMPONENTS SYSTEM
PBp1 PBp2
207
160 606 606
278x5 266
264 264
SECTION J-J
SECTION K-K
24-29
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-30
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-31
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24. COMPONENTS SYSTEM
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
69~78 (51~58) 101 Body ; M27 1 541 Seat 1
69~78 (51~58) 102 Plug ; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1
24-32
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24. COMPONENTS SYSTEM
371 361 340 319 308 317 340 361 371 350
351
Fig. 24-31 Arm 2 spool
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
308 Spool 1 16~18 (33~35) Loctite #638 350 Plug 1
317 Plunger 1 16~18 (33~35) Loctite #638 351 Plug 1
319 Plunger 1 361 O-ring 2
340 Spring 2 371 Buckup ring 2
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
301 Spool 1 16~18 (12~13) Loctite #638 350 Plug 1
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Buckup ring 1
24-33
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24. COMPONENTS SYSTEM
101
164
171
201
321
PLc A B Dr
166 541 167 511 161
Fig. 24-33 Lock valve selector
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
101 Casing 1 10~14 (7.4~10.3) 171 Socket bolt 3
161 O-ring 4 49~59 (36~44) 201 Plug 1
164 O-ring 1 321 Spring 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1
24-34
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
2 2E
6 ,H
Fig. 24-34 Bypass cut valve
24-35
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24. COMPONENTS SYSTEM
Fig. 24-35 Swing shuttle valve cover
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
166 O-ring 1 542 Seat 1
202 Cover 1 25~29 (18~21) 554 Plug 1
541 Steel ball 1 7.9~9.8 (5.9~7.2) 555 Plug 1
24-36
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
104
107
102
101
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
101 Poppet 1 20~29 (15~21) Loctite #262 104 Plug 1
102 Poppet 1 107 Spring 1
24-37
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
CMR1
PL CMR2
PTb PBL
Travel straight
PCb PAL Travel left
P1 unload
AL
CT2 CP2 BL
CT1
(T3) Boom conflux
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr CCb
PBs
Dr
LCb LCs Pss
(HEAD) Ab
PAa1 Arm 1
PBb
LCc Aa (HEAD)
Bucket PAc
CRa
(ROD) Bc PLc2
(HEAD) Ac
Ba (ROD)
PCc
PBc
LCAT2
LCAP2 LCo
Ao
Bo
PBo
PBa2
MU
PBp1 PBp2
(P3) (P4)
24-38
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.2.2.3 OPERATION
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through
tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system,
because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the
hydraulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though
the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut
valve (606) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to
the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic
oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut
valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic
pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which
passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into
low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
(D)
Pss
606
517 52
306
YA1 YBG1
T1
P2
P1
309
310 606
55
(D)
Connected to low
pressure circuit of
P2 side casing
24-39
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-40
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24. COMPONENTS SYSTEM
24-41
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24. COMPONENTS SYSTEM
PAc
PCc PBc
Bc Ac
LCc
321 (D)
322 304 511
(R) (H)
Fig. 24-41 In bucket digging operation (Stroke limiter ON)
24-42
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
53
(D')
216 Downstream of
boost check valve
PAc
PCc PBc
Bc Ac
LCc
321
322 304 511
(R) (H)
24-43
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
(4) Boom
1) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward
against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional
valve [XI] acts on port PCa and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs
(325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches
unloading spools (310).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load
check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of
boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.
24-44
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24. COMPONENTS SYSTEM
Fig. 24-44 In boom up conflux operation (Boom conflux spool)
24-45
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
Fig. 24-45 In boom down operation
24-46
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24. COMPONENTS SYSTEM
56
PBa1 PAa1
P1
(D')
Arm 1 (D) LCAT2 LCAP2
(D') P1
RR RH HH
52 PAa2 PBa2
(D') Dr Dr
Arm 2
To arm 1 spool
PBa2 PAa2 Aa (HEAD)
Ba
(ROD)
53
To pilot cut valve
MU
AP2 515
328
321 308 511 LCAT2 LCAP2
24-47
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
56
PBa1 P1
PAa1
(D')
Arm 1 (D) LCAT2 LCAP2
(D') P1
PAa2 PBa2
RR 52 RH Dr
(D) HH Dr
Arm 2
(a) To arm 1 spool
Aa (HEAD)
PBa2 PAa2 Ba
[XR]
(ROD)
53 To pilot cut valve
MU Circuit (I)
317
328 515
321 308 319 (D)
511 LCAT2 LCAP2
Fig. 24-47 In arm in operation (At light load: arm recirculation function)
24-48
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24. COMPONENTS SYSTEM
56
PBa1 PAa1 P1
(D')
(D) LCAT2 LCAP2
Arm 1
(D') P1
(D) RR 52 RH
HH
PAa2
Dr
PBa2
Dr
Arm 2
(a) To arm 1 spool
PBa2 PAa2 Aa (HEAD)
[XR] Ba
53 (ROD)
To pilot cut valve
MU
Circuit (II)
317
328 515
308 (D)
321 319 511 LCAT2 LCAP2
Fig. 24-48 In arm in operation (In heavy load operation)
24-49
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24. COMPONENTS SYSTEM
Fig. 24-49 Swing operation
24-50
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24. COMPONENTS SYSTEM
24-51
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
Fig. 24-51 Lock valve operation (At boom spool neutral position)
24-52
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
A A PLc Sa Sb Dr
SECTION A-A
Sa
321 322
PBb
(D)
301
Dr
Fig. 24-52 Lock valve selector operation (At boom down operation)
24-53
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
[X1]
PBp1
301 302
(b)
(C)
Dr
201 101
(a)
(D)
52
24-54
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
PBp1
302
301
(b)
(C)
Dr
201 101
(a)
(D)
202
52
24-55
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
Fig. 24-55 Boost check valve operation
24-56
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
527
528
(D') T2
518
T1
102
517
(D)
24-57
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-58
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.3.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
PORT 1, 3 PORT 2, 4
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
0 0 0 0
0 1.1 2 4 6 7 0 1.12 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDRAULIC SYMBOL
24-59
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.3.2 CONSTRUCTION
302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
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)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.
24-60
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-58)
The action of spring (509) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201).
Therefore, spool (201) (for return) is pushed up by
spring (221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is that the
output pressure is equal to the tank pressure.
216
509
221
201
Fig. 24-59 When the lever is tilted
(3) Lever held (See Fig. 24-60)
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (509) 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, 509
ports (2,4) and the P port open while ports (2,4) and
the T port close. Thus the secondary pressure is
T PORT
kept constant.
P PORT
24-61
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-62
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.4.1 OUTLINE
(1) Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
(2) Specifications
P T
Item Specifications
Part No. YN30V00105F1
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
24-63
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
5
3
8 10
3
11 12
4
10
9
9
7 6
2
24-64
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.5.1 SPECIFICATION
(1) General view
P
Port Tightening torque
Symbol Port name
size N.m (lbf.ft) Dr
A,B Main port PF3/4 162 (119.5)
THREAD FOR
Dr Drain port PF3/8 74 (55) EYE BOLT GB
2-M12 DEPTH 24
Mu Make-up port PF1 255 (188) B
GA,GB Pressure measuring port PF1/4 36 (27)
P Parking brake release port PF1/4 36 (27)
Gear oil level gauge
L,AR Air breather port PT1/2 65 (48)
RELIEF
GIN Gear oil lubrication port PT3/4 98 (72) VALVE B
A
RELIEF GA
VALVE A
Au
Mu GIN L, AR
Au Mu
GA(GB)
A(B)
P
AIR BREATHER
PORT P
Au
GIN L, AR
Dr
GB GA
B Mu A
HYDRAULIC DIAGRAM
24-65
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
(2) Specifications
Displacement cm (in )
3 3 151 (9.2)
Working pressure MPa (psi) 28.5 (4,130)
Max. flow L/min (gal/min) 253 (66.8)
Braking torque N•m (lbf•ft) 685~891 (505~657)
Release pressure MPa (psi) 3.1 (450)
Relief set pressure MPa (psi) 25.8 (3,741)
Weight kg (lbs) 53 (117)
Part No. LQ32W00011F1
Speed reduction type Planetary 2-stage
Reduction unit
Swing unit
Mechanical brake
Relief valve
Make-up valve
By-pass valve
24-66
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.5.2 CONSTRUCTION
(1) Swing motor
17
41
42
SECTION A-A
15,16
32 33
A PORT SIDE
RELIEF VALVE
A PORT
b 34
g
TOP DEAD POINT h BOTTOM DEAD POINT
i
B PORT
B PORT SIDE
31 RELIEF VALVE
30 a DRAIN PORT
29
28 34 39 38 37 36 35
MAKEUP PORT
16 15
17 18
14 19
13 20
43 b
c 21
12
MECHANICAL BRAKE
11
RELEASE CHAMBER
10 d 22
9 e 23
8 f 24
7 25
6 26
5 40
4
3 2 1 27
24-67
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 INNER RING 1 22 NEEDLE BEARING 1
2 OIL SEAL 1 23 SNAP RING 1
TAPERED ROLLER
3 1 24 CYLINDER 1
BEARING
4 BACKING SPRING 1 25 HOUSING 1
5 CAM PLATE 1 26 COLLAR 1
6 RETURN PLATE 1 27 SNAP RING 1
7 PISTON ASSY 9 78 (58) 28 BYPASS VALVE ASSY 2
8 LINING PLATE 3 29 BACK-UP RING 2
9 PLATE 3 30 O-RING ; 1B P18 2
10 O-RING 1 31 O-RING ; 1BP12 2
11 PISTON 1 32 COVER 1
12 O-RING 2 78 (58) 33 RELIFE VALVE 2
13 SPRING 19 34 O-RING ; 1B P26 4
14 PISTON 2 284 (209) 35 SOCKET BOLT ; M1660 4
29 (22) 15 CAP 3 36 CHECK VALVE 2
16 O-RING ; 1B P11 3 37 SPRING 2
17 PARALLEL PIN 2 137 (101) 38 CAP 2
18 SCROWAVE 4 39 BACK-UP RING ; T2 P26 2
19 TEFLON RING 4 40 PLUG 1
20 BUSH 4 41 PISTON 2
21 BALANCE PLATE 1 42 TEFLON RING 2
24-68
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
SECTION A-A
Tightening torque
- 4.4 N.m (51.0 +
69.1 + - 3.2 lbf.ft)
Apply seal tape or Loctite #577.
Fill up this space
with grease.
24-69
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.5.3 OPERATION
16 15 MAKEUP PORT
17 18
14 19
13 20
b
c
12 21
11 MECHANICAL BRAKE
RELEASE CHAMBER
10 d 22
9 e 23
8 f 24
7 25
6 26
5 40
4
3 2 1 27
24-70
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
j P1 L m
k n P2
24-71
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-72
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.6.1 SPECIFICATIONS
Tin
Pm2 P2
Pp
Tightening LUBRICATION PORT
torque PORT
PORT SIZE N.m PORT NAME
SYMBOL
(lbf.ft)
P1 Motor drive port
PF1 255 (188)
P2 Motor drive port LEVEL CHECK PORT
PF1/2 108 (79.7) T Drain port
Ps 1st,2nd speed change over pilot port
Pm1 P1 side pressure detecting port
PF1/4 36.3 (26.7) Pm2 P2 side pressure detecting port
Pp Parking brake release port
Tin Lubrication port in the inside of motor case
DRAIN PORT
VIEW A
24.1.6.1.2 SPECIFICATIONS
24-73
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.6.2 CONSTRUCTION
24-74
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-75
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-76
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.6.3 OPERATION
24.1.6.3.1 SUMMARY
The hydraulic circuit diagram for piston motor is shown
in Fig. 24-67.
This travel motor is made up of the following units, and
those functions are described below.
(1) Piston motor
The piston motor is of swash plate type, and is used
to convert fluid energy of pressure oil from the
hydraulic motor to mechanical energy and outputs
the power in low speed and high torque.
(2) Double counterbalance valve (Brake valve)
The purpose of this valve is to control the motor Fig. 24-67 The hydraulic circuit diagram for piston
speed according to the supply flow rate. Therefore motor
the overrun of motor due to the outer load is
prevented.
(3) Crossover relief valve
The purpose of this valve is to decide the driving
force and braking force of motor. Therefore, for this
valve, the shockless function is employed to soften
the shock generated when the motor starts or stops
and to provide the preferable operability. And this
function is integrated into the counter balance relief
valve in compact size, composing a brake circuit.
(4) Auto 2-speed change over mechanism
This motor is equipped with auto 2-speed change
over mechanism, enabling it to select either the low
speed mode fixed position or the auto 2-speed
position. In the auto 2-speed position, the motor
capacity corresponding to the motor load pressure
is selected to automatically change the speed, high
speed or low speed.
(5) Parking brake
For the piston motor, a parking brake function is
contained. When the motor stops, the mechanical
brake actuates and prevents the rotation of motor
due to the outer load.
(6) Reduction unit
The simple epicycle 2-stage speed reduction
mechanism is employed as low speed mechanism,
and the mechanism is of the rotary casing type.
This speed reduction unit converts the power in
high speed and low speed torque output by the
piston motor to the power in low speed and high
torque and outputs it through the reduction unit Fig. 24-68 Travel motor made up
casing.
In addition, the floating seal is contained in it to
prevent the entry of mud, sand, water, etc.
24-77
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
This way, the piston motor converts the hydraulic fluid energy from the hydraulic pump to the mechanical energy,
and outputs the turning effort at low speed and high torque. And the torque and speed of the piston motor is
decided according to the pressure and flow rate. If the pressure and flow rate are raised, the torque and speed
of piston motor are also raised.
36
38
37
62
46
24-78
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-79
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
Fig. 24-71 Double counter balance valve when motor is rotated
24-80
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
Fig. 24-72 Double counter balance valve and relief valve when piston motor is braked.
24-81
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
5) Shuttle valve function for high pressure selection (See Fig. 24-73)
The double counter balance valve contains the high pressure select shuttle valve function for the release of
parking brake self-pressure additionally.
When the pressure oil is supplied through P1 port, plunger (3) moves rightward to the position shown in Fig.
24-73. And oil passage D to cylinder chamber E of the parking brake opens, and the pressure oil is led into
oil passage G through orifice and flows into cylinder chamber E of the parking brake to release the parking
brake.
In addition, when the piston motor stops, plunger (3) returns to the neutral position, oil passage D closes and
parking brake is actuated by the action that the brake pistons (56) are pushed back with spring (59).
OIL PASSAGE D
OIL PASSAGE D
OIL PASSAGE D
ORIFICE 59 56
24-82
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-83
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
PS (PILOT PRESSURE)
T1 T2
19,20
OIL PASSAGE B
A1
A2
PISTON
CHAMBER F
48
48 FACE B
2-SPEED FACE C M1 M2
CONTROL
PISTON THRUST (38)
PISTON
THRUST
SPRING
THRUST (43)
46
47 FACE A
1 47
Fig. 24-77 High speed (low capacity)
24-84
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
2) When switching the motor capacity to large capacity (low speed mode), (See Fig. 24-78)
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 (19,20) is moved rightward by the spring (21) force until it comes into contact
with plug (22). 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
(38) and spring (43) until the face B of swash plate (46) comes in contact with flange holder (1), consequently
the tilt angle of swash plate (46) becomes larger and the piston motor speed switches to low speed.
PS (PILOT PRESSURE)
22
T1 T2
OIL PASSAGE B
A1
A2
PISTON
CHAMBER F
48
FACE B
48
FACE C M1 M2
PISTON THRUST (38)
SPRING
THRUST (43)
46
47 FACE A
1 47
24-85
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
T1 OIL T2
PASSAGE
B
Pin
M2 M1
24-86
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
PS (PILOT PRESSURE)
T1 OIL T2
PASSAGE
B
Pin
M2 M1
24-87
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-88
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
Fig. 24-83 Construction of reduction unit
24-89
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.7.2 SPECIFICATIONS
Item Specifications
Assy parts No. YN55V00053F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
F Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length : L 368 mm (14.5")
Weight 25 kg (245 lbs)
24-90
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.7.3 CONSTRUCTION
#$!#$ !%&
' () (" * () +,(,!-
.!#! )
#$!#$ !%&
' () (" * () +,(,!-
.!#! )
24.1.7.4 OPERATION
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.
24-91
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.8 CYLINDER
24.1.8.1 SPECIFICATIONS
(1) General view
B A
n gth gth
n
d le d le
de te
xten rac
ly e et
Fu
l l ly r
Fu
24-92
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.8.2.1 CONSTRUCTION
(1) Boom cylinder
B
-0.5
-0.5
120 0
120 0
PS1/8
PT1/4
With hole
DETAIL B (1 place) DETAIL C
T=7750 (5716)
T=56.9 (42)
9 8 7 6 3 4 5 11 10 2 1 13 14 16 17 18 19 15 20 21
SLIT
Orientation of cut off part
of cushion bearing (13)
P/No LQ01V00028F1
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 9 Wiper ring 1 17 Buckup ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 19 Slide ring 2
4 Bushing 1 12 Socket bolt; M1880 12 20 Set screw; M14 1
5 Snap ring 1 13 Cushion bearing 1 21 Steel ball 1
6 Buffer ring 1 14 Cushion seal 1 22 Pin bushing 4
7 U-ring 1 15 Piston 1 23 Wiper ring 4
8 Buckup ring 1 16 Seal ring 1
24-93
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
T=56.9 (42)
Hole 1 place
-0.5
-0.5
130 0
130 0
28 29 29 28
PS1/8
PT1/4
P/No LQ01V00038F2
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 11 Buckup ring 1 21 Piston nut 1
2 Piston rod 1 12 Socket bolt; M20 10 22 Set screw ; M14 1
3 Rod cover 1 13 Cushion bearing 1 23 Steel ball 1
4 Bushing 1 14 Cushion seal 1 24 Cushion bearing 1
5 Snap ring 1 15 Piston 1 25 Cushion seal 1
6 Buffer ring 1 16 Seal ring 1 26 stopper 2
7 U-ring 1 17 Buckup ring 2 27 Snap ring 1
8 Buckup ring 1 18 Slide ring 2 28 Pin bushing 4
9 Wiper ring 1 19 Slide ring 2 29 Wiper ring 4
10 O-ring 1 20 Shim 1
24-94
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
22 21 12 T=267 (197) 21 22
B
-0.5
-0.5
107 0
107 0
PS1/8 PS1/8
With hole
DETAIL B (1 place) DETAIL C
9 8 7 6 3 4 5 11 10 2 1 13 15 16 17 18 14 19 20
P/No LQ01V00030F2
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 9 Wiper ring 1 17 Slide ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 19 Set screw; M12 1
4 Bushing 1 12 Socket bolt; M1675 12 20 Steel ball 1
5 Snap ring 1 13 Cushion bearing 1 21 Pin bushing 4
6 Buffer ring 1 14 Piston 1 22 Wiper ring 4
7 U-ring 1 15 Seal ring 1
8 Buckup ring 1 16 Buckup ring 2
24-95
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24.1.8.2.2 OPERATION
If pressurized oil is fed alternatively to the oil inlet and Cushion bearing (13) Chamber "A" Passege "B"
outlet provided in the cylinder, force acts on the piston Tank
which in turn causes the piston rod (2) to extend and Piston (15)
Rod (2)
retract.
Rod side
Head side
(1) Operation of cylinder with cushion
1) Cushion on rod side
The cushion mechanism is provided to prevent Rod cover (3)
Cushion stroke
the generation of shock when the moving speed
of piston (15) is not reduced and strikes cylinder Fig. 24-90 Cushion mechanism on the rod side
head (3).
An oil in chamber "A" returns to the tank by
passing through passage "B" at a fixed flow rate
in a intermediate stroke state (Fig. 24-90) of
pressing head side. Next, in a state of just before
stroke end (Fig. 24-91), cushion ring (13)
plunges into passage "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and the
piston part movement slows down. Fig. 24-91 Cushioning action on the rod side
2) Cushion on head side (See Fig. 24-92)
This construction is similar to the one of cushion
on rod side. In a state of intermediate stroke
pressing rod side, an oil in chamber "A" returns
to tank by passing through passage "B" at a fixed
flow rate.
Next, in a state of just before stroke end, cushion
bearing (22) plunges into passage "B". At this
time, the oil in chamber "A" flows only through
clearance "D" and mouth gap "C" of cushion seal
(23). So the returning oil volume drops suddenly
and the piston movement slows down.
Fig. 24-92 Cushion mechanism on the head side
24-96
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
D - 10 Diode
D - 12 Diode
D - 13 Diode
D - 14 Diode
D - 16 Diode
D - 17 Diode
E - 1 Fuse and Relay box YN24E00016F1
E - 2 Alternator VH270402192A
E - 3 Hour meter YT58S00006P1
(E) Electric fittings
24-97
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
valve
solenoid valve
(YN35V00047F1)
PSV - B P2 unload propo. valve YN35V00048F1
Solenoid valve assy
PSV - C Travel straight propo. valve
PSV - D P1 unload propo. valve
PSV - P1 P1 pump propo. valve (LQ10V0018F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump
R - 1 Battery relay YN24S00008F1
R - 2 Starter relay VHS283001271A
R - 3 Glow relay VHS286201420A
R - 4 Safety relay YN24S00010P1
R - 5 Horn relay
R - 6 Working light relay
R - 8 Travel alarm relay
R - 9 Cab working light relay
(R) Reray
24-98
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
24-99
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
YN22E00214F1
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
YN59S00021F1
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
C-4
Controller
YN20M01468P1
Air-con Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
24-100
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-5
Rated voltage DC24V
Controller
Maker's (Hino) P/No. S8347-01230
VHS834701230
Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
Hino P/No. : 82580-8050A
(YAZAKI : 7382-1680)
Hino P/No. : 82580-8870A
(YAZAKI : 7283-1080)
C-8
Controller 89661-E0010
VH89661E0010 Maker's P/No. SOFTWARE
( P/No. 89663-E1400 )
Engine controller Rated voltage 24V (DC)
LQ12 - 06001 ~ Working voltage 16~32V (DC)
LL12 - 05001 ~ Operating voltage
(at starter ON) 9~32V (DC)
Back-up source
(reference value) 5mA MAX (BAT=24V)
24-101
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E-1
Fuse capacity and circuit
Fuse & Relay box
YN24E00016F1
Fuse & Relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
Front side of machine
E-2
Alternator M6
B terminal
VH270402192A
Generator
YN11 - 45001 ~
YQ11 - 06001 ~
LQ12 - 06001 ~
LL12 - 05001 ~
E-3
Hour meter Movement Quarts
Operating voltage 10~80VC
YT58S00006P1 GM terminal : 2962447
GM connector : 2962448
Service meter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
24-102
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 5, 6
Type Bottom L : Low sound
Horn H : High sound
Rated voltage DC24V
LC53S0001D1 (High) STAMP
Operating voltage range DC20~30V
LC53S0001D2 (Low)
Sound level 113+5dB(A)/2m
Warning sound
420+20Hz high sound
YN11 - 45001 ~ Basic frequency 350+20Hz low sound
YQ11 - 06001 ~ Insulation resistance More than 3M /DC500V
LC10 - 07001 ~
YC10 - 03501 ~ o 8.5
LQ12 - 06001 ~
LL12 - 05001 ~
E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
YN54S00041P1
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
YN11 - 45001 ~ Desiccant moisture 17% or over than the
weight of desiccant
YQ11 - 06001 ~ adsorption capability (Include initial absorption 2%)
LC10 - 07001 ~ Refrigerant HFC-134a
YC10 - 03501 ~ Inner volume/Desiccant 578cm3/300g Inlet (From condenser)
LQ12 - 06001 ~
LL12 - 05001 ~
E - 11
Air-con compressor !"#$"###
YX91V00001F1
%&'
Air-con
'### (
YX03 - 01601 ~
)* +
YX04 - 01773 ~
$,!'
YX05 - 02001 ~
-.$&#/,!0
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
24-103
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 12
Type 115F51
Battery
Voltage 12V
YN72S00014P1
Capacity (5HR) 96Ah
Power
Weight (Incl. fluid) Approx. 26.5kg (58.4 lbs)
YN11 - 45001 ~
Electrolyte Approx. 6.7 L (1.77 gal)
YQ11 - 06001 ~
LC10 - 07001 ~ Negative
terminal
Positive
terminal
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
(0.67")
(0.67")
Taper
Taper
17
17
17.9 19.5
(0.705") (0.768")
502 (19.76")
180 (7.09")
255 (10")
210 (8.27")
E - 14
Cigarette lighter !
"# $%
YN81S00003P1
&! - +
Cigarette lighter ./
YN11 - 45001 ~
' (
)&%
YQ11 - 06001 ~
LC10 - 07001 ~
* + (,$&
YC10 - 03501 ~
LQ12 - 06001 ~ 01 +
LL12 - 05001 ~
E - 15
Fusible link
LQ13E01143S002
Fuse
LQ12 - 06001 ~
LL12 - 05001 ~
24-104
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 27
Resistance 2
Rated voltage DC 5V
Accel redundant volume
Resistance 2 TOCOS
YN52S00052P1 Parts E-27 RA30YME20FB202
Accel redundant volume
YN11 - 45001 ~ After soldering,
insulate this part
YQ11 - 06001 ~ with heat shrinkable tube
Clip
LC10 - 07001 ~
Adhesive
YC10 - 03501 ~
LQ12 - 06001 ~
Fix this resistance with tape HOUSING : 172131-5
LL12 - 05001 ~ PVC tube (Black) TERMINAL : 170340-1
Dial
VIEW I
L - 1, 6
Light (Halogen)
YW80S00001F1
Boom work light (LH, RH)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
L - 2,7
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effective area of lens 71cm2
Deck work light
Cab working light front
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
24-105
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L-3
Meker Knight beam (Imasen)
Light
Type BL46-146
YM80S00001F1
Bulb DC 24V, 25W
Flasher lamp (LH)
Lighting cycle 90 times / min
Rear work light
YN11 - 45001 ~
AV0.85 W
YQ11 - 06001 ~ AV0.85 Y REAR WORKING
LC10 - 07001 ~ SWING LIGHT LIGHT
YC10 - 03501 ~ AMP PART NO.
LQ12 - 06001 ~ HOUSING : 174259-2
TERMINAL : 171661-1
LL12 - 05001 ~ AV0.85 R
HARNESS SEAL : 176886-2 AV0.85 B SWING LIGHT
L-4 LOCK PLATE : 1-174260-1 GND
VIEW I
Light
YM80S00001F2
Flasher lamp (RH)
Rear work light
YN11 - 45001 ~
YQ11 - 06001 ~
SECTION A-A
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens
YT80S00001P1
Room light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Bulb
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~ SECTION A-A Door
Switch
24-106
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
YN11 - 45001 ~ Controller
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~ Wiper sw
OFF-Stop
ON-Start
LL12 - 05001 ~ Stop signal
Reverse signal
Electric diagram
M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 600cc (0.16 gal) / min or more
YN54C00001F1
Capacity 1.5L (0.4 gal)
Window washer
Injection pressure 88.3 kPa (12.8 psi) or more
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A
YN24S00008F1 Exciting current 0.4A or less / 24V
Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
YN11 - 45001 ~ Closed circuit voltage 16V or less VIEW I
Terminal B
YQ11 - 06001 ~ Open circuit voltage 7V or less HOUSING AMP
GND terminal
LC10 - 07001 ~
174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
YC10 - 03501 ~ TERMINAL AMP
171661-1
LQ12 - 06001 ~ WIRE PROOF PLUG AMP
172888-2
Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)
24-107
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R-2 Length of coupler harness
Hino P/No. S2830-01271A
Relay (From outlet to coupler)
Rated voltage DC24V L=215mm
VHS283001271A
Rated time 30 sec 18 o4 MAX
Starter relay Vynil tube (Red)
Exciting current 3A or more (at 20 )
YN11 - 45001 ~
Min operating voltage DC18V or less (at 20 )
YQ11 - 06001 ~
Insulation resistance 1M or more
LC10 - 07001 ~
YC10 - 03501 ~ Black
LQ12 - 06001 ~
LL12 - 05001 ~
Blue
Vynil tube (Red) M6
Terminal C Terminal B
Electric diagram
Tape
M6
R-3
Hino P/No. S2862-01420A
Relay
Rated voltage DC 24V
VHS286201420A
Rated load 100A flow
Glow relay
Min. operating voltage DC 18V or less
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
S terminal
YC10 - 03501 ~
(Red)
Name plate
LQ12 - 06001 ~
LL12 - 05001 ~
F terminal
Connector
090 II Non water-proof male 2P blue
SW terminal Hino P/No. 82580-7320A
Yazaki P/No. 7282-1020-90
Mating connector
090 II Non water-proof female 2P
Hino P/No. 82580-7330A
L terminal Yazaki P/No. 7383-1020-**
Electric diagram
24-108
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R - 4,5,6,9,23,24,25,
26,28,29,30,31,32,45 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
YN24S00010P1
Rated voltage DC 24V
Safety relay
Horn realy Contact 1C
Work light relay * Accessory of relay box
Cab working light relay
Auto idle stop relay 1, 2
Engine emergency stop relay
Lever lock relay Pin assignment
Alternator relay
Wiper motor relay
Washer motor relay
Boom cyl. working light relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
Terminal arrangement
LL12 - 05001 ~
R - 19
Relay
YY24S00001P1 UPPER
Flasher relay
YN11 - 45001 ~
YQ11 - 06001 ~
LQ12 - 06001 ~
LL12 - 05001 ~
TERMINAL NUMBER
SE - 1 ~ 5, 7 ~ 11,20
Pressure range 0~3MPa (435 psi)
Pressure sensor
Allowable max. pressure 7.0MPa (1010 psi) O-ring
(Low pressure) (P11 1B)
Rated voltage 5+0.5V DC
YX52S00013P1 Vout
50M or more /DC50V megger HEX24
Bucket dig and dump, Insulation resistance
(Between Body terminal)
Boom up and down,
Swing,
Connection (Arrangement)
Arm in and out,
Travel RH and LH and other
Vcc GND
LC10 - 07001 ~ PF1/4
Tightening torque 29.4~34.3 N.m
YC10 - 03501 ~ (21.7~25.3 lbf.ft)
LQ12 - 06001 ~
LL12 - 05001 ~
24-109
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SE - 13
Output voltage 2.8V or more
Speed sensor
Clearance 1.0mm
VHS894101290A Sumitomo : 090-II (4P : B)
E/G speed sensor P/No. : 6188-0265
Hino. P/No.
YN11 - 45001 ~ Sensor side : 82580-6120A (B)
Harness side : 82580-6130A (B)
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
M16 x 1 Hex. : 17
LL12 - 05001 ~
Hex. : 22
Tightening torque : 47N.m (34.7 lbf.ft)
SE - 15
Float operation
Fuel sending unit
Float Resistance
YN52S00045F1 +0.1
FULL 10 -0.6
Fuel level
3/4 (19)
YN11 - 45001 ~
1/2 32+5
YQ11 - 06001 ~
1/4 (49.5)
LC10 - 07001 ~
EMPTY 85 +10
0
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
Float
SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage
YN11 - 45001 ~
Notch part
YQ11 - 06001 ~
LC10 - 07001 ~ Potentio
YC10 - 03501 ~ 3MA JM II + AMP
Bracket HOUSING : 174359-2
LQ12 - 06001 ~
TERMINAL : 171661-1
LL12 - 05001 ~
Dial
24-110
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SE - 22, 23 Electric diagram (Arrangement)
Pressure range 0~50MPa (7250 psi)
Pressure sensor
Max. allowable press. 120MPa (17400 psi)
(High pressure)
Operating source voltage 5+0.5V DC
YN52S00048P1
100M or more/DC50V megger
P1 pump Insulation resistance
(Between casing and terminal)
P2 pump
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Source (+)
P3/8
YC10 - 03501 ~ Tightening torque Output (+) Econo seal J series
: 73.5 N.m O ring P14 Common (+) (Mark II (+)
LQ12 - 06001 ~ (54.2 lbf.ft) JIS B2401 3 pole
LL12 - 05001 ~
PSV - A, B, C, D
Proportional solenoid valve
Hydraulic solenoid valve
Hydraulic symbol A5 to A8
(YN35V00047F1)
YN35V00048F1
YN35V00049F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
HYDRAULIC SYMBOL
Arm 2 speed
P1 unload
Travel straight
P2 unload
Attachment boost
Swing parking
Lever lock
PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
YN35V00052F1 TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
Pump P1, P2 HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
YN11 - 45001 ~
Rated voltage DC 24V
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Sleeve O-ring Solenoid Seal nut
LQ12 - 06001 ~ 1B P20
LL12 - 05001 ~
24-111
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
Rated voltage DC 24V
valve (8 spool) assy pressure
Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A4 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YN35V00047F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
SW - 1 Auto return
Switch
Connection
YN50S00026F1 Terminal
Position
Starter switch
Auto return
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ VIEW A Terminal
YC10 - 03501 ~ arrangement
LQ12 - 06001 ~
LL12 - 05001 ~
SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
YN50S00047P1 Rated DC30V, 10A
Swing parking brake Insulation resistance
release
Vinyl tube
YN11 - 45001 ~ YAZAKI
T No.
YQ11 - 06001 ~ Contact construction : Position Red (2) 7122-2237
7114-2020
LC10 - 07001 ~ Swing parking release
YC10 - 03501 ~ Normal
LQ12 - 06001 ~
White (3) Blue (1)
LL12 - 05001 ~
SW - 5, 10, 20, 21
*+ ,-
Switch - ).
YN03M01861F1
(Right grip)
!" #$ $%
& & '
YN03M01862F1 (%" )
(Left grip)
Horn, ATT Power boost
LC10 - 07001 ~
YC10 - 03501 ~ )) ) - /012-, 34+# 5! ) 6
LQ12 - 06001 ~ )) ) - &$7-, 8!#+9!8!
7 5)) ) : ( #6
LL12 - 05001 ~
24-112
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 7
Type Normal close
Switch
Working pressure 39.2~58.8kPa (5.7~8.5psi)
VHS835301471D
Rating DC 24V/12W
E/G oil pressure switch More than 100M / 090 II Water proof connector
Insulation resistance DC500V megger
YN11 - 45001 ~ Color : Black
Hino P/No. : 82580-6830
YQ11 - 06001 ~ Yazaki P/No. : 7383-1114
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
SW - 8
Switch
YR11P00008S005
Air cleaner
Clogging switch !
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
SW - 11
Switch
YN50S00041F1
Lock lever
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ ! "
LQ12 - 06001 ~
LL12 - 05001 ~
! "
#$
SW - 15
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040DD Type (alternate)
Conflux / single flow More than 1M /
Insulation resistance DC500V megger UP
switching (OPT)
YN11 - 45001 ~ Terminal connector
YQ11 - 06001 ~ Position
Connector
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
24-113
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 19
Switch
Rated voltage DC 12V
YT50S00004P1
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
Insulation resistance 5M or more
YN11 - 45001 ~
Operation force Initial motion 0.8+0.3
0 kg
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
Max. stroke
SW - 26
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040D4 Type (alternate)
Cab work light switch More than 1M /
Insulation resistance DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~ Terminal connector
LC10 - 07001 ~ Position
Connector
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
SW - 27
Purpose Coolant level detection
Switch
Working temperature -40 ~130
VHS834601510A
Coolant level switch Hino P/No. : 82580-71708
Sumitomo P/No. : 6188-0110
YN11 - 45001 ~
Electrode side
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ CONNECTOR
Housing side
LQ12 - 06001 ~ (To ground) Mating connector
LL12 - 05001 ~ M18, P=1.5 Hino P/No. : 82580-71808
Sumitomo P/No. : 6189-0189
24-114
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 28
Switch
VHS233002800A
Fuel filter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Fuel outlet
Fuel inlet
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
Deposit container
Drain
SW - 55
Switch
YN50S00040D1
Boom work light switch !
"## &%
$
YN11 - 45001 ~
YQ11 - 06001 ~ $
LC10 - 07001 ~ %
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
24-115
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
24. COMPONENTS SYSTEM
[MEMO]
24-116
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
25.8 TROUBLESHOOTING.....................................................................................................25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.3 EXPLANATION OF MONITOR MODE ...................................................................25-46
25-1
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
25-2
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. 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.
25-3
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
COMPRESSOR
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
25-4
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
27
33 30
27-1
40
32
39
27-3 27-4
27-2
35
35-7 35-6
35-1
35-2 35-5
34 35-8
35-10 35-9
25-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
25.2.2 CONSTRUCTION
(1) Air conditioner unit
49
47
48
46 44
31
42 31
41
50
3 1
45 1
A
1 32 43
39
37
38
36
40
B
2
33
25-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
14 16
6 1 1 31
1
5
15
1
31
62
1 3
1 1
D
E 4
7
28 1
A 1 1
27
1
20
26
13
C 60
11
29
23
21 22
24 82
24
83
51 54 79
9 63
78 23 C 84 61
17
E
18
31
D
B
10
19
12
1 25
3
31
77
25-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1
25-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
25.3 PIPING
25.3.1 AIR CONDITIONER
NOTE
1. Apply oil for refrigerant R134a to the
O-rings of all air-conditioner hose fittings.
2. Refrigerant volume : 900 50g
3. T : Tightening torque N.m(lbf.ft)
B
30
C 40
D
A
3 14
1
56 2
57
7
23 6
24
35
17
49
3 5
56
57 25
34 6
24
A
39 54 8 13
C
27
12
15
25 55 5
58 8 L
8
2
B 16
21 10
52 11
22 53
33
25 23
13 9
50 25 10
6 5
14
25 1
51 8
12
8
25 25 15
4
25
INITIAL BELT TENSION
17
When the belt is pushed by the
force of 28N, adjust the
deflection of L part to be 6mm.
D
25
25
25
E
Fig. 25-5
25-9
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Hose : L = 3550 1 23.0 (17.0) 23 Sems bolt : M825 4
2 Hose : L = 2950 1 24 Clip 3
3 Bracket 2 25 Clip 18
4 V-belt 1 27 Air conditioner assy 1
3.92~4.9 (2.9~3.6) 5 Clip 4 30 Panel 1
6 Sems bolt : M1025 5 32 Compressor assy 1
7 Sems bolt : M620 2 33 Pulley assy 1
8 Sems bolt : M820 9 34 Condenser 1
9 Capscrew : M8100 4 35 Air dryer assy 1
10 Washer 6 39 Filter 1
23.0 (17.0) 11 Capscrew : M825 2 40 Solar radiation sensor 1
12 Tube for heater : L = 2400 1 49 Clip 1
13 Tube for heater : L = 1500 1 50 Connector 1
14 Tube for D hose : L = 2650 1 51 Bracket 1
15 Tube for S hose : L = 2200 1 52 Clip 1
16 Bracket 1 53 Sems bolt : M1020 1
17 Tube for L hose : L = 1700 1 54 Grommet 1
18 hose : L = 90 1 55 Grommet 1
20 Clip 2 4.4 (3.2) 56 Capscrew : M650 4
21 Bracket 1 57 Washer 4
46.5 (34.3) 22 Sems bolt : M1040 2 58 Tube for L hose : L=100 1
32 COMPRESSOR ASSY
L TUBE (10)
25-10
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
&
#
! )
"
'
"
!
%
) ,
#
, *
+ $
+
*
Fig. 25-6
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Receiver dryer 1 6 D hose 1
2 Bracket 1 7 L hose 1
3 Capscrew 2 8 L hose 1
4 Capscrew 2 9 S tube 1
5 S hose 1 10 L tube 1
25-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows
Chemical formula CH2FCF3
through the cooling circuit changes its phases from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
(compartment) to the high temperature part
Critical density 511 kg/m3 (31.9lb/ft3)
(outside of the vehicle). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Many kinds of refrigerants that change in that Specific volume of saturated
0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient 0
• It is easy to liquefy (condense). (It dose not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)
• It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
• It has small specific heat. (Since the
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held
down to a minimum.)
• It has a high critical temperature and a low
solidification point.
• It is stable chemically and does not corrode
and permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-
mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used,
sufficient refrigeration will not be performed
or the equipment in which the refrigerant is
used may be broken. Therefore, always use
a designated refrigerant for the cooling unit.
Table shows the principal characteristics of
the R134a refrigerant that is used in this
machine.
25-12
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25. AIR-CONDITIONER SYSTEM
25-13
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25. AIR-CONDITIONER SYSTEM
25-14
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25. AIR-CONDITIONER SYSTEM
25-15
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25. AIR-CONDITIONER SYSTEM
25-16
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
25-17
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
25-18
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25. AIR-CONDITIONER SYSTEM
1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)
25-19
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25. AIR-CONDITIONER SYSTEM
Fig. 25-15
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.
CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-16
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING
AIR MIX
ROD SUB
AIR MIX
ROD SUB
Fig. 25-17
25-20
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25. AIR-CONDITIONER SYSTEM
Fig. 25-18
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.
EVAPORATION SENSOR
Fig. 25-20
25-21
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25. AIR-CONDITIONER SYSTEM
Fig. 25-23
25-22
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25. AIR-CONDITIONER SYSTEM
Fig. 25-24
25-23
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25. AIR-CONDITIONER SYSTEM
• Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it
with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
25-24
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25. AIR-CONDITIONER SYSTEM
(3) Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side
Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter
25-25
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25. AIR-CONDITIONER SYSTEM
Fig. 25-25
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when
sound is heard.
3) Connect the center valve of the gauge manifold
with the charging hose of the vacuum pump.
25-26
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25. AIR-CONDITIONER SYSTEM
25-27
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25. AIR-CONDITIONER SYSTEM
• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)
25-28
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25. AIR-CONDITIONER SYSTEM
25-29
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25. AIR-CONDITIONER SYSTEM
25-30
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25. AIR-CONDITIONER SYSTEM
25-31
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25. AIR-CONDITIONER SYSTEM
NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)
MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING
FUSE 5A
COMPRESSOR
JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111
25-32
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25. AIR-CONDITIONER SYSTEM
EVA SENSOR
SUN SENSOR
MOTOR ACTUATER
(FOR AIR MIX)
MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)
BLOWER MOTOR
BLOWER AMP
MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY
25-33
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25. AIR-CONDITIONER SYSTEM
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
(1) Control panel and control unit
The control unit is integrated into control panel, and
processes the signal input by each sensor, etc. and
the signal input by each switch through control
panel with the function of the built-in micro
Fig. 25-34
computer, and comprehensively controls each
actuator (Inner and outer air flow select, air mix),
fan motor and compressor on the output side.
And the self-diagnosis performance is provided to
facilitate the trouble shooting.
TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)
In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-35
* The installing position is provided on the left side
of air-con unit.
25-34
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25. AIR-CONDITIONER SYSTEM
(3) 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 tripped by the control
amplifier and electronic thermostat control. Fig. 25-36
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
this relay has polarity.
5. Inspection: Inspect the continuity between 3
and 4 according to the conditions mentioned
below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2: Not
continued
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.
When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR
25-35
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25. AIR-CONDITIONER SYSTEM
0.02MPa(2.9psi) 0.59MPa(86psi)
ON
OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
25-36
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25. AIR-CONDITIONER SYSTEM
25.8 TROUBLESHOOTING
"HL.*" is shown on the set temp. . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
A snow mark ( ) on A snow mark ( )
the panel is flashing. on panel is flashing. Inspect and correct or replace parts.
NO YES
. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.
A
NO YES
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch
eliminate cause, correct on and off. Inspect and
correct electric circuits. Controller is faulty Inspect duct or
and measure operating or inner air sensor eliminate cause for
force. (less than 14.7N : OK) is faulty. cool air intrusion.
Refer to Troubleshooting
for refrigeration cycle.
Inspect and replace.
NO YES
25-37
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25. AIR-CONDITIONER SYSTEM
NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES
NO YES
Inspect and replace.
25-38
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25. AIR-CONDITIONER SYSTEM
NO YES
Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES
Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES
25-39
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25. AIR-CONDITIONER SYSTEM
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 ~ 9.
NO YES
CASE (2)
YES NO
25-40
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25. AIR-CONDITIONER SYSTEM
Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.
No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes
Replace
25-41
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25. AIR-CONDITIONER SYSTEM
25-42
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25. AIR-CONDITIONER SYSTEM
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES
High pressure
is lower.
NO YES
Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.
25-43
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25. AIR-CONDITIONER SYSTEM
2) MODE is flickering.
3) R/F is flickering.
Check harness or connector to motor actuator for the inner and outer
air damper for disconnection.
Note) The above indication and flickering does not function if the
harness and connector were disconnected under the condition
the panel ON/OFF switch is ON.
After the failure was occured, if the panel ON/OFF switch is
turned ON, it functions.
After correction of failure, if the main switch is not switched from
OFF to ON the error indication and flickering are not released.
25-44
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25. AIR-CONDITIONER SYSTEM
Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the
condition the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.
25-45
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25. AIR-CONDITIONER SYSTEM
ON/OFF SW
1) Press inner and outer air flow select switch and ON/OFF switch simultaneously for 1 second.
2) Press AUTO switch.
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3) Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd
digit of segment in three digits. The 1st digit is indicated by "H".
4) Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing
UP or DOWN of blower switch, and the required sensor is selected from the list below.
1 EVAPORATOR SENSOR
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF
switch for 1 second again, or turning off the main switch of excavator.
Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.
25-46
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25. AIR-CONDITIONER SYSTEM
THIRD SEGMENT
SECOND SEGMENT
When the segment exclusively used for monitor indicates 0
(displays the inner air sensor condition),
since the segment indicates 3F, the sensor is in normal
operating condition according to the list of 3 segments.
--> The inner air sensor is in normal operating condition.
2) Example 2
3) Example 3
4) List of 3 segments
SECOND SEGMENT
25-47
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25. AIR-CONDITIONER SYSTEM
[MEMO]
25-48
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31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
31
31-1
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31. DISASSEMBLING AND ASSEMBLING
31-2
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31. DISASSEMBLING AND ASSEMBLING
31-3
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
31. DISASSEMBLING AND ASSEMBLING
[MEMO]
31-4
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32. ATTACHMENT
TABLE OF CONTENTS
32
32-1
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32. ATTACHMENT
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".
(3) 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.
(4) The removing and installing 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.
32-2
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32. ATTACHMENT
(D) ARM CYLINDER HEAD PIN (C) BOOM CYLINDER ROD PIN
2. BUCKET
3. ARM
BUCKET CYLINDER
(J) BUCKET DRIVE PIN
(I) IDLER LINK PIN
IDLER LINK BUCKET LINK (B) BOOM CYLINDER
(K) BUCKET ATTACHING PIN HEAD PIN
(H) BUCKET CYLINDER ROD PIN
32.1.2 BUCKET
SECTION OF BOSS
32-3
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32. ATTACHMENT
32-4
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32. ATTACHMENT
spatula. (ab) B
3 : O-RING
12 : WASHER
11 : CAPSCREW b a
(2) When adjusting clearance (B), bring the non-
adjusting side of the bucket in contact with the arm.
8 : PLATE
(4) Adjust clearance (B) where it is more than 1.0mm
Install pin (10) until the top
(0.04in). 9 : SHIM 10 : PIN of pin is even surface
with bushing.
(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0mm (0.04in).
32-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
32.1.3 ARM
(3) Removing bucket cylinder rod pin (H) After adjustment of shim, the total gap
Loosen nut (9), remove capscrew M16140 (8), should be within 0.6~1.0mm (0.02~0.04in).
SHIM
and push out pin (H). 8
: 24mm
9
G A H SECTION D-D
H D A Install plastic shims
to bucket link side.
D
PLASTIC SHIM STEEL SHIM
Fig. 32-10 Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G)
Install plastic shims
Loosen nut (3), remove capscrew M16150 (2), to bucket link side.
and push out pin (G). 3 2
SHIM
After adjustment of
shim, the total gap
should be within
: 24mm 0.6~1.0mm (0.02~0.04in).
SHIM Apply grease
to inner wall
of bushing
G
SECTION A-A
Fig. 32-11 Detail of bucket cylinder head pin (G)
32-6
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32. ATTACHMENT
: 30mm
: 22 mm SHIM
Install plastic
shims to arm
Insert pin (F) into the original hole. side.
32-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
CLEARANCE
: 24 mm, 30 mm
Tightening torque
Classification Size
N.m (lbf.ft)
M14 144 (106)
Metric threads M16 147 (108)
M20 181 (134)
PF,PT threads 1/8" 16.7 (12.3)
32-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
32.1.4 BOOM
BLOCK
STAND
: 24 mm
4 3
SECTION A-A
Fig. 32-18 Detail of boom cylinder rod pin (C)
32-9
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
A A
: 22 mm
A
32-10
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
D
D
:12 mm
D
SECTION D-D
3) Removing arm cylinder head pin (D)
Fig. 32-21 Removing arm cylinder
Loosen nut (3), remove capscrew M20165 (2)
and pull out pin (D).
: 30mm
32-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
: 27,32,36,41mm C3
C2
C3
Fig. 32-22 Removing and installing boom cylinder
4) Removing boom cylinder foot pin (B) After adjustment of shim,
(See Fig. 32-23,Fig. 32-24) the total gap should be within Apply grease
0.6~1.0mm (0.02~0.04in). to inner wall
Loosen nut (5), remove capscrews M16150 (4) SHIM of bushing
and pull out pin (B).
4
B
B
: 24mm
32-12
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
32.2.1.1.2 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.
An oil reservoir is required to collect oil spilt on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
32-13
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
• For the details of special tools and jigs, refer to the back pages of this manual.
AIR
OIL PAN
Fig. 32-26 Preparation
32-14
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32. ATTACHMENT
25 24 12 24 25
PS1/8
PT1/4
SLIT 15
ONE HOLE
DETAIL 6 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
SLIT
C
No. Parts name Q’ty No. Parts name Q’ty No. Parts name Q’ty
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Back-up ring 1 20 Shim *1
3 Rod cover 1 12 Socket bolt 12 21 Piston nut *1
4 Bushing 1 13 Cushion bearing 1 22 Setscrew ; M12 1
5 Snap ring 1 14 Cushion seal 1 23 Steel ball 1
6 Buffer ring 1 15 Piston 1 24 Pin bushing 4
7 U-ring 1 16 Seal ring 1 25 Wiper ring 4
8 Back-up ring 1 17 Back-up ring 2
9 Wiper ring 1 18 Slide ring 2
Note : In case of piston with piston nut type, the parts with * are not used.
32-15
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32. ATTACHMENT
32.2.1.3 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. 32-27.
• 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.
(2) Pull out piston rod (2) about 200mm (8in). Because
the piston rod is heavy, finish extending it with air
200mm
pressure after the above-mentioned oil draining (8")
operation.
(3) Loosen and remove socket bolts (12) of the rod
cover in sequence.
Fig. 32-28
Cover the extended piston rod (2) with cloths to prevent
it from being accidentally damaged during operation. ALLEN WRENCH 12
Turn counterclockwise
3
Cover here with cloths
2
Fig. 32-29
32-16
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32. ATTACHMENT
• At this time, the weight of piston rod (2) is loaded KNOCK THIS EDGE
on rod cover (3). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the
rod weight may be held.
3
2
Fig. 32-30 Drawing out piston rod assy (2).
(5) Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
Since the piston rod assy is heavy in this case, lift the HORIZONTALLY
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 OIL PAN
to draw it completely. However, since the plated surface
Fig. 32-31 Method of drawing out the piston rod
of piston rod (2) is lifted, do not use a wire rope which
assy
may score the surface, but use a strong cloth belt or a
rope.
19
18
32-17
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32. ATTACHMENT
21
23
TURN COUNTER
• Since piston nut (21) is tightened to a high torque,
CLOCKWISE.
use a eye wrench suitable for the outside diameter 15
of piston nut (21). EYE WRENCH
21
• In case that piston and piston nut are combined,
Fig. 32-36 How to loosen piston nut (21)
apply the eye wrench to hexagonal part of piston
and loosen the piston directly.
32-18
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32. ATTACHMENT
Cut the seal ring (16) by tapping it with a screwdriver or SCREWDRIVER (OR CHISEL)
a chisel. Take care not to strike it too hard, otherwise
the groove may be damaged. BACK-UP RING SEAL
17 RING
16
32-19
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32. ATTACHMENT
WOOD PIECE
WOOD PIECE
VISE
BLOCK TOOL C
32-20
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32. ATTACHMENT
Fig. 32-44 Drawing out pin bushing (24)
32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with
commercial detergent.
(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.
32-21
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32. ATTACHMENT
16 O-RING
Heat them, and they may be soften. But never heat
them over 100°C (212.0°F) or more.
17
(2) Fit back-up ring (17) on the other side. After fitting,
correct it immediately to prevent from expansion of Fig. 32-46 How to fit seal ring (16)
seal ring (16) with correcting jig (H) as shown in Fig.
PRESS HERE
32-47. 16 17
CORRECTIONAL
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).
Fig. 32-47 Installing seal ring (16)
(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
32-22
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32. ATTACHMENT
(3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in INSERT U-RING INTO GROOVE FROM THIS SIDE.
their grooves in that order. Before setting packings,
coat them with hydraulic oil (or vaseline if not
available). If you forget the coating, the packings
may be scored. When attaching seals, deform them
in a heart shape as illustrated.
7
8
9
Fig. 32-50 How to fit U-ring (7)
(2) Install rod cover (3) on piston rod (2) with inserting
guide jig (I) as shown in Fig. 32-51 paying attention
2
for the lip section of U-ring not to be caught on the
stepped section.
Fig. 32-51 Inserting rod cover (3)
32-23
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32. ATTACHMENT
FLAT SECTION
32-24
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32. ATTACHMENT
(4) Put steel ball (23) into hole and tighten setscrew
(22).
: 6mm
After tightening the setscrew to a specified torque,
caulk the two places of the thread of the piston nut 21 V-BLOCK
side to secure the setscrew.
Fig. 32-56 Attaching slide ring (18), (19)
See para 32.2.1.7.3 for torque.
(5) Attach two slide rings (18) and (19). Take off vinyl
tape wound around the perimeter of piston (15),
apply high-quality grease (or vaseline) to slide ring
(18), (19) and attach the slide rings in a manner that
they may be coiled around the groove. Set the slide
rings about 180 degrees apart with each other so
that the slits may not point to the same direction.
32-25
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32. ATTACHMENT
: 14 mm
ALLEN WRENCH
TURN CLOCKWISE
Fig. 32-58 Tightening socket bolts (12)
32-26
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32. ATTACHMENT
32-27
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
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 0.1mm (0.004in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.
32-28
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32. ATTACHMENT
32-29
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32. ATTACHMENT
32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause Remedy
1. Oil leak through sliding 1. Back-up ring 1. Foreign matter is trapped in the 1. Remove foreign matter.
surface of piston rod. Oil bore of back-up ring
ring is formed on piston 2. Lips on outer and inner diameter 2. Replace back-up ring.
rod, and the ring grows up surfaces of back-up ring are
to oil drops, and they drip. scored.
3. Other back-up ring are failed. 3. Replace back-up ring
2. U-ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
OIL LEAKS FROM HERE bore of ring.
2. Score is present on the bore of ring. 2. Replace U-ring.
3. Other rings are failed. 3. Replace U-ring.
3. Buffer ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of ring.
2. Score is present on the bore of ring. 2. Replace buffer ring.
3. Other rings are failed. 3. Replace buffer ring.
4. Wiper ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of wiper ring.
2. Lip on the bore of wiper ring is 2. Replace wiper ring.
scored.
3. Another wiper ring is failed. 3. Replace wiper ring.
5. Piston rod 1. Score is present on the sliding 1.Smooth out the sliding surface with
surface of piston rod. an 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.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged. 1. Replace O-ring.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube. 1. Replace cylinder tube.
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is trapped in the 1. Remove foreign matter
[When the rod is loaded with sliding surface of seal ring.
a static load equal to the 2. Score is present on the sliding
2. Replace seal ring..
maximum working pressure surface of seal ring.
multiplied by the area of the 1. Sliding surface of slide rings is
2. Slide ring 1. Replace slide ring.
cylinder bore, the maximum scored.
movement of the piston is 3. Piston rod 1. Elongation.Piston rod and piston 1. Replace piston rod.
more than 0.5mm (0.02") in are elongated. (Loose nut)
ten minutes.]
32-30
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32. ATTACHMENT
D
For press fitting wiper
32.2.1.5.2
ring
E H
F
I
For inserting rod cover 32.2.1.5.4
32-31
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32. ATTACHMENT
32-32
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
12-S
d D Cylinder Used
5
C2 R2 R0.2 80 94 Bucket
10 12-S
90 104 Boom, Arm
25-S
oD -0.2
-0.4
oD -0.5
oD -3-4
-1
Unit : mm (inch)
B Cylinder Used
115 Arm
110 Boom
100 Bucket
32-33
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
)
4
5 (0.197")
(CHUCK)
32-34
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32. ATTACHMENT
CHUCKING JIG A
32-35
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32. ATTACHMENT
oD
15 (0.59") 15 (0.59")
od 10
10
Unit : mm (inch)
Class
(Nominal size) d D h
o55 (2.17) 62 (2.44) 88 (3.46) 80 (3.15)
o60 (2.36) 67 (2.64) 96 (3.78) 80 (3.15)
o65 (2.56) 72 (2.83) 96 (3.78) 80 (3.15)
o70 (2.76) 77 (3.03) 100 (3.94) 80 (3.15)
o75 (2.95) 82 (3.23) 110 (4.33) 80 (3.15)
o80 (3.15) 87 (3.43) 112 (4.41) 80 (3.15)
o85 (3.35) 92 (3.62) 124 (4.88) 90 (3.54)
o90 (3.54) 97 (3.82) 135 (5.31) 90 (3.54)
o95 (3.74) 102 (4.02) 145 (5.71) 90 (3.54)
C
o100 (3.94) 107 (4.21) 145 (5.71) 90 (3.54)
o105 (4.13) 112 (4.41) 150 (5.91) 90 (3.54)
o110 (4.33) 117 (4.61) 165 (6.50) 90 (3.54)
o115 (4.53) 122 (4.80) 170 (6.69) 90 (3.54)
o130 (5.12) 137 (5.39) 190 (7.48) 90 (3.54)
6) Removing of bushing
a. Move block (C) and rod cover (3) with tool
under the press.
b. 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 32~52mm
(1.26in~2.04in). (But it varies according to the
difference of dimension of cylinder head.)
32-36
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32. ATTACHMENT
4
Do not work under the press because it is very
dangerous.
A
8) Removing of bushing
a. Place chuck tool (A) with bushing (4)
sideways, and loosen adjuster bolt with allen
wrench and lever.
b. Place the chuck tool (A) vertically and turn the
adjuster by hand until the wedge is raised
about 5mm (0.2 in).
c. Remove the wedge from the edge of chuck.
32-37
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32. ATTACHMENT
32-38
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
32-39
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
32. ATTACHMENT
CHUCK(A)
BUSHING(4)
BUSHING PRESS-
FITTING PART
32-40
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32. ATTACHMENT
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.
LIFTING THREAD
ADJUSTER BOLT
WEDGE
CHUCK
32-41
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32. ATTACHMENT
[MEMO]
32-42
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
TABLE OF CONTENTS
33-1
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) 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.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding
the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize
the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component
and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in
specification.
33-2
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33. UPPER STRUCTURE
33.1.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
A1-1
seat (A1) to ease handling.
2) Move the whole control stand to its foremost A1
position.
3) Move the operator’s seat to its forward end. C1
4) Incline the reclining seat as forward as possible.
C2
(2) Remove operator’s seat. (Include upper rail.) B2
C1
1) With the above-mentioned condition, remove C2
two cap screws (B2) M820 from the upper rail.
Then move the control stand to its rearmost end
and remove two capscrews (B2) M820.
1
: 6 mm
2) Remove the operator’s seat. [about 20kg (44 8
lbs).]
Carry out the following operations as required.
3) Remove seat belt (C1).
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (8).
33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to
the tightening torque table.
A4 A5
Allen Tightening torque
Tightening position wrench
HEX N·m (lbf·ft)
A2
Capscrew (B2) 6 23.5 (17.3)
Sems bolt (C2) 17 46.1 (34) A6
33-3
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33. UPPER STRUCTURE
33.1.2 CAB
33.1.2.1 REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7)
Lift cover (A7) upwards and remove it. (Fixed with
2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M616 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1). A22
(4) Remove the harness connector (See Chapter 23) A1
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71) (CN-72) and (CN-500)
at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 33-3 Disassembly and assembly of cover (A7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
(6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M625 and 1 sems bolt (A39) M616. And right A3
A14
panels (A4) and (A4-1B) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed
A22
with 3 clows and 2 clips)
B2
3) Unfix 3 harness clips (A4-1H) of inside on right A40
A4-1H
panel (A4-1B). And free the harnesses A29
A4
connected to key switch.
A4-1H A39
4) With harnesses are connected condition, install A40
key switch cover (A3) to bracket (A1) of rear cab A4-1H
temporally. (See Fig. 33-5)
5) Disconnect harness connectors of work light A29 A4-1B
switch on right panel (A4), air conditioner panel
and cigarette lighter, and remove right panel (A4) A22
and (A4-1B). (See Chapter 23)
6) Loosen sems bolts (A22) M616 and (A23)
M640 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver
A5-2
A23
Fig. 33-4 Disassembly and assembly of right panels
(A4-1B), (A3) and (A5-2)
33-4
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33. UPPER STRUCTURE
RELAY BOX
ASSY
33.1.2.2 INSTALLATION
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 79.4 (60
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)
33-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.3 BATTERY
33.1.3.1 REMOVING
(1) Open left panel assy (21).
1) Open it with starter key.
2) Open left panel assy (21).
3) Fix it with stay.
: 17 mm
(3) Remove battery cable
1) Remove cable (A3) [between the earth and 21
battery (–)].
Fig. 33-8
(Always remove (-) terminal first and install it at
last.) 7
Tightening torque
2) Cable (A5) [between battery (+) and (-)] 15.7 N.m (11.6 lbf.ft)
1
3) Cable (A7) [between battery (+) and battery
relay]
2
: 13 mm
33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (3) against battery (B1), and
tighten capscrew (4).
: 17 mm,
Tightening torque : 10.8N•m (8.0 lbf•ft)
(2) Installing grounding cable
Install grounding cable (A3) last. Especially care
must be taken that the grounding face is free from
painting, rust, etc.
: 13 mm
33-6
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33. UPPER STRUCTURE
33.1.4 GUARD
31
23
4
21
Fig. 33-10 Arrangement of guard assy
: 19 mm
Weight : 42kg (93 lbs)
7
7
Fig. 33-11 Removing bonnet assy (11)
(2) Remove guard (5) 43b
1) Remove 4 sems bolts (43a) M1225 on upper
43a
side.
5
2) Remove 3 sems bolts (43b) M1225 on the side.
3) Remove guard (5)
43a
: 19 mm
Weight :19kg (42 lbs) C
33-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 19 mm D
3
Fig. 33-13 Removing guard (6) and (3)
(4) Remove stay (7)
1) Remove 2 sems bolts (43) M1225.
2) Remove 2 sems bolts (50) M1240. 7
: 19 mm
50
A
Fig. 33-14 Removeing stay (7)
(5) Remove cover (2)
43
1) Remove 2 sems bolts (43) M1225.
2) Remove connector for right side deck light. 2
3) Remove cover (2).
DECK LIGHT
: 19 mm
: 17 mm 4
Weight : 15kg (33 lbs)
33-8
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33. UPPER STRUCTURE
: 17 mm
Weight : 10kg (22 lbs)
: 17 mm
Weight : 17kg (37 lbs)
14
43
43
16
15
Fig. 33-19 Removing guard assy (16) and guard
(14), (15).
(10)Remove pillar (11)
C
1) Remove 4 sems bolts (44) M1230 and remove
pillar. 11
: 19 mm 44
33-9
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33. UPPER STRUCTURE
: 19 mm
Weight : 18kg (40 lbs) 4
10
12
33-10
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 19 mm 6
: 19 mm
B
43
43
19
43
33-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 19 mm
Weight : 30kg (66 lbs)
43
33.1.4.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
33-12
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33. UPPER STRUCTURE
33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,8)
1) Remove attaching sems bolts (9) M1230.
2) Remove covers.
: 19 mm
1
8
2
5
6
9 9
9
9 7
9
3 9
9
9 4
33.1.5.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7,8)
: 19 mm
Tightening torque : 80.0 N•m (59.0 lbf•ft)
33-13
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33. UPPER STRUCTURE
33.1.6.2 REMOVAL
(1) Remove 4 capscrews (A1) M1645.
B2
: 24 mm
(2) Hook the wire to the lifting eye on the fuel tank assy
A4
(C1) and remove the fuel tank.
Weight : 184kg (406 lbs) C1
A6
(3) Remove shim (A3).
A3
A1
A8
33-14
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33. UPPER STRUCTURE
33.1.6.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A1) M1645
Tightening torque
No. Name Q'ty N.m (lbf.ft)
A1 Capscrew 4 191 (140)
A6 Machine screw 5 1.96 (1.4)
A8 Cock 1 34 (25)
33-15
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33. UPPER STRUCTURE
33-16
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33. UPPER STRUCTURE
33.1.7.2 REMOVAL
(1) Draw out the suction hose (A3)
Remove 2 clips (A19) of the tank side and pull out
hose (A3).
2 : Flat-blade screwdriver
A13
At installing suction hose, A3
apply PERMATEX to the
inner end of both hoses. A12
5
: 19 mm
6
: 36 mm 18
C/V
T2
3 H/P
(4) Remove drain hose (5) of swing motor Dr
: 22 mm
A1
: 22 mm
3
33-17
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33. UPPER STRUCTURE
: 30 mm
)
Fig. 33-37 Removing hydraulic tank
Record the shim locations.
33.1.7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M2040 with
Loctite #262. (See Fig. 33-37.)
33-18
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33. UPPER STRUCTURE
B2 SUCTION
1. Two elements (D) are used as one set. STRAINER
YW50V00004F7
2. Replace O-ring (C) and packing (F) with new ones F
respectively. ELEMENT KIT
(B-100)
(7) Install return element. (See Fig. 33-32) YN52V01008R600
(8) Installing suction strainer (B2)
(9) Tighten sems bolts (C5) M1025 that attach tank
covers (C2), (C3). Fig. 33-38 Element & suction strainer
M10 Tightening torque : 46.1 N•m (34 lbf•ft)
33-19
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
Hyd.tank
16 15
Fig. 33-40 Removing guards
33-20
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33. UPPER STRUCTURE
33.1.8.2 REMOVAL
(1) Loosen sems bolts (A15) M1240 and remove half A15
clamp (A4). And disconnect 2 hoses (A1), (A2) from A2
the delivery side. A4
A15 A2
: 19 mm
A4
(2) Remove pilot pump suction hose (1) C/V
P2 6
(See Fig. 33-42) A15
A1 A11
A4
: 36 mm
A1
(3) Remove suction hose (A3) and drain hose (6) A15 Dr
a2
1) Remove 4 capscrews (B2) M1230. A4
a1
C/V
: 10 mm P1
A3
2) Remove elbow (B1) of suction hose (A3) from PH2
PH1
pump.
3) Remove drain hose (6) (Dr).
B1
: 36 mm
B2
Fig. 33-41 Removing hoses
(4) Removing other hoses
3 A3
1) Disconnect hoses of the following ports. Dr3
Hose
Port No. Tool Remarks 2
Dr3 3 22 Drain 4
B3
*Psv1 4 19 Pilot primary pressure P1 side Psv2
Psv1
*Psv2 2 19 Pilot primary pressure P2 side
B1 A11
Psv1 A11 22 Pilot pump delivery 1 SOL/V
P1
33-21
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33. UPPER STRUCTURE
PSV-P2:
Engine P2 pump
side proportional
valve
CLIP
SE-22: Using Zip-tie, clamp
Pressure sensor : the corrugated part of
P1 pump harness to the solenoid.
CLIP SE-23:
Using Zip-tie, clamp the corrugated Pressure sensor :
part of harness to the pressure sensor. P2 pump
Fig. 33-43 Removing connector
(6) Remove main pump 3 0
1) Put a wire sling on the hydraulic pump and
tension the wire sling a little. Loosen 8
capscrews (4) M1035.
: 17 mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the tension of 4
the wire rope.
On that occasion, the assembly is drawn out with
the insert NA (2-3) remaining on the flywheel 2-5
side. 2-4
3) Remove element (2-1) from the tip of the spline
shaft.
4) Remove 4 capscrews (2-5) M1650 that fasten 2-6
insert R (2-4) and remove insert R (2-4).
2-2 1
: 14 mm
2-5
5) Remove hub (2-2)
If you loosen 2 set screws (2-6) M1622, hub 2-3
2-7 2-1
comes off from the spline shaft of the pump.
Fig. 33-44 Removing pump
: 8 mm
6) Remove 4 capscrews (2-5) M1650 that fasten
the insert NA (2-3) with the engine side flywheel,
as necessary. Then remove and spring pin (2-7)
from insert NA (2-3).
: 14 mm
7) Removing bracket (1)
Loosen 4 capscrews (3) M2055, and remove
bracket (1) from pump (0).
33-22
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33. UPPER STRUCTURE
33.1.8.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Installing bracket (1)
Tighten bracket (1) with capscrew (3) and install
bracket temporarily.
: 17 mm
Tightening torque : 431 N•m (318lbf•ft)
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 1mm
(0.04in) from the end face of the spline (See Fig.
33-45 Detail aa). Then install two set screws (2-6)
and fix them together.
: 8 mm
Tightening torque : 110 N•m (81 lbf•ft)
(3) Installing insert R (2-4)
Install insert R (2-4) into hub (2-2) by means of
capscrews (2-5).
: 14 mm
Tightening torque : 210~230 N•m (155~170 lbf•ft)
(4) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert R (2-4).
(5) Installing insert NA (2-3)
Put spring pin (2-7) into insert NA (2-3) and install it
to the engine flywheel by means of capscrews (2-
5).
: 14 mm
Tightening torque : 210~230 N•m (155~170 lbf•ft)
33-23
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33-24
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33. UPPER STRUCTURE
33.1.9.2 REMOVAL
(1) Pulling out hose (3).
1) Loosen clips (5), (6) on both sides of hose (3).
2) Pulling out hose (3)
: Flat-blade screw driver
(2) Remove air cleaner assy (1)
1) Remove 4 sems bolts (8) M1025
: 17 mm
2) Remove air cleaner assy (1) from plate (4).
Fig. 33-48 Removing air cleaner
33.1.9.3 INSTALLATION
(1) Installing is the reverse order of removing with Replacing parts
attention paid to the following items:
1) Put in air hoses (2), (3) to the end as shown in
Fig. 33-48.
2) Tightening torque :
O-RING (1-6)
No. Name Tightening torque N.m (lbf.ft) (EB11P00001S003)
33-25
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.10 MUFFLER
33.1.10.2 REMOVAL
(1) Remove U bolt (4). 1
4
1) Remove 4 nuts (10) M8. 10
: 13 mm 5 10
2) Remove 2 U bolts (4). 9
(2) Remove clamp assy (5)
8
1) Remove 2 capscrews (9) M1035 12
11
: 17 mm
18
2) Separate clamp assy (5) from muffler (1). 8
2
(3) Removing other parts 10
Remove brackets (2).
: 19 mm
B
C
A
Procedure of
fastening U bolt Installing clamp side (5)
33-26
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.10.3 INSTALLATION
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (4) (See Fig. 33-50)
1) Tighten 4 nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm
the C dimensions on the right and left once
again.
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
4) Tightening torque
Nut A : 8.8 N•m (6.5 lbf•ft)
Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (5)
1) Place the end of clamp (5) 10mm (0.40in) away
from the tip of the muffler slit so the joint of clamp
does not extend over the slit in the muffler. (See
Fig. 33-50)
2) Install the clamp assy (5) in the illustrated
direction.
(3) Tightening torque :
33-27
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33. UPPER STRUCTURE
33.1.11 COUNTERWEIGHT
: 55 mm
33.1.11.2 REMOVAL
(1) Lifting up counterweight temporarily A3
Hook wire rope to slinging jig, and lift it and stretch
wire rope to the degree where it is providing no
slack temporarily.
Weight of counterweight ;
Approx. 5,820kg (12,830 lb)
Wire more than ø16 (0.63 inch) ; C1
1.5m (5ft)2 pcs.
(2) Removing counterweight
1) Remove 4 capscrews (A1) M33350. A4
A5
A6
: 50 mm
2) Remove shim (A4), (A5), (A6). (Select)
3) Remove counterweight (C1).
A2
A1
33.1.11.3 INSTALLATION
(1) Install counterweight in the reverse order of A3
removing.
(2) Install shim (A4), (A5), (A6) as it was. (select)
(3) Slinging counterweight
Check that the attaching bolts can be screwed in by
hand.
(4) Apply Loctite #262 on capscrews (A1), and tighten A4,A5,A6
them with washers (A2).
: 50 mm
Tightening torque : 2250 N•m (1660 lbf•ft)
(5) Remove slinging tools, and attach plugs (A3).
A1,A2
Fig. 33-53 Fastening the counterweight attaching
capscrew
33-28
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33. UPPER STRUCTURE
: 19 mm
(7) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose
for draining water. Clip
10
[Water capacity of radiator : 5.5L (1.5gal)]
1
(8) Remove hose from radiator sub tank (1)
Remove clip of radiator cap side and disconnect
hose (8).
: 13 mm, 17 mm
2) Move a set of air-conditioner condenser and
receiver tank. 23
34
(10)Disconnect connector of coolant level switch (B5).
(See Fig. 33-57)
Tightening
Tighteningtorque
torque
46.1N
46.5N .m.m(34.3 lbf..ft)
(34 lbf ft)
6
35
33-29
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.12.2 REMOVAL
(1) Remove radiator stay (A1).
B10
1) Remove a sems bolt (A2) M1235 and 3 sems
bolts (A3) M1230.
: 19 mm
2) Remove 2 stays (A1). B5
A3
B9
(2) Remove water hose (2),(3) A1
B1
1) Loosen the hose bands (30) for water hose (2).
A
: Flat-blade screwdriver
2) Remove hose (2). A2
A3 A3
3) Loosen hose band (30) on water hose (3) and
A1
remove capscrew (22) M1025.
: Flat-blade screwdriver
A2 B
: 17 mm
4) Remove hose (3).
A
22
30
31
: 13 mm
33-30
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
and (2). 2
(6) Remove radiator assy. (See Fig. 33-57)
15
1) Remove 4 sems bolts M1235. 20 A2
IN
: 19 mm 18
: 19 mm
Fig. 33-59 Removing hydraulic oil hose (1), (2)
2) When lifting the engine fan, shift the radiator so
it does not interfere with the engine fan.
3) Plug up pipe ends with clean cloth, etc.
4) Removing radiator
Place a wire sling in the lifting eyes of the radiator
assy and remove the assy by crane.
Weight : 110kg (243 lbs)
33-31
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.12.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
And removed clips of hose should be clamped at
original position.
Insert width Insert width
(2) Install radiator assy of hose of hose
(1.77in)
45
(1.57in)
40
: 19 mm Insert width
of hose
Tightening torque : 121 N•m (89 lbf•ft)
(4) Adjust the clearance between the fan and the
radiator shroud all around the circumference, as
below :
Circumferential direction: 40 (1.57in) CLIP
Torque
20±5mm (0.8in±0.2in) 5.9N.m (4.4 lbf.ft)
39±5mm (1.5in±0.2in) Fig. 33-60 Inserting width of hose
(5) Clean the plastering area of the insulation
thoroughly before plastering it.
(6) Making up hydraulic oil and LLC (Long Life
Coolant)
After completion of other installation, make up
hydraulic oil and water.
Coolant volume of engine body : 9 L (2.4gal)
Coolant capacity of radiator : 8.6 L (2.35gal)
Hydraulic oil capacity of oil cooler : 2.9 L (0.77gal)
33-32
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
(2) Disassembly
1) Loosen each 2 bolts (30), (31) at head and
bottom of shroud, remove upper plate (27) and
lower plate (28).
2) Disconnect wiring connector of radiator coolant
A Inter- Radiator oil
level switch. cooler cooler
3) Loosen 4 sems bolts (7) M820 attaching plate
assy (2), remove plate assy (2).
4) Loosen 2 capscrews (14) M1030 attaching
radiator core.
5) After confirming that the coolant has been
drained out completely, loosen and remove only
the radiator side of hose bands (30) at the top
and bottom of the radiator. (See Fig. 33-58)
DRAIN VALVE
6) Lift and remove radiator core using lifting eyes
and hoist on the radiator core.
Weight : 15kg (33 lbs)
Confirm the missing of rubber bushing (17)
under the radiator core.
17
7) Loosen 2 capscrews (14) M1030 attaching the
top of the inter-cooler core. Detail of radiator
core mounting part
8) Loosen and remove only the inter-cooler side of
hose bands (31) at the top and bottom of the
inter-cooler. (See Fig. 33-58)
9) Lift and remove inter-cooler using lifting eyes
and hoist on the inter-cooler.
Confirm the missing of rubber bushing (14)
28
under the inter-cooler.
31
VIEW A
33-33
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
(3) Installing
Installing is done in the reverse order of removing.
33-34
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33. UPPER STRUCTURE
33.1.13 ENGINE
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to Tools)
33-35
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33. UPPER STRUCTURE
33.1.13.2 REMOVAL
28
28
17
17 Pin
14
7 13
2
* 26 14
15
3 27
C
B
6
28 13 24
26
17
14
* 15
17 21
28 14
36 21
13 5 27 15
3
21 A
26 A
13 24
15 30
21 23
29 31 6
A D
2
25 D
7
2
1
* 5
B C
: 17 mm, 41 mm
(2) Plug connector of filter side and hose.
(3) Loosen engine mounting bolt of frame
1) Loosen 4 nuts (21) M18.
: 27 mm
2) Loosen 4 capscrews (28) M18150.
3) Remove 4 plates (17).
4) Remove upper rubber mounts (13) and (14) 2 each.
(4) Slinging engine body
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to "Tool".)
1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 580 kg (1,280 lbs)
Wire: ø6 (0.236")1m (3ft 3in) - 2pcs.
(5) Position engine on the stand stably.
33-36
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33. UPPER STRUCTURE
33.1.13.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Tightening torque
Tightening torque
No. Name Remarks
N.m (lbf.ft)
5 Bolt 26.5 (20)
Apply Loctite
24 Sems bolt 64.7 (48) #262
Apply Loctite
25 Sems bolt 79.4 (59) #262
Apply Loctite
26 Sems bolt 115 (85) #262
Apply Loctite
27 Sems bolt 172 (127) #262
Apply Loctite
28 Capscrew 226 (167) #271
30 Sems bolt 46.1 (34)
Apply Loctite
31 Sems bolt 46.1 (34) #262
33-37
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1) During pushing 4 locked claws of boot retaining
plate (4) with flat-blade screw driver, lift the plate
(4) and remove it.
: Flat-blade screwdriver
2) Loosen 3 sems bolts (10D) M616.
: Plus screw driver
3) During lifting right upper console cover (9D) up;
disconnect connector of tuner and antenna.
Move boot (3) upwards and remove console
cover (9D).
• Removing of boot and lever is unnecessary. Fig. 33-65 Removing plate (4)
4) Loosen 3 sems bolts (16A) M616 and remove 10D
lower console (4). 9D
: Plus screw driver 10D
(2) Removing left-hand console cover 16A
16B
1) Remove the boot retaining plate (4) in the same
way as right-hand console cover. (See Fig. 33- 5 16B 4 16A
65) 16B
: Flat-blade screwdriver
16C
2) Loosen 2 sems bolts (A6) M820 and remove left
armrest assy.
6
: 13 mm
3) Loosen 4 sems bolts (16B) M616.
: Plus screw driver
4) Remove the left upper console cover (5) in the
same way as right-hand console cover.
5) Loosen 2 sems bolts (16C) M616 while lifting
left under console cover (6) up, and remove left Fig. 33-66 Removing console covers
lower console cover.
33.1.14.2 INSTALLATION
Install it in reverse order of removing according to the
tightening torque table.
A6
Item Bolts Tightening torque N.m (lbf.ft)
33-38
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
Tightening torque
Mark each hose with a port name before removing it. 284N.m(209 lbf.ft)
4 Tightening torque
235N.m (173 lbf.ft)
33.1.15.2 REMOVAL
(1) Remove 3 capscrews (4) M1645, and remove
control valve (1) by hoist.
: 24 mm
Weight :Approx. 235kg (518 lbs)
33.1.15.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 3 capscrews (4) M1645.
: 24 mm
Tightening torque : 235 N•m (173 lbf•ft)
2)
Connector / Bolt Hose nut
Tread
size Ports Opposing Tightening Opposing Tightening Remarks
Name torque torque
flats N.m (lbf.ft) flats N.m (lbf.ft)
Pss,PLc2,PBp1,PBp2,PL,
PF1/4 PB1,PTb,PCa,PCb,PCc 19 36 (27) 19 29 (21)
ORS Joint
PAa1,PBa1,Pab,PBb,Pac,
PBc,PAL,PBL,Par,PBr,Pas,
PF3/8 PBs,PAa2,PBa2,Pao,Pbo,DR 22 74 (55) 22 49 (36)
PF3/4 MU 36 162 (119) 36 118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc 14 70.6 (52.1)
M10 Ab,Bb Sems bolt 14 57 (42)
P1,P2 17 62.2 (45)
M12 T1,T2 17 96 (70)
33-39
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
P1 P1 pump
P2 P2 pump
33-40
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33-41
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.16.2 REMOVAL
(1) Remove hoses from your side to far side in order. !
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See Fig. 33-71)
: 22 mm
(3) Turn and loosen lever (2-1) tightened in pilot valve,
and remove lever assy in a set. (See Fig. 33-71) *+, *!+
%& ' ( ""'
(4) Remove 4 capscrews (A14) M625. (See Fig. 33- % ' ""'
72) % ' !
: 5 mm -%. /*/
(5) Remove pilot valve. *+, *!+
(6) Plug hose ends.
" ##
Plug PF1/4, PF3/8 )' ' ( $
! 01 0 " ##
Fig. 33-72 Pilot valve connector
33.1.16.3 INSTALLATION
Install it in the reverse order of removal and tighten it. Front of machine
T Arm (R) Boom (R)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew (Green) T (Gray)
(A14) Bucket (R)
Swing (R) (Blue)
(Red)
Swing (L)
(Gray)
33-42
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
A6
A7
A5
B1
A8
33.1.17.2 REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and
SE-10 (A9) at the connector. %
4 () "56)
: 24 mm 27 &82*
0%
(2) Attach tag, and discount connectors and hoses .
(A2), (A3), (A4), (A5) 1.23 &*
% - 1/ &*
: 19 mm (P port)
: 22 mm (T port, 1~4 port) 0/
-
(3) Plug hose ends
1/ &*
Plug PF1/4, PF3/8 "
(4) Remove 4 sems bolts (A8) M825, and remove
+,
+/
right and left pedals (A5), (A6).
+,
: 13 mm +
(5) Remove 4 sems bolts (A7) M1020 and remove
right and left lever (A1), (A2).
: 17 mm
(6) Remove 4 sems bolts (A11) M1030.
: 17 mm
% !"# $$
(7) Remove pilot valve lifting it upward.
(8) Stop up holes with plugs PF1/4.
&'( )"*
Fig. 33-75 Installing and Removing pilot valve
33-43
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.17.3 INSTALLATION
Install it in the reverse order of removal and tighten it.
Sems bolt (A11)
33-44
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.18.2 REMOVAL
(1) Remove hose. 5
1) Remove hose (7) from the connector in the 4
makeup port M. S/J H/D TANK
E
: 36 mm 14 7
2) Remove 2 hoses (4), (5) from the Tee in the drain
port Dr. 13 M C/V
Dr
MU
: 27 mm
3) Remove hose (A2) from the elbow of the PG port
(For swing parking brake) (See Fig. 33-77)
: 19 mm B
A
: 36 mm
A7
Put in plugs PF3/4, PF1/2, and PF1/4 into the
A4 C/V
removed ports. Bs C/V
As
2 2
A2
PG
1
1
33-45
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 30 mm
1) Remove two plastic caps (2) M12 at the top of
the swing motor and install eye bolts.
: Flat-blade screwdriver
2) Put a wire sling in the eye bolts and remove the
swing motor unit.
Weight of swing motor unit ;
Approx. 274kg (604 lbs) (Include reduction assy)
33.1.18.4 INSTALLATION
Install the swing motor unit in the reverse order of
disassembly, confirming the orientation of the swing Coat all the mounting surface of
the swing motor with Loctite #515
motor unit. equivalent. 1
: 30 mm
Tightening torque : 539N•m (400 lbf•ft) Apply
Loctite #262 Detail of swing motor unit assy mount
(2) Fill inside from motor drain port to casing with Apply Loctite #262
hydraulic oil before piping for drain 1 equivalent.
Tightening torque
539N.m (400 lbf.ft)
FILLING PORT
Put sealing tape on the both
sides of thread portion of
filling tube.
Tightening torque
108 N.m (80 lbf.ft)
LEVEL GAUGE
Put sealing tape on the thread
portion of tube for level gauge.
Tightening torque 69.1 N.m (51 lbf.ft)
33-46
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.19.2 REMOVAL
(1) Remove travel motor hose and tube
1) Remove 2 hoses (A16). (E port : PF1/2)
T : Tightening torque
of connector
A2 N.m (lbf.ft)
A4
SWIVEL JOINT
T=255
(188)
A7
T=255 (188) B2 T=36.3 (26.8)
A7
A3
A1
A16
T=108 (80)
T=108 (80)
A16
33-47
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 27 mm
Tightening torque : 78 N•m (58 lbf•ft) 4
2) Remove hoses (A8), (A6).
(A, CÉ|Å[Ég : 1-3/16-12UN)
A9
: 36 mm
Tightening torque : 177 N•m (130 lbf•ft)
3) Remove hoses (A9), (A25).
(B, D port : 1-3/16-12UN)
: 36 mm
Tightening torque : 177 N•m (130 lbf•ft)
4) Remove hose (A7).
A6
(Travel 2-speed change over port : PF1/4)
A8
: 19 mm
Tightening torque : 29 N•m (21 lbf•ft) 14
A7
: 36 mm
mm
13 At assembling,
this distance
should be 13mm (0.512in).
33-48
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 19 mm & '$
(See 11.7 SPECIAL TOOLS No.9 Plug)
$ %
!" #$!
33.1.19.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Piping tightening torque
(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.
33-49
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.20.2 REMOVAL
(1) Lifting up upper frame temporarily
Lift the upper frame temporarily by after mentioned
three points using lifting tool
(Refer to the chapter of the tool).
Use the near 2 holes of the boom foot pin and the
rear of the upper frame at this work.
(2) Marking match marks on swing bearing
Put match marks on upper frame and swing
bearing.
Fig. 33-85 Matching mark on swing bearing and
upper frame
(3) Removing upper frame attaching bolts
Remove 32 capscrews (9) M20115 and a reamer
bolt (10) used to install swing bearing and upper
frame.
: 30 mm
(4) Slinging upper frame
Sling according to Fig. 33-84, and remove upper
frame and put it on a stand.
Weight : Approx. 5ton (11,000lbs)
33-50
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.1.20.3 INSTALLATION
(1) Installing is done in the reverse order of removing. Apply Loctite #515 to the race surface
(2) Cleaning mating surfaces of upper frame and swing over the whole circumference (shaded area)
on the inside of capscrew.
bearing.
(3) Apply Loctite #515 to the inside of the capscrews
on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (10)
and a washer (11) temporarily.
: 30 mm Apply Loctite #262
Tightening torque : 490 N•m (360 lbf•ft)
Apply Loctite #262
(5) Install swing bearing
Install 32 capscrews (9) M20115.
: 30 mm
Tightening torque : 490 N•m (360lbf•ft)
33-51
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33. UPPER STRUCTURE
983 531
981 . 534
548 792
702
B 532
732 X
789 Z
535 W
886 Y
953 A
806
728
468
113
127
123
127
824 271
325 808
717
04 490 954 546901
251 312
725
401 407 490
C
124
727 886
314
717 D
141 546
157 E
156
151 153 885 727
. 886
152 467
B 725
211 466
214 406
212 261 D
774 E
710
F
A
116
724 710
717
313 326
124 F 414 05
111
C
885
Fig. 33-89 Structural exploded view of main pump
33-52
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33. UPPER STRUCTURE
33-53
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33. UPPER STRUCTURE
434
311
312
434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)
Fig. 33-90
33-54
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 19 mm, 36 mm
: 6 mm, 8 mm
: 6 mm
6) Remove socket bolt (401)
Loosen socket bolts (401) that fasten swash
plate support (251), pump casing (271) and
valve block (312).
: 17 mm
33-55
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33-56
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33-57
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
312
• The valve plate may come off during the
operation under 6).
314
(313 :
Opposite Side)
33-58
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33-59
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
4) Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251).
251
111
: 6 mm $
Tightening torque : 29 N•m (22 lbf•ft)
"$
• Coat the oil seal in seal cover (F) with a thin
film of grease.
• Handle the oil seal with sufficient care so it is
not scored.
312
• Do not mistake the suction and delivery sides
of the valve plate.
314
(313 :
Opposite Side)
33-60
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 17 mm
Tightening torque ; 430 N•m (320 lbf•ft)
: 6 mm,
Tightening torque ; 17 N•m (12.5 lbf•ft)
: 6 mm,
Tightening torque ; 29 N•m (21 lbf•ft)
Socket bolt (414) …… PTO Cover (326)
: 8 mm,
Tightening torque ; 57 N•m (42 lbf•ft)
: 19 mm, 36 mm
Tightening torque ; 36 N•m (27 lbf•ft)
Tightening torque ; 170 N•m (125 lbf•ft)
33-61
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
Clearance between piston and cylinder
0.039 0.067
bore Replace piston or cylinder.
(0.0015 ) (0.0026 )
(D-d)
Gap between piston and caulked part of
shoe 0 ~ 0.1 0.3
Replace piston shoe assy.
(0.004 ) (0.012 )
( )
Thickness of shoe 4.9 4.7
Replace piston shoe assy.
(t) (0.193 ) (0.185 )
Free height of cylinder spring 41.1 40.3
Replace cylinder spring.
(L) (1.618 ) (1.587 )
Combined height of retainer plate and
23.0 22.0 Replace a set of spherical bushing or
spherical bushing
(0.906 ) (0.866 ) retainer plate.
(H-h)
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
33-62
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on
it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements
may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valveÅfs relief valve are of regular frequency. In
case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This
will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes
by measuring pressures.
(2) Troubleshooting
1) Overloading to engine
2) Pump’s oil flow rate is extremely low and delivery pressure is not available.
33-63
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33-64
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33-65
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.2.1.2 REGULATOR
626
625
624
753
627
623
621 D 728
B 645
611
622 F
874 646
733 613
732 875 644
631 612
898
652 875
A 643
651
836 G E
897 C
655
654
653
814
630
438
629
763
802
628
756
801
924
412
656 413
438 757
Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722 858
466 496 734
755 G
887
708 F
A 876
662 B 724 614
439 C
642 730 725 8-724 755
858
041 755
755 466
466 755
641
33-66
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
33-67
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 5 mm
630 924
Fig. 33-110 Removing cover (C) (629)
33-68
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 5 mm
439
641
33-69
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
$"
$!&%#
$
Fig. 33-118 Removing feedback lever (611) [2]
33-70
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
"$$
$"
Fig. 33-120 Part of exploded view of regulator
33-71
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
• Make sure that the spool and the sleeve (652) SPOOL FEEDBACKLEVER(611
move smoothly in the casing.
• Beware of the direction of the spool. Fig. 33-122 Direction of the spool (652)
33-72
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
9) Installing return spring and the spring seat Fig. 33-126 Installing adjust plug (615)
(See Fig. 33-108 (A) section)
Assemble return spring (654) and spring seat
(653) into the spool hole and fit snap ring (814).
33-73
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 5 mm
Tightening torque ; 12 N•m (8.7 lbf•ft) $ $
Fig. 33-128 Assembling compensating parts
11) Installing spool and spring
"$$
Assemble spool (642) and spring (662) into pilot
cover (641), and tighten VP plugs (466).
$$
$"
"$$
$"
Fig. 33-129 Assembling spool (642)
12) Assembling into the pilot hole and the
compensating hole
(See Fig. 33-108 (E),(D) section)
Put spring seat (644), pilot spring (646) and
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating
hole.
: 5 mm
Tightening torque ; 12 N•m (8.7 lbf•ft)
14) Installing block cover (See Fig. 33-109)
Attach block cover (656).
: 5 mm
Tightening torque ; 12 N•m (8.7 lbf•ft)
Fig. 33-131 Installing cover (C) (629)
This completes assembly.
33-74
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33. UPPER STRUCTURE
414
117 128
216 435
826 886 711
128 326
414
115
886 262
728
885 125 468
118
125
825
710 435
435
414
262
414
33-75
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 27 mm
• Drain out the oil from the plugs of the front
pump and the rear pump.
4) Remove cover FLANGE SOCKET (M10)
Remove the socket bolts (414). Then remove the Tightening torque : 33N.m (25 lbf.ft)}
cover (262).
: 8 mm
5) Remove PTO gear casing (OPT.) 414
Remove flange socket (435) and PTO gear
casing.
: 8 mm
262 COVER
PTO GEAR CASING
414
262 COVER
Fig. 33-132 Removing gear pump
PTO
GEAR CASING
33-76
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
6) Removing the 2nd gear, the roller bearing and HOLE FOR
the bearing spacer IDLE SHAFT (115)
Draw out the spring pin (885) and remove idle
shaft (115). Then draw out 2nd gear (117), roller
bearing (126) and bearing spacer (128). 117 (126,128)
• Roller bearing (126) can not be separated
from 2nd gear (117).
118
33-77
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
!
!" !"
!" !"
!"
!" !"
!" !"
!"
!
33-78
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket
Arm 1
F F
PBa2 PAo
PA
Arm 2 MU Option
G G
K PBp1 PBp2
K
(P3) B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10
33-79
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
%"$.
Fig. 33-138 Section (3/6)
33-80
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
Swing
204
203 PBs
Boom
333 PBb 333
331 Pss
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb 162
Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
164 551
Bucket
209
PCc
216 201
333 Arm 1 333
PBa1
331 331
PBc
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRa
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac
162 Aa
161
264 302
603 PAc PAa1 264
205 AcR SECTION F-F 205
AaR 602
Fig. 33-139 Section (4/6)
33-81
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
201
333 Arm 2 Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao
521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
SECTION G-G
205
205
T2
161
P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164
SECTION H-H
33-82
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
PBp1 PBp2
207
160 606 606
278x5 266
264 264
SECTION J-J
SECTION K-K
33-83
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33-84
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.2.2.3 DISASSEMBLY
The figures in parentheses after part names in this
manual represent those item numbers in the structural
sectional drawing under Fig. 33-136 to Fig. 33-141.
(1) Place the control valve on a work bench so as to
locate back pressure check valve upwards.
33-85
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33-86
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
33.2.2.3.2 Disassembling the travel spool (left travel and right travel)
(1) Loosen the socket bolts (273) and remove the
spring cover (201) and the O-ring (261) for travel.
33-87
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
(3) Fix the boom conflux spool with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (325),
(326) and stopper (339) from boom conflux spool
(305).
(2) Draw out the assy of boom spool (301), spring seat
(331), springs (321), (322), stopper (336) and bolt
(333) from casing B (102).
33-88
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
(3) Fix the boom spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (336) from boom spool (301). Do
not disassemble boom spool (301) further unless
there is special reason.
(2) Draw out the assy of swing spool (303), spring seat
(331), springs (321), (322), stopper (336) and bolt
(333) from casing A (101).
(3) Fix the swing spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (336) from swing spool (303).
33-89
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33. UPPER STRUCTURE
33-90
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33. UPPER STRUCTURE
(3) Fix the arm 1 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (321, 322)
and stopper (336) from arm 1 spool (302).
(3) Fix the arm 2 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (321, 328)
and stopper (340) from arm 2 spool (308). Do not
disassemble arm 2 spool (308) further unless there
is special reason.
33-91
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33. UPPER STRUCTURE
(3) Fix the option spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (323, 324)
and stopper (336) from option spool (311).
(3) Fix the travel straight spool assy with vise via a
protective plate (aluminum plate, etc.). Remove
bolt (333) and separate spring seat (331), springs
(327, 329) and stopper (336) from travel straight
spool (307).
33-92
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33. UPPER STRUCTURE
(2) Swing
Loosen socket bolts (273) and remove spool cover
(206) and O-ring (264), (266). Do not disassemble
spool cover (206) further unless there is special
reason.
33-93
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33. UPPER STRUCTURE
33.2.2.3.13 Removing relief valve and plug assy for relief valve hole
(1) Remove the main relief valve (601) and overload
relief valve (602) and (603) from the casing.
33-94
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33. UPPER STRUCTURE
33-95
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33. UPPER STRUCTURE
33-96
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33. UPPER STRUCTURE
The plug and spring in use differ from the above (1). Do
not mix the parts when assembling parts again.
(3) Load check valve on arm 2 section Fig. 33-177 Removing plug (551),(556),(552)
Remove plug (551) and then remove poppet (515)
and spring (521).
The poppet in use differs from the above (1). Do not mix
the parts when assembling parts again.
33-97
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33. UPPER STRUCTURE
Take care not leave lapping compound behind in the casing or block.
4) Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches,
dents, and the like. Remove any small defects with an oil stone or lapping compound.
5) Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are
free from foreign matter.
6) Replace any broken or deformed spring with new one.
7) Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
8) Replace all O-ring with new ones.
33.2.2.4 REASSEMBLY
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the structural
sectional drawing. (Fig. 33-136 to Fig. 33-141)
(3) Precautions on reassembling O-ring
1) Confirm that O-rings are free from defects caused by poor handling.
2) Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3) Do not stretch O-rings to the extent that they become permanently set.
4) When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after
installation, and can cause oil leaks.
5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance
Standards."
33-98
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33. UPPER STRUCTURE
Take care to prevent misassembling of parts and assembling position error because the parts in (1) to (5) are similar
in shape.
Take care to prevent drop of poppet (606-201) and spring (606-202) when attaching by-pass cut valve.
33-99
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33. UPPER STRUCTURE
33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (603) and relief valve hole plug assembly (604) in
respective place to the specified torque.
Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief
valves (602), (603) are similar in shape.
Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten
socket bolt (273) to the specified torque.
(2) Place travel straight spool assembly in item (1) in casing B (102).
Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and
tighten socket bolt (273) to the specified torque.
33-100
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33. UPPER STRUCTURE
Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten
socket bolt (273) to the specified torque.
(2) Place arm 2 spool assembly in option in item (1) in casing B (102).
Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
socket bolt (273) to the specified torque.
Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten
socket bolt (273) to the specified torque.
33-101
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33. UPPER STRUCTURE
Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly and tighten
socket bolt (273) to the specified torque.
(4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified torque.
Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and
tighten socket bolt (273) to the specified torque.
33-102
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33. UPPER STRUCTURE
Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and
tighten socket bolt (273) to the specified torque.
(2) Place boom conflux spool assembly in item (1) in casing A (101).
Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and
tighten socket bolt (273) to the specified torque.
(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).
Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten
socket bolt (273) to the specified torque.
33-103
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33. UPPER STRUCTURE
Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten
socket bolt (273) to the specified torque.
33-104
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33. UPPER STRUCTURE
33-105
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33. UPPER STRUCTURE
33.2.2.6 TROUBLESHOOTING
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main
pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure,
load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and
reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system
is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.
2. Machine does not 1) Malfunctioning travel straight valve. 1) Check pilot pressure.
move straight during • Sticking spool. • Correct sticking part with oil stone.
simultaneous
• Replace spring.
operation of travel
• Broken or deformed spring. • Remove foreign matter.
and attachment.
• Clogged small hole in spool.
2) Malfunctioning main relief valve. 2) Remove main relief valve.
33-106
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33. UPPER STRUCTURE
33-107
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33. UPPER STRUCTURE
33-108
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33. UPPER STRUCTURE
312
302
Apply grease on
rotating and
501
Apply grease on 301 sliding sections.
Be careful the
top section assembling
212 direction
213
151
* 246
* 218-2
211
214
* 218-1
216-2 216-1
241-2 241-1
201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.061 in),
1 pc
PORT PORT
2,4 1,3
Fig. 33-179 Pilot valve (For ATT)
Apply loctite #277 to areas marked
33-109
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33. UPPER STRUCTURE
33.2.3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it with
kerosine. 501
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).
302
33-110
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33. UPPER STRUCTURE
: 24mm
301
33-111
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33. UPPER STRUCTURE
211
101
217
201-1
201-2
212
211
33-112
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33. UPPER STRUCTURE
212
213
33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2). 201-1 241-1 216-1
216-2
201-2 241-2
217
33-113
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33. UPPER STRUCTURE
221
214 213
PLUG (211)
SEAL (213)
-RING (214)
PUSH ROD
(212) Apply hydraulic oil
(5) Insert push rod (212) in plug (211) and install spring
(*246) and spring seat (*218-1) to push rod (212) on
port 1,3 side.
And install spring seat (*218-2) to push rod on port
2,4 side.
33-114
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33. UPPER STRUCTURE
101 211
151
101
A
33-115
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33. UPPER STRUCTURE
: 22mm
• Apply Loctite #277 to threads of joint.
Tightening torque : 68.6 N•m (51 lbf•ft)
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
(11)Cover it with boots. GREASE
301
212
33-116
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33. UPPER STRUCTURE
33.2.3.6 TROUBLESHOOTING
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer
to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required. The following table does not cover causes
and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and
causes.
33-117
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33. UPPER STRUCTURE
33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
(1)
Material ; SCM415 (N)
Carburizing and Quenching
(2) BUSHING
Material ; S45C
SECTION AA
A A
33-118
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33. UPPER STRUCTURE
33.2.4.1 CONSTRUCTION
T=Tightening torgue
N.m (lbf.ft) 12-o
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
g
14
q 11
T=5 (3.7) r 15
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)
33-119
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33. UPPER STRUCTURE
Fig. 33-205
(2) Switch plate removal
1) Remove :
• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm
socket wrench. (See Fig. 33-206 No.1)
* Reassembly :
• Apply a droplet of Loctite #262 on the
locking screw thread.
• Torque :1.2 N•m (0.89 lbf•ft)
3) Fit a M3 screw on the switch plate axis in order
to remove it
(Using pliers if necessary). (See Fig. 33-206
No.2)
* Reassembly :
• Position the axis so that the hole is aligned
with the locking screw as shown on the
picture (See Fig. 33-206 No.3)
4) Mark out the position of the switch plate before
removing it.
Fig. 33-206
5) Repeat the operation for the second switch plate.
6) Reassemble parts in reverse order.
33-120
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33. UPPER STRUCTURE
Fig. 33-209
33-121
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33. UPPER STRUCTURE
Fig. 33-210
(5) Damping plunger seals replacement
1) Remove
• The pilot control unit from the machine.
• Both rubber boots. (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
WIPER RING
2) Remove the wiper ring of the damping plunger
1 2 DAMPER PLUNGER
(1).
(See Fig. 33-211 No.1) Fig. 33-211
* Reassembly :
• Replace with a new wiper ring.
Always place the damping plunger prior to the wiper
ring, and make sure the wiper ring is correctly
positionned.
Fig. 33-212
4) Using a needle, remove the seal placed inside
the body (See Fig. 33-213 No.3, 4)
* Reassembly :
• Replace with a new seal and grease it.
3 4
Fig. 33-213
33-122
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33. UPPER STRUCTURE
Fig. 33-215
33-123
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33. UPPER STRUCTURE
Fig. 33-216
• Inspect the return springs. If defects are
detected, replace the 4 springs.
Fig. 33-217
(7) Throttle kit replacement
1) Remove
• The pilot control unit from the machine
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
• The damping plungers and springs (See
33.2.4.2 (5))
Fig. 33-218
33-124
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33. UPPER STRUCTURE
THROTTLE
Fig. 33-219
(8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine
Fig. 33-221
33-125
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33. UPPER STRUCTURE
Fig. 33-223
(9) Check valve kit removal
1) Remove the pilot control unit from the machine
Fig. 33-225
33-126
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33. UPPER STRUCTURE
Fig. 33-226
33-127
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33. UPPER STRUCTURE
33.2.5.1 CONSTRUCTION
(1) Swing motor
17
41
42
SECTION A-A
15,16
32 33
A PORT SIDE
RELIEF VALVE
A PORT
b 34
g
TOP DEAD POINT h BOTTOM DEAD POINT
i
B PORT
B PORT SIDE
31 RELIEF VALVE
30 a DRAIN PORT
29
28 34 39 38 37 36 35
MAKEUP PORT
16 15
17 18
14 19
13 20
12 b
c 21
12
MECHANICAL BRAKE
11
RELEASE CHAMBER
10 d 22
9 e 23
8 f 24
7 25
6 26
5 40
4
3 2 1 27
33-128
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33. UPPER STRUCTURE
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 INNER RING 1 22 NEEDLE BEARING 1
2 OIL SEAL 1 23 SNAP RING 1
TAPERED ROLLER
3 1 24 CYLINDER 1
BEARING
4 BACKING SPRING 1 25 HOUSING 1
5 CAM PLATE 1 26 COLLAR 1
6 RETURN PLATE 1 27 SNAP RING 1
7 PISTON ASSY 9 78 (58) 28 BYPASS VALVE ASSY 2
8 LINING PLATE 3 29 BACK-UP RING 2
9 PLATE 3 30 O-RING ; 1B P18 2
10 O-RING 1 31 O-RING ; 1BP12 2
11 PISTON 1 32 COVER 1
12 O-RING 2 78 (58) 33 RELIFE VALVE 2
13 SPRING 19 34 O-RING ; 1B P26 4
14 PISTON 2 284 (209) 35 SOCKET BOLT ; M1660 4
29 (22) 15 CAP 3 36 CHECK VALVE 2
16 O-RING ; 1B P11 3 37 SPRING 2
17 PARALLEL PIN 2 137 (101) 38 CAP 2
18 SCROWAVE 4 39 BACK-UP RING ; T2 P26 2
19 TEFLON RING 4 40 PLUG 1
20 BUSH 4 41 PISTON 2
21 BALANCE PLATE 1 42 TEFLON RING 2
33-129
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
SECTION A-A
Tightening torque
- 4.4 N.m (51.0 +
69.1 + - 3.2 lbf.ft)
Apply seal tape or Loctite #577.
Fill up this space
with grease.
33-130
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
33. UPPER STRUCTURE
: 14 mm, 10 mm
36
25
: 14 mm
25
33-131
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33. UPPER STRUCTURE
32
18
32
33-132
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33. UPPER STRUCTURE
25
Oil seal (2) and outer race of taper roller bearing (3) are
left inside of housing (25).
25
33-133
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33. UPPER STRUCTURE
25
SOFT CLOTH
ETC. 24
24
33-134
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33. UPPER STRUCTURE
24
33-135
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33. UPPER STRUCTURE
ROUND AREA
24
24
33-136
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33. UPPER STRUCTURE
3
End surface of cylinder (24) is sliding face. So, protect (INNER RACE)
24
Be careful not to attach a bond to the roller of bearing
(3).
Wipe off the bond which came out between a inner ring
(1) and bearing (3).
25
33-137
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33. UPPER STRUCTURE
JIG 3
Be careful to keep cylinder (24), as it is slippery with oil. Top of housing
25
Check that backing spring (4) is held in place by the
probe part of the return plate (6).
30~40
When assemble cylinder assembly, splined shaft of the (1.18~1.58 in)
PAD
cylinder (24) is protruded from the end of housing,
therefore put pad with length 30~40 mm (1.18~1.58 in) Fig. 33-251 Assembling cylinder assy
under bottom of housing (25).
33-138
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33. UPPER STRUCTURE
8
Apply hydraulic oil to each side.
25
11
10
Lubricate O-rings (10), (12) with grease.
25
33-139
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33. UPPER STRUCTURE
18
Be cautions of assembling direction of balance plate
(21).
32
32
33-140
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33. UPPER STRUCTURE
: 14 mm
Tightening torque ; 137 N•m {101 lbf•ft}
• Assemble bypass valve assembly (28) to cover
(32).
28
32
: 10 mm
Tightening torque ; 78 N•m {58 lbf•ft} Fig. 33-261 Assembling valve assy
33-141
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33. UPPER STRUCTURE
(3) Tools
Jig 1 Jig 3
(For assmbling roller bearing (3) and inner race (1)) (For assembling cylinder assembly (24))
Jig 2 Jig 4
(For assembling oil seal (2)) (For assembling brake piston (11))
(0.04")
33-142
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33. UPPER STRUCTURE
33.2.5.3.1 Tools
Unit : mm (in)
Code Tool name Remarks
450 (17.7)
Material : Mild steel
330 (13.0)
a Stand
280 (11.0)
22 (0.9)
216 (8.5)
Material : Mild steel
250 (9.8)
13- 24
Spherical bearing (13) (0.9)
b (Position
removing jig (I) space equally)
P.C.D 170
(6.7) VIEW X
X
110 (4.3)
removing jig (II)
160 (6.3)
Material : Mild steel
Oil seal (14)
(0.4)
110 (4.3)
g
9
installing jig
33-143
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33. UPPER STRUCTURE
33.2.5.3.2 Disassembly
The numbers in parentheses correspond to the ones in
construction drawings .
(1) Preparation
1) Before disassembly, clean the outside of the
reduction unit thoroughly and check for no
damage and scoring.
2) Drain gear oil from the reduction unit.
3) Disconnect the drain tube.
4) Matching Mark
To facilitate the reassembly of the unit, put
matching mark on the joining parts of the housing
before disassembly.
: 12 mm 4
2
33-144
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33. UPPER STRUCTURE
33-145
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33. UPPER STRUCTURE
16
17
JIG (a)
JIG (c)
17
16
12
33-146
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33. UPPER STRUCTURE
14
• Do not use the removed oil seal and bearing.
13
15
JIG (d)
8 22
Pinions (6) can not be replaced singly. Replace them it
Fig. 33-272 Disassembling #2 spider assy
in a set of four.
33-147
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33. UPPER STRUCTURE
33.2.5.3.3 Assembly
(1) Preparation
1) Sufficiently clean every part with wash oil and dry
it with compressed air.
16
12
33-148
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33. UPPER STRUCTURE
15
Fig. 33-278
33-149
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33. UPPER STRUCTURE
13
15
33-150
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33. UPPER STRUCTURE
Fix the snap ring with the sharp edge on the motor side
(top side in the position of Fig. 33-282).
18
4
SNAP RING (20)
Motor side 3
20
Insert shaft (6) into spider (8) so spring pin hole (22) is 11
aligned.
6
19
8 22
33-151
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33. UPPER STRUCTURE
15
: 12 mm
15
(10)Filling Lube Oil
Fill in 7.0L 1.9gal) of gear oil SAE90 (API Service Fig. 33-287 Installing #1 spider assy
Grade GL-4).
33-152
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33. UPPER STRUCTURE
33-153
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33. UPPER STRUCTURE
2) Gears
a. Inspect that the gear teeth do not show pitting and seizure.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.
3) Bearing
Turn the bearing and check that it does not develop abnormal sound, catching and other faults.
Do not reuse spherical bearing
33-154
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33. UPPER STRUCTURE
Unit : mm (in)
Code Item Repairable level Service Limit Remedy
A Wear in #1 planetary shaft ø40
0
(1.57 -0.0004 ) Replace entire spider assy.
No flaking
B Wear in #2 planetary shaft ø40
0
(1.57 -0.0004 ) Replace four shafts as a set.
There should be no pitting
Replace
Condition of tooth face exceeding 1.6mm (0.0630in) dia,
C Gears (Planetary pinion should be
abnormal wear or seizure.
replaced in a set of four.)
Condition of tooth flank There should be no cracks.
D Thickness of thrust washer 1.6±0.1 (0.06 ±0.0039) 1.3 (0.0512) Replace
E Thickness of thrust washer 2.0±0.1 (0.08 ±0.0039) 1.6 (0.063) Replace
Wear in shaft
F (Diameter of part coming in contact ø105 0
(4.13 -0.003 ) ø104.9 (4.13) Replace
with oil seal )
Apply Three-Bond 1360K and
G Socket bolt tightening torque M14- 181 N•m (130 lbf•ft)
tighten to specified torque.
Gear oil SAE90
H Lube oil 7.0 L (1.9 gal) Replenish or replace.
(API Service Grade GL-4)
33-155
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33. UPPER STRUCTURE
33.2.5.5 TROUBLESHOOTING
parts ports and apply a pilot pressure smoothly at a torque of 30~40 parts or the whole motor
of 3.2~4.9 MPa (464~711 psi) N•m (22~30 lbf•ft) it is assembly.
to the brake release port then highlylikely that an internal
check that the output shaft can parts in broken so disassemble
be turned through at by a the motor to investigate.
torque of approximately 30~40
N•m (22~30 lbf•ft).
Miss-setting of the relief Use a pressure gauge to Reset to the regulation
valve in the circuit measure loaded pressure. pressure setting.
Measure the drain volume. If the drain volume is 2.5 L/min See table B.
Excessive slippage
33-156
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33. UPPER STRUCTURE
circuit in the drain filter.Open the does not turn smoothly at a Replace the motor
motor inlet and outlet ports and torque of 30~40N•m (22~30 assembly.
apply a pilot pressure of lbf•ft), it is highly likely that an
3.2~4.9 MPa (464~711 psi) to internal part is broken so
the brake release port then disassemble the motor to
check that the output shaft can investigate.
be turned through at by a
torque of approximately 30~40
N•m (22~30 lbf•ft).
Oil leakage from joints
Loose bolts Inspect for loose bolts. Tighten to the correct torque.
Abnormal pressure Investigate the pressure in the Reduce pressure within the Replace the oil seal.
inside the case case and the drain volume. case to 0.3 MPa (44 psi) or less. Repair or replace
If the drain volume is excessive, damaged parts.
disassembly and investigation Replace the motor
is required. assembly.
Table B
33-157
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33. UPPER STRUCTURE
()
*)
# $ %
$
+)
!
33-158
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33. UPPER STRUCTURE
#$!#$ !%&
' () (" * () +,(,!-
.!#! )
#$!#$ !%&
' () (" * () +,(,!-
.!#! )
33-159
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33. UPPER STRUCTURE
33.2.6.2.1 Tools
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m1.5m (4ft5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.
33-160
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33. UPPER STRUCTURE
33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure
correspond to those of a construction drawing in Fig.
33-289.
(1) Removing cover
1) Mark cover (4) and body (1) with matching marks
for convenient reassembly.
2) Place a V-block on a work bench, place a swivel
joint set on the side, fix it and loosen socket bolt
(9) by means of a pipe and wrench. Alternately,
the swivel joint may be fixed by holding stem (2)
in a vise.
"
: 6 mm
33-161
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33. UPPER STRUCTURE
O-RING
GROOVE
OIL GROOVE
SEAL (5) SEAL GROOVE
33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of
assembly.
Apply grease on the groove of seal to be installed on
seal assembly (6) and O-ring (13).
(1) Assembling seals to body
1) Apply hydraulic oil to O-ring (13) thinly and insert
it in O-ring groove.
Check the twist of O-ring
33-162
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33. UPPER STRUCTURE
WORK BENCH
: 6 mm,
Tightening torque : 30.4 N•m (22 lbf•ft)
33-163
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33. UPPER STRUCTURE
ALLEN WRENCH
PIPE
33-164
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33. UPPER STRUCTURE
33-165
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33. UPPER STRUCTURE
Replace
(With back-up ring)
2) Slipper ring 1.5mm (0.06in) narrower than seal groove,
or narrower than back-up ring.
Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)
BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)
Replace
(With back-up ring)
33-166
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33. UPPER STRUCTURE
Open stop valve (6) on the side of low pressure !
relief valve (5) and while watching the pressure
"
gauge (for low pressure) connected to the body
# " # +
side and also by regulating low pressure relief valve
,&- . / 0
(5), gradually increase the pressure and check for
outside leakage with a color check at a pressure of "
"
% &
33.2.6.3.4 Troubleshooting
33-167
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33. UPPER STRUCTURE
[MEMO]
33-168
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34. TRAVEL SYSTEM
TABLE OF CONTENTS
34
34-1
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34. TRAVEL SYSTEM
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(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.
34-2
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34. TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD LOWER FRAME
GREASE NIPPLE OF THE 3. UPPER ROLLER
TRACK SPRING ADJUSTER 4. LOWER ROLLER
Fig. 34-1 Designation and location of undercarriage
34.1.2 CRAWLER
: 19 mm
When using a big hammer, wear protective goggles
Fig. 34-3 Removing/fixing position of master pin
and a long-sleeved uniform so you do not injure
yourself by flying objects.
34-3
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34. TRAVEL SYSTEM
34.1.2.2 INSTALLING
Installing is done in the reverse order of removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in the
figure on the right.
34-4
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34. TRAVEL SYSTEM
: 19 mm
A
Fig. 34-8 Adjusting crawler tension
34.1.2.3 CONSTRUCTION
FLAT SHOE
2
1-6
1-1
1-8
1-4
1-3
1-8 GROUSER SHOE 8
1-7 2
1-1
9 7
1-7 1-5
1-2 1-2
Fig. 34-9 Track link assy and shoe plate
SK250-8 SK260LC-8
LQ60D00022F1 LQ60D00023F1
Shoe assy
Shoe assy
LQ60D00022F2 LQ60D00023F2
LQ60D00022F3 LQ60D00023F3
LQ60D00022F5 LQ60D00023F5
No. NAME Q'TY No. NAME Q'TY
1 . LINK ASSY YN62D00017F2 1 1 1 1 1 . LINK ASSY YN62D00017F4 1 1 1 1
1-1 .. TRACK LINK R 47 47 47 47 1-1 .. TRACK LINK R 51 51 51 51
1-2 .. TRACK LINK L 47 47 47 47 1-2 .. TRACK LINK L 51 51 51 51
1-3 .. BUSHING 46 46 46 46 1-3 .. BUSHING 50 50 50 50
1-4 .. PIN 46 46 46 46 1-4 .. PIN 50 50 50 50
1-5 .. MASTER BUSHING 1 1 1 1 1-5 .. MASTER BUSHING 1 1 1 1
1-6 .. MASTER PIN 1 1 1 1 1-6 .. MASTER PIN 1 1 1 1
1-7 .. COLLAR 2 2 2 2 1-7 .. COLLAR 2 2 2 2
1-8 .. SEAL 92 92 92 92 1-8 .. SEAL 100 100 100 100
2 . SHOE 600mm 47 - - - 2 . SHOE 600mm 51 - - -
. SHOE 700mm - 47 - - . SHOE 700mm - 51 - -
. SHOE 800mm - - 47 - . SHOE 800mm - - 51 -
. SHOE 600mm FLAT - - - 47 . SHOE 600mm FLAT - - - 51
7 . BOLT 2420Z1292 188 188 188 - 7 . BOLT 2420Z1292 204 204 204 -
8 . BOLT 2420T7262D2 - - - 188 8 . BOLT 2420T7262D2 - - - 204
9 . NUT 2420Z1293 188 188 188 188 9 . NUT 2420Z1293 204 204 204 204
34-5
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34. TRAVEL SYSTEM
F E
D D G
B
Fig. 34-10
Unit : mm (in)
REPAIRAB SERVICE
No. ITEM STANDARD VALUE REMEDY
LE LEVEL LIMIT
A Link pitch 190 ± 0.1 (7.4803 ± 0.0039) 194 (7.64) 198 (7.80) Replace the link
B O.D. of bushing ø 58.78 (2.3142 ) ø 55 (2.17) ø 54 (2.13) assy if the service
C Height of link 106 ± 0.3 (4.1732 ± 0.0118) 100 (3.94) 98 (3.86) limit is exceeded
Basic
Tolerance Fit Fit
dimension
Interference between bushing + 0.11
D Interference
and link ø 58.78 (+0.0043) Interference
Shaft 0.05
(2.3142) - 0.05 0
(0.0020) Replace
(-0.0020)
+ 0.1
Interference
Interference between track pin ø 36.63 (+0.0039) Interference
E Shaft 0.05
and link (1.4421) - 0.05 0
(0.0020)
(-0.0020)
- 0.03
Interference
Interference between master ø 36.50 (-0.00118) Interference
F Shaft 0.05 Replace Link
pin and link (1.43701) - 0.088 0
(0.0020)
(-0.00315)
8 (0.32) 10 (0.39)
G Clearance between links 1.5 (0.06) (both side) Replace
(both side) (both side)
H Tightening torque of shoe bolt 853 N•m (629 lbf•ft) Reassembly
Unit : mm (in)
NAME OPPOSING FLATS
30 (1.2)
Socket
(2) Jig
NAME SHAPE
34-6
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34. TRAVEL SYSTEM
34.1.3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned). 3
4
: 30 mm
34.1.3.3 INSTALLING
Installing is done in the reverse order of removing.
(1) Inspection
Before reassembling, check it that it rotates smooth COUNTER-
manually and for leak. SINKING
end upward.
: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
2 1 3,4
34-7
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34. TRAVEL SYSTEM
34.1.3.4 CONSTRUCTION
" #
" # $
%
!#
" #
!" #
1 10 5 9
Fig. 34-13 Construction of upper roller
2) Removing snap ring (11)
Mount the end face inside upper roller (1) on
stand jig (f) and separate snap ring (11), using
snap ring pliers.
B
: 10mm
34-8
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34. TRAVEL SYSTEM
!
B
Collar (3) is press fitted into shaft (2). Therefore do not
disassemble it.
(2) Assembly
Assembly of the upper roller is done in the reverse f
order of disassembly.
1) Place upper roller (1) on the top end face of jig
(f), with its floating seal setting side facing down.
2) Confirm that the outer surface of bushing (6) is Fig. 34-18 Pushing in bushing
not scuffed and coat the outer surface of the
inserting side of the bushing, with molybdenum
disulfide grease. 2
7
3) Put jig (i) into bushing (6) and press it in, using
the bore of the bushing and the bore of the roller 7 1
as guides.
3
34-9
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34. TRAVEL SYSTEM
: 6mm,
Tightening torque : 23N•m (17 lbf•ft)
B
• After assembling the upper roller, confirm that
oil is not leaking from it and that it rotates
smoothly by hand.
34-10
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34. TRAVEL SYSTEM
C
A
E
F
D D
B
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. ø 140 (6.30) — —
B Width 150 (5.91) — —
Replace
C Tread dia. ø 120 (4.72) ø 107 (4.21) ø 105 (4.13)
D Tread width 33 (1.30) — —
Basic
Tolerance Fit Fit
dimension
Clearance between - 0.025
E
shaft and bushing (-0.00098) Clearance Clearance
ø 45 (1.772) Shaft
- 0.040 0.7 (0.028) 1.0 (0.039) Replace bushing
(-0.00157)
+ 0.030
Interference between Interference Clearance
F ø 50 (1.969) Hole (+0.00118)
roller and bushing 0 0.01 (0.0004)
0
Tightening torque of
G 115 N•m (85 lbf•ft)
socket bolt
Oil Engine oil API grade CD #30, 30cc (1.83cu•in) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly
34-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
Unit : mm
NAME OPPOSING FLATS
30
Socket
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
120 (4.72)
90 (3.54) 160 (6.30)
f Stand jig
52.5(2.07)
For extruding
g
(0.709)
bushing
18
49(1.93)
For extruding
h
(1.18)
shaft
+0.1
+0.1
60(2.36)
49.5 0
44.6
Bushing fixing
i
jig
1.756 +0.004
1.949 +0.004
(1.26)32
0
(1.46)37 50(1.97)
87(3.43)
34-12
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
2 1 B2
Apply Loctite #262
T=397N.m (290 lbf.ft)
Fig. 34-23 Lower roller assy and track guide
34.1.4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wood) at the front and back
of the lower frame.
: 27mm,
Weight of track guide : Approx. 25kg (55 lbs)
ROLLER
B2,B5
SK260LC-8 LC LQ01F00031F1 STD
ITEM NAME Q'TY
B2 TRACK GUIDE : YN63D00003P1 2 2
B5 CAPSCREW : M18X40(P=1.5) 8 8
34-13
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
34.1.4.3 INSTALLATION
(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and
fasten all 4 capscrews temporarily. Then tighten
them to a specified torque.
: 27 mm,
Tightening torque : 397N•m (290 lbf•ft)
(2) Installation of track guide
Capscrews (4) with Loctite #262 and fasten all 4
capscrews temporarily. Then tighten them to a
specified torque.
: 27 mm,
Tightening torque : 397N•m (290 lbf•ft)
(3) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
: 19 mm,
Tightening torque : 59N•m (43 lbf•ft)
34-14
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34. TRAVEL SYSTEM
34.1.4.4 CONSTRUCTION
STD 4 16 275
LOWER ROLLER LQ64D00029F1
LC 8
: 6mm 2
JIG M
The shaft (3) extrusion operation may cause the
remaining lube oil to flow out. Prepare an oil container
beforehand.
34-15
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
JIG M
34-16
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
(2) Installing % !
1) Attach O-ring (7) to one side
Install O-ring (7) to groove on shaft.
• Grease O-ring.
• Replace O-ring with new one without fail at Fig. 34-33 Attach O-ring (7) to one side
reassembling.
6 5
7 2
34-17
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
PIN HOLE
• Grease O-ring.
2
• Replace O-ring with new one without fail at
reassembling. PIN HOLE
7
8) Press fitting collar (2)
Press-fit collar (2) to shaft (3).
3
• Press-fit collar (2) on aligning pin (5) hole.
: 6 mm,
Fig. 34-39 Installing filling oil plug (8)
Tightening torque : 21.6~24.5 N•m
(16~18.1 lbf•ft)
34-18
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34. TRAVEL SYSTEM
C C
B
E
A
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A O.D. of flange ø 185 (7.28) — — Reinforcement weld,
B Tread dia. ø 150 (5.91) ø 134 (5.28) ø 128 (5.04) repair or replace
C Flange width 23.5 (0.925) 18 (0.709) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 65 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft
(2.55905) - 0.090 0.7 (0.276) 1.0 (0.394) Replace bushing
(-0.00354)
+ 0.030
Interference between ø 69 (+0.00118) Interference Clearance
E Hole
roller and bushing (2.71653) - 0.020 0 0.01 (0.0004)
(-0.00079)
F Oil Engine oil API grade CD #30, 160cc (9.8 cu•in) Refill
Execute air leak test at 0.2MPa (28psi)
H Plug (8)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
34-19
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34. TRAVEL SYSTEM
Unit : mm
NAME OPPOSING FLATS
19, 27
Socket
Allen wrench 6
(2) Jig
Unit : mm (in)
No. NAME SHAPE
K V-block
100(3.94)
Pin (5)
(0.551)
L
14
extrusion rod
16 (0.630)
200(7.87)
Bushing
N
extrusion rod
290(11.4)
160(6.30)
M Stand jig
(4.92)
125
270(10.6)
Shaft
P
(2.52)
extrusion jig
64
(1.18)
30
86(3.39)
94.5(3.72)
64.5(2.54)
Bushing
Q
fixing jig
+0.1
64.6 0
(2.543 +0.004
0 )
34-20
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34. TRAVEL SYSTEM
34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
(3) Installing
Installing is done in the reverse order of removing.
! "
34-21
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34. TRAVEL SYSTEM
34.1.5.3.1 CONSTRUCTION
: 5 mm
U
3
34-22
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34. TRAVEL SYSTEM
34-23
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34. TRAVEL SYSTEM
: 5 mm
Fig. 34-52 Installing collar (3) and filling oil
• After installing the idler assy to the idler
adjuster assy, make certain that no oil leaks
from floating seal and plug (8) and that idler
(1) rotates smoothly.
F
D
E
B
A
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. of idler projection ø 535 (21.1) — —
B Tread dia. ø 497 (19.6) ø 490 (19.3) ø 487 (19.2) Replace
C Flange width 84 ± 0.5 (3.307±0.020) 78 (3.07) 76 (2.99)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 75 (-0.00118) Clearance Clearance
Shaft Replace
(2.95275) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
+ 0.035 Clearance
Interference between idler and ø 83 Interference
E Hole (+0.00138) 0.01
bushing (3.26771) 0
0 (0.0004)
F Oil Engine oil API grade CD #30, 200cc (12.2cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble
34-24
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34. TRAVEL SYSTEM
Unit : mm
NAME OPPOSING FLATS
24
Socket
Allen wrench 5
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
(0.591)
(1.18)
15
30
R Pin striking jig
(0.591)
105(4.13) 15
340 (13.4)
300(11.8)
Approx.150
(5.91)
Approx.600
(23.6)
U Stand
Approx.
400
(15.7)
2
(0.787)
105(4.13)
20
90(3.54)
jig
+0.1
74.6 0
(2.937 +0.004
0 )
103(4.06)
W Collar press fitting jig
(1.18)
30
34-25
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34. TRAVEL SYSTEM
34.1.5.4.1 CONSTRUCTION
: 46 mm
3) Draw out grease cylinder (See Fig. 34-54)
Draw out piston (6) from grease cylinder (1) of 5
the idler adjuster assy.
4) Removing oil seal (9), O-ring (8) (See Fig. 34-54)
Remove oil seal (9) and O-ring (8) from grease
cylinder (1).
V
5) Slinging work idler adjuster
Set the idler adjuster assy on the stand of the jig, Fig. 34-56 Slinging work idler adjuster
with its bracket side facing up.
34-26
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34. TRAVEL SYSTEM
: 46 mm HOLDING-DOWN NUT
RETAINER PLATE
4
Fig. 34-57 Fixing idler adjuster assy
7) Compression of spring (5) #
Remove spring pin (4), press spring (5) lifting it
with jack so that nut (3) can be turned freely, and
remove nut (3).
: Bar ø7.5120
: 85 mm
2
11
34-27
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34. TRAVEL SYSTEM
(2) Assembly
Assembly is done in the reverse order of W
disassembly. 1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1), collar (7) into spring
5
(5) and attach lifting eye nut (W) to screw
M56P3 at the tip of the grease cylinder. Lift the
grease cylinder by crane and erect it in the
center of the jig stand upright.
: 46 mm
3) Compressing spring (5) and tightening nut (3)
HOLDING-
Extend the hydraulic jack, compress spring (5) to DOWN NUT
a set length and screw in nut (3) to the screwed
part at the tip of grease cylinder (1). RETAINER
PLATE
Set length of the spring : 437mm (17.2in)
2
4) Installing spring pin (4)
4
Tighten nut (3) till the holes for locking spring 3
pins (4) are aligned. Then fit spring pin (4).
11 7
: 85 mm 1
34-28
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34. TRAVEL SYSTEM
: 19 mm,
Tightening torque : 59 N•m (43 lbf•ft)
X
E
C
Y F
A, B
X D
DETAIL Y
SECTION XX
Fig. 34-65
34-29
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34. TRAVEL SYSTEM
34.1.6 SPROCKET
34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to "34.1.2 CRAWLER",
lift up crawler frame with attachment, and put it on
square timbers to float and stabilize.
: 24 mm
34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction unit
and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.
: 24 mm
Tightening torque : 279 N•m (206 lbf•ft)
34-30
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
96.07mm NUMBER OF
PITCH 21
(3.78in) TEETH
SPECIFICATION
ø58.72mm 644.602
ROLLER DIA. PITCH DIA.
(2.31in) (25.333in)
C
Fig. 34-69 Sprocket
Unit:mm (in)
REPAIRABLE SERVICE
No. NAME STANDARD VALUE REMEDY
LEVEL LIMIT
Reinforcement weld,
A O.D. of sprocket ø 659 (25.9) ø 651 (25.6) ø 649 (25.6)
repair or replace.
B Width of sprocket teeth 66±2 (2.520±0.079) 60 (2.36) 58 (2.28) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 586 (23.1) ø 578 (22.8) ø 576 (22.7)
repair or replace.
Unit : mm
NAME OPPOSING FLATS
24
Socket
34-31
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34. TRAVEL SYSTEM
Unit : mm (in)
)
6"
0 .23
( 6
R
.7823)
96.07(3
34-32
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
3
APPLY LOCTITE #262
OR EQUIVALENT
TIGHTENING TORQUE:
279 N.m(206 lbf.ft)
34.1.7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
(2) Removing cover (1)
Remove sems bolt (6) M1225 and also remove
covers (1).
$
: 19 mm
(3) Preparation of oil pan
(4) Removing hydraulic pipe
Release pressure from travel circuit, and bleed air Fig. 34-72 Removing and installing cover (1)
in hydraulic oil tank, then remove all pipes
connecting to travel motor. Then plug up all pipes
and joint section to protect them from entry of dust.
34-33
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34. TRAVEL SYSTEM
: 24 mm
3
Fig. 34-74 Removing and installing sprocket
(6) Loosening travel motor attaching bolts (3) REMOVE PIPES (DISCONNECT)
Apply match marks on travel motor and crawler
frame, and remove seventeen (one side)
capscrews (3) M2060.
: 24 mm
34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the
reverse order of removal.
1) Cleaning "# "* $ '+ ) $" .
Check that contact surface of travel motor and
crawler frame is free from burr and stain. "$ #) + #,* #%$ /#$#
2) Tightening torque "% " & "* - )*+$
Tighten capscrew and hydraulic pipes to the
"' # & +# - "),""%
- #,&#%%
torque specified in "Tightening Torque". ! #' )"
3) Fill inside from motor drain port to casing with "() "* - #* )#" ,
hydraulic oil before piping for drain. When
"(# #, - ,' &&, *
starting operation, operate motor in low idling "() "* - +$ +#,
"(# #, - "%''%
and at low speed for several minutes, and check - #&&"*%
it for possible oil leakage and noise.
" )"
34-34
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34. TRAVEL SYSTEM
FRONT A A
SECTION AA
34.1.8.2 REMOVING
(1) Matchmarks
SWING BEARING
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame. OUTER RACE
INNER RACE
(2) Remove 36 capscrews (2) M2070 for installation
inner race. MATCHMARKS
: 30 mm
GREASE BATH
34-35
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34. TRAVEL SYSTEM
34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust
and dirt.
(2) Installing
Install swing bearing on lower frame meeting the
: 30 mm
(4) Regular tightening of inner race
Tighten the capscrews (2) at 180 degrees intervals Fig. 34-80 Location of S mark on swing bearing
alternately to a specified torque.
: 30 mm,
Tightening torque : 564 N•m (416 lbf•ft)
(5) Filling grease 1
Fill grease bath with 11.3kg (24.9 lbs) of grease
(NIHON GREASE CO.LTD EP-2K) or equivalent. LOCTITE #262 OR
2 EQUIVALENT
TO BE APPLIED
SECTION AA T=564N.m (416 lbf.ft)
34.1.8.4 CONSTRUCTION
6
SWING BEARING LQ40F00014F1
1 8
No. NAME Q'TY No. NAME Q'TY
9
1 OUTER RACE 1 6 SEAL 1
7
2 INNER RACE 1 7 TAPER PIN 1 3
3 BALL 116 8 PLUG 1
5
4 RETAINER 116 9 GREASE NIPPLE(PT1/8) 1 2
5 SEAL 1
Fig. 34-82 Sectional view of swing bearing
34-36
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34. TRAVEL SYSTEM
2
4
3
Fig. 34-84 Removing balls (3) and retainers (4)
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1) and
the groove for seal (5) located on the outer
surface of inner race (2). Coat the grooves with 1
adhesive Cyano Bond PX-3000 equivalent, fit PUSH ROD 6
seal (5) and place it on a surface plate.
2) Lower outer race (1) to the position where upper 2
surface of inner race (2) and lower portion of seal SQUARE 3
WOODEN BLOCK 5
groove is mated, put adjusting washer under
outer race (1) so that outer raceway surface of Fig. 34-85 Fitting balls (3)
ball (3) aligns with inner raceway, and support it.
EYE BOLT
3) Insert ball (3) and retainer (4), on which grease
is applied, through plug (8) hole on outer race
(1), alternately.
HOOKED ROD
To insert ball (3) and retainer (4), use a push rod, etc.,
to protect persons from injury from inserting fingers into 4
plug hole. SQUARE
WOODEN BLOCK
4) Fit plug (8) to outer race (1) while checking it for Fig. 34-86 Fitting retainer (4)
direction and position of taper pin hole.
5) Coat seal (6) with adhesive Cyano Bond PX-
3000 equivalent and fit it in the groove of outer
race (1).
6) After completion of assembly, caulk the edge of
taper pin (7) by punching.
7) Check that grease nipple (9) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.
• Shell Albania EP#2 ; 200cc (12.2cu•in)
34-37
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
Fig. 34-87 Cross-sectional view of travel motor unit assembly (1/2)
34-38
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34. TRAVEL SYSTEM
34-39
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
1 FLANGE 1 44 COLLAR 1
2 BASE PLATE 1 45 PIN 3
3 PLUNGER ; FOR BRAKE VALVE 1 46 PLATE (SWASH PLATE) 1
4 CHECK VALVE 2 47 BALL 2
5 SPRING 2 48 PISTON ASSY 2
137 (100) 14 6 PLUG ; M24, P=1.5 2 49 BALL BEARING 1
7 O-RING 1B P21 2 50 BALL BEARING 1
8 SPRING SEAT 2 51 PIN 1
9 SPRING 2 205 (150) 12 52 CAPSCREW ; M1435 10
10 SPRING SEAT 2 53 OIL SEAL ; TCZ50729 1
11 CAP 2 54 DISK PLATE 3
12 O-RING 1B G45 2 55 FRICTION PLATE 2
108 (80) 10 13 CAPSCREW ; M1240 8 56 BRAKE PISTON 1
14 O-RING 1B P8 2 57 O-RING 1
20.6 (15) 14 15 PLUG ; PF1/8 2 58 O-RING 1
373 (270) 27 17 RELIEF VALVE ASSY ; PF1-5/16 2 59 SPRING 6
9.8 (7.2) 2.5 18 PLUG ; METAL PLUG M5 8 60 PIN 4
19 SPOOL A ; 2-SPEED SELECT 1 61 SPRING 2
20 SPOOL C 1 62 VALVE PLATE 1
21 SPRING 1 63 O-RING 1B P10 4
118 (87) 10 22 PLUG ; PF1/2 1 64 O-RING 1
23 O-RING 1B P18 2 65 NAME PLATE 1
24 SPRING GUIDE 1 66 RIVET 2
118 (87) 10 25 PLUG ; PF1/2 1 67 PLUG ; PT1 2
26 WASHER 1 68 PLUG ; PT1/2 1
2.45 (1.8) 2.5 28 ORIFICE ; M55 1 69 PLUG ; PT1/4 1
2.45 (1.8) 2.5 29 ORIFICE ; M55 3 70 FLOATING SEAL 2
2.45 (1.8) 2.5 30 ORIFICE ; M55 2 71 ANGULAR BEARING 2
36.8 (27) 6 31 PLUG ; PF1/4 4 72 HOUSING (RING GEAR) 1
32 O-RING 1B P11 4 73 SHIM 1
33 BALL 2 74 HOLDER C 1
34 SPRING 2 75 WASHER 8
36 SHAFT 1 539 (400) T90 76 BOLT ; M2070 8
37 CYLINDER BLOCK 1 77 THRUST PLATE 4
38 PISTON ASSY 9 78 INNER RACE 4
39 RETAINER PLATE 1 79 NEEDLE BEARING 4
40 RETAINER HOLDER 1 80 PLANETARY GEAR C 4
41 SNAP RING 1 81 THRUST PLATE 4
42 SPRING SEAT 1 539 (400) T90 82 BOLT ; M20130 4
43 SPRING 1 83 SUNGEAR C 1
: Apply loctite
34-40
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34. TRAVEL SYSTEM
34-41
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
34.2.1.2 TOOLS
34-42
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34. TRAVEL SYSTEM
Plunger (3) and base plate (2) have a very tight fit. 2
Therefore, do the work, paying attention to the
following. 3
• In case plunger (3) gets stuck halfway and does not
Fig. 34-90 Removing double counterbalance
come out, do not try to force it out. If it is pulled out
valve spool (3)
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.
34-43
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
: 27 mm
17-6 2
Relief valve assy (17) is set at certain pressure. The set 17-16
17-15
pressure of it determines the starting power and the
braking power of the motor. 17
For this reason, do not do the following. Fig. 34-91 Removing relief valve (17)
• 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
Fig. 34-92 Removing poppet seat (17-3)
(5) Removing auto 2-speed select spool (19)
Loosen plugs (22), (25) and take off plugs (22), (25)
and spring (21). Next, push out part of spool (19)
from base plate (2) by pushing the end of spool
25
(19). Then draw spool (19) out of base plate (2), 21
while holding the end of spool (19) by hand and
turning it.
2
19
Spool (19) and base plate (2) are combined to a very
small fit. For this reason, execute the work, paying 22
attention to the following. Fig. 34-93 Removing auto 2-speed select spool (19)
• 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.
34-44
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
: 12mm
52
When removing base plate (2), do the work, taking care
of the following. 2
59
• Base plate (2) is pushed up by the action of spring
(59). Therefore, loosen the cap screws evenly all
round. Fig. 34-94 Removing base plate (2)[1]
• 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.
2
• 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 60
care so valve plate (62) does not fall.
34-45
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34. TRAVEL SYSTEM
56
57
58
54
55
54
54 55
34-46
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
37
38
39
Fig. 34-101 Removing piston assy (38)
2) Give a matching mark to piston assy (38) and
retainer plate (39) so they can be reassembled in
the same position. Then remove piston assy (38)
from retainer plate (39).
39
38
Fig. 34-102 Removing retainer plate (39)
34-47
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
37
40
When removing snap ring (41), take care as below, so
Fig. 34-103 Removing retainer holder (40) and
as not to injure yourself.
pin (45)
• 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 41
jig to remove the snap ring and make certain that
the claw of the pliers is set in the hole of the snap
ring. JIG
37
43
42
37
34-48
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
47
36
34-49
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
: 12 mm
• Do not lift the reduction unit too high, but do the Fig. 34-109 Draining oil from reduction unit
work at as low level as possible.
(height of your knees)
: 8 mm 96
91
94
Fig. 34-111 Removing thrust plate (94)
34-50
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
93
Fig. 34-112 Removing drive gear (93)
(20)Removing the 1st stage holder assy
Remove the 1st stage holder assy that consists of
holder B (85), planetary gear B(89), needle bearing
(88), inner race (87), thrust plate (86), thrust plate
(90), thrust plate (91) and screw (92).
34-51
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
83
Fig. 34-115 Removing sun gear C (83)
(23)Removing planetary gear C (80) 1
Fix flange (1), loosen bolt (82) and remove it. Next,
separate thrust plate (81), planetary gear C (80),
needle bearing (79), inner race (78) and thrust plate
(77), in that order. 79
: 17 mm
78
Exercise care of the following when loosening bolt (82) : 80 77
81
• Bolt (82) is coated with adhesive Loctite to prevent 82
it from loosening. Fix flange (1) securely for that Fig. 34-116 Removing planetary gear C (80)
reason.
• When loosening bolt (82), use a tool with a
sufficiently long extension such as iron pipe. If you
do not use it and try to loosen by force, you may
injure your waist or other parts.
: 17 mm
76
When loosening bolt (76), use care of the following : 99
• Coat bolt (76) with screw locking agent to prevent it
from loosening. For that purpose, fix flange (1) Fig. 34-117 Removing holder (74)
securely.
• To loosen bolt (76), use a tool with a sufficiently
long extension such as an iron pipe. If you loosen it
by force, you may injure your waist or yourself in
some cases.
34-52
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34. TRAVEL SYSTEM
99
72
72
Fig. 34-118 Separating flange (1) from housing (72)
(26)Removing floating seal (70)
Remove floating seal (70) by pushing up the outer
circumference of floating seal (70) with a flat-blade
screwdriver.
(27)Storage of parts
This completes disassembly. Clean the
disassembled parts thoroughly, coat them with a
thick film of rust preventive oil, put them in plastic
bags and store them in a cool, dark, dry place.
If the parts are stored in a hot humid place, they 70
may be rusted even if rust preventive oil is applied.
Keep the parts so no dust adheres to them.
Fig. 34-119 Removing floating seal (70)
34-53
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34. TRAVEL SYSTEM
1
Make certain that there is no dust on the surface of 70
flange (1) in contact with floating seal (70).
• Thoroughly degrease the surface where floating
seal (70) of flange (1) is located. FLOATING SEAL FIXING JIG
• Make sure that no dust is there on the O-ring of
Fig. 34-120 Assembling floating seal (70)
floating seal (70).
• Thoroughly degrease the surface of the O-ring in
floating seal (70).
72
71
ANGULAR BEARING FIXING JIG
Make certain that there is no dust and foreign matter on FLOATING SEAL
FIXING JIG
the surface on which floating seal (70) in housing (72) 70
is located.
• Thoroughly degrease the surface where floating
72
seal (70) in housing (72) is located.
Fig. 34-122 Fixing floating seal (70)
• 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).
34-54
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34. TRAVEL SYSTEM
1
Make certain that there is no foreign matter on the
moving surface of the seal ring located in floating seal
(70).
72
• Apply lubricating oil for the reduction unit or
Fig. 34-123 Assembling housing (72) into flange (1)
hydraulic oil to all sliding surface of seal ring located
in floating seal (70).
• When assembling housing (72) into flange (1),
make sure that the shaft centers are aligned with
each other.
34-55
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34. TRAVEL SYSTEM
73
Confirm that pins (99) are not inclined. 74
• Washer (75) is equipped with a spike to prevent it
from getting slack. Fit the spike to the seat of holder
C (74).
• Thoroughly clean the threads of bolt (76), degrease
it and coat it with adhesive Loctite.
99
• Thoroughly clean and degrease the inside of the 75
screw threads of flange (1). 75 Beware of the assembling
76 direction of washer (75).
Look at the direction on the
figure on the right.
34-56
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34. TRAVEL SYSTEM
: 8 mm 82 81 82
Tightening torque : 539N•m (400 lbf•ft)
Use care of the attaching direction of thrust plate (81). Place so C2 chamfer side
comes on the seat side.
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 Loctite.
• Clean the screw threads in the tapped hole of
holder C (74) thoroughly and degrease it
thoroughly.
81
84 83
Fig. 34-128 Assembling sun gear C (83)
(10)Assembling holder B (85)
Engage the inner gear teeth of holder B (85) with
the teeth of sun gear C (83) and assemble holder B
(85) into sun gear C (83).
83
85
Fig. 34-129 Attaching holder B (85)
34-57
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34. TRAVEL SYSTEM
85
Attach thrust plate (86) to planetary gear B (89) so the 87
88
draft side (by press) of thrust plate (86) is located on the Place the draft on
89 86 88 87
holder B side (85). the holder (85) side.
: 8 mm 93
Tightening torque : 58.8N•m (43 lbf•ft)
Assemble drive gear (93) to three planetary gears
B (89) by directing the spline of drive gear (93) 92
toward the motor assembling side. Then engage
the teeth of planetary gear B (89) with the teeth of 78 79 80 81
drive gear (93).
Place the draft on the
planetary gear C (80)
74 side.
holder B (85) and the threads of screw (92). Fig. 34-131 Assembling drive gear (93)
34-58
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34. TRAVEL SYSTEM
Unit : mm (in)
Shim
Step dimension (T) Thrust plate code thickness (t)
1.20 ~ 0.67 20941 - 62306 2.3
(0.0472 ~ 0.0264) 72
0.66 ~ 0.04
(0.0260 ~ 0.0016) 20941 - 62307 2.8
0.03 ~ -0.16 Measure the step T.
(0.00122 ~ -0.0063) 20941 - 62308 3.0
-0.174 ~ -0.41
(-0.00685 ~ -0.0161) 20941 - 62309 3.2
-0.42 ~ -0.80 91
(-0.0165 ~ -0.0315) B0841 - 23017 3.6
94
: 8 mm
Tightening torque : 73.4N•m (54 lbf•ft)
(15)Fitting plugs (97)
Take off O-ring (98) from plug (97), replace it with a
95
new one and place it in plug (97).
Then, attach plugs (97) to the oil inlet / outlet and
the level ports (3 in all) of cover (95), and tighten
98
them to specified torque.
97
: 12 mm
Tightening torque : 157N•m (120 lbf•ft)
34-59
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34. 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 SEAL
FIXING JIG
53
47
Before fixing steel balls (47), apply hydraulic oil to the
bore surface in the spherical part of flange (1) and steel
balls (47). 1
34-60
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34. TRAVEL SYSTEM
34-61
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34. TRAVEL SYSTEM
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 Fig. 34-140 Assembling cylinder block (37)
make sure that the claw of the snap ring pliers is
41
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 JIG
cylinder block with that of the press.
37
34-62
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34. TRAVEL SYSTEM
37
40
Fig. 34-143 Attaching retainer holder (40)
5) Attach piston assy (38) [9pcs.] to retainer plate
(39) so the tapered face of retainer plate (39)
faces downward.
39
38
Fig. 34-144 Assembling retainer plate (39)
6) Install piston assy (38) to cylinder block (37).
38
Fig. 34-145 Assembling piston assy (38)
34-63
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34. TRAVEL SYSTEM
Disk plate (54) is a wet type disk. Before assmbly, Fig. 34-147 Assembling disk plate (54)
immerse the disk plate (54) in hydraulic oil so disk plate
(54) sucks in sufficient hydraulic oil.
34-64
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34. TRAVEL SYSTEM
59
Place valve plate (62) with the copper alloy side facing 2
upward.
• Coat the matching face between base plate (2) and
Fig. 34-150 Attaching valve plate (62)
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).
34-65
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34. TRAVEL SYSTEM
34-66
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34. TRAVEL SYSTEM
: 27 mm
Tightening torque : 373N•m (210 lbf•ft)
17-17,18 2
17-3
17-7
Replace O-ring (17-7) with a new one, before
assembly. 17
• Make sure that O-ring (17-7) and backup ring (17- Fig. 34-153 Assembling relief valve (17)
18) are fitted to poppet seat (17-3).
• Coat O-ring (17-17) and backup ring (17-18) with
grease, before assy.
34-67
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34. TRAVEL SYSTEM
13
Coat O-ring (12) with grease. Fig. 34-155 Fitting cap (11)
34-68
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34. TRAVEL SYSTEM
34-69
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34. TRAVEL SYSTEM
34-70
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34. TRAVEL SYSTEM
34-71
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34. TRAVEL SYSTEM
34-72
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34. TRAVEL SYSTEM
34-73
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34. TRAVEL SYSTEM
34-74
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34. TRAVEL SYSTEM
34-75
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34. TRAVEL SYSTEM
34-76
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
34-77
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
34-78
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
34-79
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
34-80
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
34-81
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
34. TRAVEL SYSTEM
34-82
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING
(BY ERROR CODES)
TABLE OF CONTENTS
46
46-1
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
46-2
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
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.
46-3
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46. TROUBLE SHOOTING (BY ERROR CODES)
46-4
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
46-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
46-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting
condition range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Service Screen No. 2 G-3 SPEED SET
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table46-2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within
condition the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Service Screen No. 9 E-1 P1 PUMP
diagnosis Screen No. 9 E-2 P2 PUMP
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
46-7
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46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-3
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom It is not normal output, but no problem in normal operation
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table46-4
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-8
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-5
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Control can be done by default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-6
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-9
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-7
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Control in the
Normal control is available.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-8
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-10
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46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-9
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch on
SE-3 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-10
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
Control in the
mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-11
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-11
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-12
Error code B022
Trouble Boom down pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-12
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-13
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
SE-4 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-127F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-14
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-13
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-15
Error code B032
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-out operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B032 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-16
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
SE-8 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B033 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-131F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-14
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-17
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-18
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B042 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-15
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-19
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
SE-7 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B043 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-130F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-20
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-16
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-21
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-22
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B053 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-17
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-23
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B054 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-24
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B062 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F
CN-101F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-18
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-25
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B063 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-26
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B064 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-19
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-27
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The swing operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B072 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-28
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B073 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B073 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-20
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-29
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B074 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B074 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-30
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel right
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-21
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-31
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B093 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B093 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-32
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B094 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B094 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-22
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-33
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-34
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B103 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B103 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-23
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-35
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B104 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B104 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-36
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B113 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B113 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-24
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-37
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B114 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B114 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-38
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-304F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-25
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-39
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B163 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-40
Error code B164
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B164 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-26
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-41
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B172 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B172 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-303F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-42
Error code B173
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B173 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B173 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-27
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-43
Error code B174
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B174 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B174 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-44
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-28
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-45
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C013 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C013 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-46
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C014 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-29
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-47
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-48
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C023 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C023 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-30
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-49
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C024 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-50
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-31
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-51
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-52
Error code C043
Trouble Boom rod pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom rod pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-4 BOOM-ROD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom rod pressure sensor When C043 is cancelled and other error occurs by turning starter switch on
SE-25 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom rod When C043 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-705F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-32
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-53
Error code C044
Trouble Boom rod pressure sensor’s power source is shortcut.
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-4 BOOM-ROD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom rod pressure sensor When C044 is cancelled and other error occurs by turning starter switch on
SE-25 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom rod When C044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-705F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-54
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-33
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-55
Error code D013
Trouble P1 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D013 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-56
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D022 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-34
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-57
Error code D023
Trouble P2 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D023 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-58
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-35
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-59
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-60
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-36
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-61
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-62
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-37
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-63
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-64
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E022 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-38
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-65
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E023 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-66
Error code F011
Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom ATT boost is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F011 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-39
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-67
Error code F013
Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F013 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-68
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-2 SWING-BRAKE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If
failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-40
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-69
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-70
Error code F031
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-41
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-71
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-72
Error code F041
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-42
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-73
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-74
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
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.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
46-43
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-75
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
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.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
CN-136F
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
Table46-76
Error code G042
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
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.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller Especially check wiring for false disconnection and noise included.
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.
46-44
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-77
G043
When cranking is executed for five seconds or more, this error code might be displayed. In case
Error code that the engine does not start, check by the table of "Section 47.3 Engine related
Troubleshooting". Execute the following check when the error code G043 is displayed afteVr
starting the engine.
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller
condition indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
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.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.
46-45
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-78
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-79
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.4k
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-46
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-80
Error code H023
Trouble Boom angle potentiometer’s wiring is disconnected.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-81
Error code H024
Trouble Boom angle potentiometer’s power source is shortcut.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-47
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-82
Error code H033
Trouble Arm angle potentiometer’s wiring is disconnected.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-83
Error code H034
Trouble Arm angle potentiometer’s power source is shortcut.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-48
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-84
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-85
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-49
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-86
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from engine controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F (There is a possibility of false disconnection.)
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-87
Error code I113
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly. It has been affected little.
condition
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20°C.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-5 WATER TEMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
46-50
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-88
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-600F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-89
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch
condition ON signal turned OFF
The power on the battery relay secondary side does not turn OFF even if the key switch is turned
Symptom
OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No. 4 K-3 KEY SWITCH OFF
checking screen Screen No.
Checking object Checking contents and remedy
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
• Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
• 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
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box Replace fuse/relay box.
E-1
4 • Mechatro controller Check that the error is corrected after replacement of controller.
46-51
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-90
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 PREVENT ARC
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay,
R-31 check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed
prevention relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R014 is left displayed
E-1
Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-52
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-91
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R024 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-53
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-92
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move after forward rotation.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CCW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R034 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-54
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-93
Error code R044
Trouble Washer motor relay error
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
Returned in
When the power is OFF
normal condition
Service Screen No. 25 MOTOR RELAY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit
R-32 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-112F, CN2-1 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R044 is left displayed
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-94
Error code R134
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Right swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D13
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R134 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-55
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-95
Error code R144
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Left swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D14
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R144 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-96
Error code R154
Trouble Travel alarm relay error
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
Returned in
When the power is OFF
normal condition
Service Screen No. 23 D15
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit
R-8 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-56
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-97
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay
R-24 unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between auto idle When R164 is left displayed with the relay removed
stop relay 2 and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-57
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-98
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-3 ENG STOP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between engine When R174 is left displayed with the relay removed
forcibly Check that no power 24V is produced on relay (-) line according to the wiring
stop relay and controller checking procedure and replace it if necessary.
CN-109F, CN2-2 When no failure found after checking on wiring and R174 is left displayed.
• Fuse & relay box Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-58
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-99
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-4 LOCK LEVER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between safety lock When R184 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-100
Error code R214
Trouble Safety relay error
Judging
The mechatro controller output line to safety relay is short-circuited with the power source.
condition
Symptom Safety relay does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-2 SAFETY RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit
R-26 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between safety lock When R214 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R214 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
46-59
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
46. TROUBLE SHOOTING (BY ERROR CODES)
[MEMO]
46-60
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS
47
47-1
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47. TROUBLESHOOTING (BY TROUBLE)
47-2
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
47-3
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47. TROUBLESHOOTING (BY TROUBLE)
47-4
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47. TROUBLESHOOTING (BY TROUBLE)
47-5
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47. TROUBLESHOOTING (BY TROUBLE)
47-6
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47. TROUBLESHOOTING (BY TROUBLE)
47-7
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
47-8
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47. TROUBLESHOOTING (BY TROUBLE)
47-9
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47. TROUBLESHOOTING (BY TROUBLE)
47-10
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47. TROUBLESHOOTING (BY TROUBLE)
47-11
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47. TROUBLESHOOTING (BY TROUBLE)
47-12
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47. TROUBLESHOOTING (BY TROUBLE)
47-13
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47. TROUBLESHOOTING (BY TROUBLE)
47-14
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47. TROUBLESHOOTING (BY TROUBLE)
47-15
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47. TROUBLESHOOTING (BY TROUBLE)
47-16
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47. TROUBLESHOOTING (BY TROUBLE)
47-17
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
47-18
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
47-19
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47. TROUBLESHOOTING (BY TROUBLE)
(16)Travel deviation
47-20
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
47-21
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
47-22
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
(19)Machine does not travel straight in simultaneous operation of traveling and attachment
(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight)
47-23
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
47-24
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47. TROUBLESHOOTING (BY TROUBLE)
47-25
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
47-26
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47. TROUBLESHOOTING (BY TROUBLE)
47-27
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47. TROUBLESHOOTING (BY TROUBLE)
47-28
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47. TROUBLESHOOTING (BY TROUBLE)
47-29
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.
47-30
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
(3) Auto accel does not actuate. (The engine speed does not automatically slow down).
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
47-31
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
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
Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF
R-30: Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.
47-32
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
47. TROUBLESHOOTING (BY TROUBLE)
Checking
Filters Liquid Leak, clogging
Muffler clogged
Engine oil leak
Coolant level
Trouble
47-33
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47. TROUBLESHOOTING (BY TROUBLE)
Hydraulic switch
Starter motor
Battery relay
Safety relay
Glow relay
Glow plug
Alternator
Trouble
47-34
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47. TROUBLESHOOTING (BY TROUBLE)
Factors
47-35
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47. TROUBLESHOOTING (BY TROUBLE)
Engine body
Factors
Damage of dumper
Trouble
47-36
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
48. TROUBLESHOOTING
(TROUBLE DIAGNOSIS MODE)
TABLE OF CONTENTS
48
48-1
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48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48-2
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG 0000 rpm
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death.Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality.
Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis.
The preliminary investigation of electric system makes the time saving and high precision diagnosis possible.
3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a
case no accordance of diagnosis obtained. In this case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
48-3
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP
OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
SEARCHABLE OPERATION
Boom up
Boom down
In the normal condition, OK is
Bucket digging displayed when the control
lever is moved to stroke end.
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P1 side option
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
48-4
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
When pump regulator does not have "Total power control of Emergency mode", "1 P1 PUMP" of No.7 and "1 P2
PUMP" of No.10 are not given a diagnosis.
48-5
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48-6
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
51. ENGINE
PREFACE
This service manual explains the single engine. Note that this manual is edited without
modification by based on the service manual of HINO MOTOR.
51
51-1
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
51. ENGINE
51-2
Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分
J05E-TH
KSS-SMJ5-E112E
2010.7
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分
GENERAL 1
STANDARD VALUE 2
PARTS TO BE PREPARED 3
ENGINE ASSEMBLY/DISASSEMBLY 4
FUEL SYSTEM 5
EMISSION CONTROL 6
ELECTRICAL 7
INTAKE 8
ENGINE MECHANICAL 9
EXHAUST 10
COOLING 11
LUBRICATION 12
STARTING AND CHARGING 13
TURBOCHARGER 14
AIR COMPRESSOR 15
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16
ENGINE DIAGNOSIS CODE 17
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GENERAL 1–1
ENGINE
1
1 GENERAL
General information
Warning................................................................... 1-2
How to read this manual ........................................ 1-3
Precautions for work ............................................... 1-7
Tightening of engine bolts and nuts ...................... 1-10
Tightening of chassis bolts and nuts..................... 1-12
Tightening of flare nuts and hoses........................ 1-14
Taper thread sealant for piping ............................. 1-15
Assembly of joints and gaskets for piping ............. 1-16
Handling of liquid gasket....................................... 1-18
Failure diagnosis table for each problem .............. 1-19
Failure diagnosis using HinoDX ............................ 1-20
Connection method of HinoDX ............................. 1-23
Chassis number and engine number ................... 1-23
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1–2 GENERAL
Warning
JP31199010102001
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
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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GENERAL 1–3
2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.
3. 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.
! CAUTION The part layouts in this manual are inserted based on illustrations and part numbers of the
parts catalog CD-ROM issued in April, 2007. (Some areas do not show exploded view. They
will be additionally issued when the parts catalog CD is revised.) Be sure to use the parts
catalog for confirmation of illustrations and part numbers and for ordering parts.
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1–4 GENERAL
(4) Troubleshooting for each Summarize inspection results obtained from Step 2.
diagnosis code Perform inspection systematically according to
"Step 3"
(5) Troubleshooting for each failure troubleshooting procedures for each diagnosis code or
status failure status.
(2) Pre-inspection
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GENERAL 1–5
Example
SAPH041170900182
SAPH311990100001
✩:It is the ID number for parts to prepare electronic data. It is not required for repair work.
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1–6 GENERAL
7. Definition of terms
Terms in this manual are defined as follows :
(1) Direction
a. 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 vehicle (chassis), 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) Service 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.
8. 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 { }.
1kgf⋅cm=0.0980665
Torque*2 N⋅m kgf⋅cm Volume L cc 1cc=1mL
N⋅m
1kgf/
2 2
kgf/cm cm =98.0665kPa Efficiency W PS 1PS=0.735499kW
Pressure Pa =0.0980665MPa
1mmHg=0.133322k Calorific
mmHg W⋅h cal 1kcal=1.163W⋅h
Pa value
*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.
Observe the standard values described for each unit.
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GENERAL 1–7
Safety information
1. General precautions
To ensure safety in work and to prevent accidents, observe the following items :
(1) Appearance
a. Wear safety goggles.
b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
c. Bind long hair at the back.
d. Be sure to wear a cap and safety shoes.
(2) Safety work
a. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during
operation of the engine.
c. Remove the starter key when the engine is not started.
d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.
e. Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the area.
f. Since the battery fluid is poisonous and corrosive, be careful for handling.
g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may
occur.
h. If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
i. To tow a failure machine, refer to "Towing" in the "Operation manual" of the machine.
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1–8 GENERAL
SAPH311990100002
SAPH311990100003
SAPH311990100004
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GENERAL 1–9
SAPH311990100005
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1–10 GENERAL
SAPH311990100006
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GENERAL 1–11
2. Precoated bolt
Precoated bolt is the bolt with an application of a seal lock
agent at the thread.
SAPH311990100008
SAPH311990100010
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1–12 GENERAL
Hexagonal bolt
Strength zone of hexagonal bolts is, in principle, indicated with recession, relief, surface depression
and upset on the head with the symbol in the table.
SAPH311990100011
Hexagonal nut
Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below :
Formula
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GENERAL 1–13
(4) Standard tightening torque table of general standard bolts and nuts
(Representative standard seating is described)
Unit : N⋅m{kgf⋅cm}
Strength
zone
Bolt 4T 7T 9T
diameter
(mm)
4.5±1.8{50±20}
(Cab)
M6 9.0±1.8{90±20} 11.5±2.0{117±23}
5.5±1.1{60±10}
(Chassis)
14.0±3.5{140±40}
(Cab)
M8 22.0±4.0{220±40} *2 29.0±5.5{300±60} *2
17.0±3.0{170±30}
(Chassis)
43.0±8.5{440±90} *2 57.0±11.0{580±110} *2
(Cab) (Cab)
M10 27.0±5.0{276±55}
51.5±10.0{530±100} 68.5±13.5{700±140}
(Chassis) (Chassis)
! CAUTION • Use the tightening torque value for seating A with flange except for *2 in the table larger by
10% than the tightening torque value in the table.
• Use the tightening torque value for seating B with flange of *2 in the table larger by 20%
than the tightening torque value in the table.
The tightening torque value of M8 for seating B with flange remaines unchanged.
• Seating B with flange of *2 in the table is interchangeable with the standard seating in
pairs. Use the standard seating for the tightening torque value.
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1–14 GENERAL
Pipe outer
diameter φ4.76 φ6.35 φ8 φ10 φ12 φ15
Material
Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80}
21.5±1.5{215±15}
Air hose Only meter gauge 41.5±2.5{425±25} —
10{100}
Packing
Brake hose — —
51.5±7.5{525±75}
Tightening
15±2{150±20} 66±6{670±60} 97±9{990±90} 209±19{2130±190}
torque
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GENERAL 1–15
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.
1. For disconnection
Removal of joint (Example: Use of magnetic valve)
Magnetic valve
(1) The sealant ( # Loctite 575) has strong sealing feature.
Frame Air pipe (Flare joint) The return torque of the taper joint is increased about 1.5
(No application of sealant) times the initial tightening torque. When the joint is
disconnected, use a long wrench for disconnection.
Since sealant is
applied to this area, (2) When a joint at a poorly accessible area is replaced,
remove accessories
with the joint remove accessories first and disconnect the joint.
attached and
Air hose
remove the joint.
SAPH311990100016
2. For connection
1/4 turn
(1) For application of sealant ( # Loctite 575), wipe the
Amount of application: 0.1 g/piece
sealing area completely with a rag or thinner. Apply
sealant directly to about three ridges for quarter round
3 threads
with offset of one ridge from the end. Tighten it according
1 thread
to the tightening torque in the table below.
Remove dirt completely from the mating part (female)
before tightening.
Screw
diameter 1/4 3/8 1/2
Material
Aluminum,
25±5{250±50} 34±5{350±50} 44±5{450±50}
brass
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1–16 GENERAL
M24 69{700}
M28 *127{1300}
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GENERAL 1–17
Sealing surface
: 4 places
Flare connector
Gasket
One piece eye joint Gasket
with sleeve Gasket Sealing surface
Gasket : 5 places Sealing surface: 5 places
Sealing surface
: 8 places
Connector nipple
Joint pipe
Bracket
Sealing surface
: 3 places
Joint bolt
Joint bolt
Joint pipe
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1–18 GENERAL
2. Removal of parts
(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the
engine.
3. Others
(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in
a cartridge, use the application gun.
Winding tool
Application gun
For a tube, desired application width may be obtained from the cut position at the nozzle end.
Nozzle of tube
General information
Description of function
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GENERAL 1–19
Engine mechanical Causes and actions are described for each item.
JP03Z01020601001
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1–20 GENERAL
1. HinoDX
Part name Part No. External shape General description and function
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GENERAL 1–21
SAPH311990100032
Unit harness ! CAUTION • Do not break the locking tab of the connector.
Signal check harness
b. Connect the signal check harness to the machine
harness and the ECU.
Test lead Signal check harness
(for common rail fuel injection system)
Part No.
09049-1080
SAPH311990100036
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1–22 GENERAL
ECU unit
Signal check
harness
SAPH311990100038
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GENERAL 1–23
1. Connection of HinoDX
(1) Remove the left side cover at the rear of the driver's seat
and connect the failure diagnosis connector with a PC
which installed HinoDX through the interface box.
Failure diagnosis
connector
SAPH311990100039
Hino-Bowie
Setup layout
Layout
SAPH311990100041
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ENGINE
2 STANDARD VALUE 2
Specification
System drawing
(performance)
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Engine Body
Standard value
JP31199020205001
Repair Service
Inspection item Standard value Action
limit limit
Tightening torque
JP31199020205002
Unit:N⋅m{kgf⋅cm, lbf⋅ft}
7.8 - 8.8
Starter B terminal
{80 - 110, 5.8 - 6.5}
3.3 - 4.4
Alternator B terminal
{33 - 45, 2.4 - 3.2}
4.5 - 5.0
Radiator hose band
{45 - 50, 3.3 - 3.7}
Fuel System
Tightening torque
JP31199020205003
Fuel filter air bleeding bolt 1.7 - 2.6 {17.3 - 23, 1.2 - 1.9}
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Electrical
Standard value
JP31199020205018
Tightening torque
JP31199020205019
Intake
Tightening torque
JP31199020205005
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Engine Mechanical
Standard value
JP31199020205006
Unit : mm {in.}
0.01 - 0.08
Cylinder liner protrusion — —
{0.003 - 0.003}
117 - 117.008
A — —
{4.6063 - 4.6066}
117.008 - 117.014
Cylinder block inner diameter B — —
{4.6066 - 4.6068}
117.014 - 117.022
C — —
{4.6068 - 4.6072}
116.982 - 116.99
A — —
{4.6056 - 4.6059}
116.99 - 116.996
Cylinder liner outer diameter B — —
{4.6059 - 4.6061}
116.996 - 117.004
C — —
{4.6061 - 4.6064}
Cylinder
112.15
Cylinder liner inner diameter 112 {4.4094} — Replace
{4.4154}
liner
Cylinder
0.088 - 0.112 Liner
Piston clearance — —
{0.0034 - 0.0044} Replace
piston
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Approx. 11.5
Top — —
{0.4527}
Free joint clearance
Approx. 14
Second — —
{0.5512}
0.3 - 0.40
Top — 1.5 {0.0591}
{0.0118 - 0.0157}
Gap between ends 0.75 - 0.9 Replace
Second — 1.2 {0.0472}
Piston of piston ring {0.0295 - 0.0354} piston ring
ring 0.15 - 0.3
Oil — 1.2 {0.0472}
{0.0059 - 0.0118}
–0.1
Top 2.5 {0.0984} —
{–0.0039}
Ring width B –0.1 Replace
Second 2 {0.0787} —
dimension {–0.0039} piston ring
–0.1
Oil 4 {0.1574} —
{–0.0039}
+0.2
Top 2.5 {0.0984} —
{+0.0079}
+0.2 Replace
Piston ring groove Second 2 {0.0787} —
{+0.0079} piston
+0.1
Oil 4 {0.1574} —
{+0.0039}
0.09 - 0.13
Top — —
{0.0035 - 0.0051}
Clearance between Replace
0.04 - 0.08
piston ring and Second — — piston ring
{0.00016 - 0.0031}
Piston piston ring groove or piston.
0.02 - 0.06
Oil — —
{0.0008 - 0.0024}
–0.04 Replace
Piston pin outer diameter 37 {1.4567} —
{–0.0015} piston pin
+0.05 Replace
Piston boss inner diameter 37 {1.4567} —
{+0.0020} piston
–0.002T - 0.025L
{0.0000 - 0.0010} Replace
Clearance between piston pin 0.05
(T : Tightening — piston pin
and piston boss {0.0020}
allowance, or piston
L : Clearance)
Replace
+0.1
Connecting rod bushing inner diameter 37 {1.4567} — connecting
{0.0039}
rod bushing
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Replace
piston pin
0.015 - 0.036 0.08
Connecting rod bushing oil clearance — or
{0.0006 - 0.0014} {0.0031}
connecting
rod bushing
Replace the
64.3
Crank pin outer diameter 65 {2.5590} — crankshaft.
{2.5315}
(Note 1)
Crank
79.3 Replace
Crank journal outer diameter 80{3.1496} —
{3.1221} shaft (Note
1)
Crank Thickness of main bearing 2.5 {0.2342} — —
shaft
Replace
0.051 - 0.102
Crankshaft oil clearance 0.2 {0.0079} — bearing
{0.0020 - 0.0040}
(Note 2)
+1.00 Replace
Center journal width 36 {1.4173} —
{+0.039} crankshaft.
Replace
0.050 - 0.219 0.50 1.219 thrust
Crankshaft end play
{0.0020 - 0.0086} {0.0020} {0.0480} bearing or
crankshaft
0.15 Ground to
Crankshaft runout — —
{0.0059} under-size
+0.8 Replace
Crank pin width 34 {13.386} —
{+0.0315} crankshaft
Note 1 : Correction with re-grinding for eccentric wear of 0.10 or more. Re-grinding for wear of 0.20 or
more. Replace crankshaft for wear of 0.7 or more.
Note 2 : Under-size bearing values are 0.25 and 0.50.
Replace
–0.8
Connecting rod large end width 34 {1.3386} — connecting
{–0.0315}
rod
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KSS-SMJ5-E111E.book 7 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Replace
0.20 - 0.52 connecting
Connecting rod end play — 1.0 {0.0394}
{0.0079 - 0.0205} rod or
crankshaft
Bearing
Camshaft bearing inner +0.15
40 {1.5748} — Replacemen
diameter {+0.059}
t
Replace
Camshaft bearing oil 0.020 - 0.063
— — camshaft or
Clearance {0.0008 - 0.0025}
bearing
0.04 Replace
Camshaft runout — 0.1 {0.039}
{0.0016} camshaft
–0.08 Replace
Rocker shaft outer diameter 22 {0.8661} —
{–0.0031} rocker shaft
Replace
+0.08
Rocker arm bushing inner diameter 22 {0.8661} — rocker arm
{+0.0031}
bushing
IN 7 {0.2756} — — Replace
Valve stem outer diameter
EX 7 {0.2756} — — valve
IN 7 {0.2756} — — Replace
Valve guide inner diameter
EX 7 {0.2756} — — valve guide
0.023 - 0.058
IN — — Replace
Oil clearance between valve guide {0.0009 - 0.0020}
valve or
and valve stem 0.050 - 0.083
EX — — valve guide
{0.0020 - 0.0033}
0.55 - 0.85
IN — 1.1 {0.0433} Replace
{0.0217 - 0.0335}
Valve sink valve and
1.15 - 1.45 valve seat
EX — 1.7 {0.0669}
{0.0453 - 0.0571}
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KSS-SMJ5-E111E.book 8 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
44.8
Set length — —
{1.764}
129N
Set load — —
{13.1kgf, 29lbf}
Inner
64.6 –3.0 Replace
Free length —
{2.5433} {–0.3543} spring
2.0 Replace
Squareness — —
Valve {0.0787} spring
spring 46.8
Set length — —
{1.8252}
314N
Set load — —
{32.0kgf, 70lbf}
Outer
75.7 –3.0 Replace
Free length —
{2.9803} {–0.3543} spring
2.0 Replace
Squareness — —
{0.0787} spring
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KSS-SMJ5-E111E.book 9 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Bushing inner
57 {2.2441} — —
diameter
Timing Replace
Clearance between 0.030 - 0.090 0.20
gear — shaft or
Main shaft and bushing {0.0012 - 0.0084} {0.0079}
bushing
idle
Gear width 44 {1.7322} — —
Bushing inner
50 {1.9685} — —
diameter
Replace
Clearance between 0.025 - 0.075 0.20
— shaft or
Sub- shaft and bushing {0.0010 - 0.0030} {0.0079}
bushing
idle
Gear width 22 {0.8661} — —
Replace
0.040 - 0.120 0.30
End play — shaft or
{0.0016 - 0.0047} {0.0012}
gear
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KSS-SMJ5-E111E.book 10 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Bushing inner
34 {1.3386} — —
diameter
Replace
Clearance between 0.025 - 0.075 0.20
— shaft or
Cam shaft and bushing {0.0002 - 0.0030} {0.0079}
bushing
idle
Gear width 22 {8.6614} — —
Replace
0.040 - 0.120 0.30
End play — thrust plate
Timing {0.0016 - 0.0047} {0.0012}
or gear
gear
Shaft outer diameter 34 {1.3386} — —
Bushing inner
34 {1.3386} — —
diameter
Replace
Pump Clearance between 0.025 - 0.075 0.10
— shaft or
drive shaft and bushing {0.0002 - 0.0030} {0.0039}
bushing
idle
Gear width 28.5 {1.1220} — —
0.016 - 0.22
End play — —
{0.0006 - 0.0087}
Grinding is
inhibited
Longitudinal because
direction 0.06 backlash
Flatness under cylinder head 0.20
{0.0024} — between
Flatness above cylinder block {0.0079}
Square direction cam idle –
0.03 {0.0012} sub-idle
gears is
changed.
0.15
Surface runout of flywheel — —
{0.0060}
187.5
long — — Replacement
{7.3819}
156.5
Head bolt middle — — Replacement
{6.1614}
126.5
short — — Replacement
{4.9803}
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KSS-SMJ5-E111E.book 11 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Valve timing
Exhaust valve open (before BDC) 54°
Tightening torque
JP31199020205007
Main bearing cap mounting bolt 69 {700, 51}+90°+45° Refer to the main text.
36 {370, 27} M8
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KSS-SMJ5-E111E.book 12 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Exhaust
Tightening torque
JP31199020205008
Cooling
Standard value
JP31199020205009
74.5 - 78.5°C
Thermostat valve open temperature {166.1 - — — Replacement
173.3°F}
10mm
Thermostat valve lift
{0.3937 in.} or — — Replacement
(Set temperature 95 °C)
more
Lubrication
Standard value
JP31199020205010
Unit : mm {in.}
Repair Service
Inspection item Standard value Action
limit limit
39kPa
Hydraulic alarm switch operation pressure {0.4kgf/cm2, — —
5.66lbf/in.2}
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KSS-SMJ5-E111E.book 13 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Repair Service
Inspection item Standard value Action
limit limit
Clearance between drive gear and 0.100 - 0.202 0.30 Replace drive
—
cylinder block {0.0039 - 0.0080} {0.0118} gear or oil pump
Backlash between drive gear and driven 0.072 - 0.277 0.30 Replace oil
—
gear {0.0028 - 0.0109} {0.0118} pump
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KSS-SMJ5-E111E.book 14 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Tightening torque
JP31199020205011
Standard Service
Inspection item Repair limit Action
value limit
1MΩor
Resistance between stator coil core and coil — — Replacement
more
Resistance of feed coil 5.6 - 6.8Ω — — Replacement
1MΩor
Resistance between feed coil core and coil — — Replacement
more
25mm 24.98mm
Front —
Shaft outer diameter of {0.9843 in.} {0.9835 in.}
Replacement
rotor assembly 17mm 16.98mm
Rear —
{0.6693 in.} {0.6685 in.}
Forward Approx.
— —
Resistance between resistance value 10Ω
Replacement
diode and rectifier holder Reverse
Infinite — —
resistance value
Forward Approx.
Resistance between — —
resistance value 10Ω
regulator terminals F — Replacement
Reverse
E Infinite — —
resistance value
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KSS-SMJ5-E111E.book 15 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Heat sink mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} Screw lock is
Regulator mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} used
Front side - Rear side mounting bolt 7.8 - 9.8 {80 - 99, 6 - 7}
Coupler holder mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}
Unit : mm {in.}
Standard
Inspection item Service limit Action
value
Resistance between
1MΩor more 1kΩor less
commutator and core
Metal bushing inner diameter of pinion case 25 {0.9843} 25.2 {0.9921} or more Replace brush
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KSS-SMJ5-E111E.book 16 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Standard
Inspection item Service limit Action
value
Replace
Bearing housing inner diameter of rear
28 {1.1024} 28.1 {1.1063} or more commutator end
bracket
frame
Commutator end frame mounting through bolt 15.7 - 17.6 {160 - 179, 12 - 13}
Brush holder set bolts of commutator end frame 3.6 - 4.9 {37 - 49, 3 - 4}
Turbocharger
Standard value
JP31199020205016
Unit : mm {in.}
Standard
Inspection item Repair limit Service limit Action
value
Tightening torque
JP31199020205017
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ENGINE
3 PARTS TO BE PREPARED
Special tool (SST)
3
Engine Body................................................................ 3-2
Special tool ............................................................. 3-2
Fuel System ................................................................ 3-2
Lubricant, etc. ........................................................ 3-2
Electrical...................................................................... 3-2
Special tool ............................................................. 3-2
Engine Mechanical ..................................................... 3-3
Special tool ............................................................. 3-3
Instruments ............................................................. 3-6
Lubricant, etc. ........................................................ 3-6
Lubrication .................................................................. 3-6
Special tool ............................................................. 3-6
Lubricant, etc. ........................................................ 3-6
Starting and Charging................................................ 3-7
Jig (reference dimensional drawing for manufacture)
................................................................................ 3-7
Instruments ............................................................. 3-8
Lubricant, etc. ........................................................ 3-8
Turbocharger............................................................... 3-8
Special tool ............................................................. 3-8
Engine Failure Diagnosis........................................... 3-9
Special tool ............................................................. 3-9
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Engine Body
Special tool
JP31199030901001
Fuel System
Lubricant, etc.
JP31199030901002
Name Remark
Electrical
Special tool
JP31199030901003
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Engine Mechanical
Special tool
JP31199030901004
For assembly/disassembly
09433–1070 Eye bolt
of cylinder head
For assembly/disassembly
09470–1170 Valve spring press
of valve spring retainer
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
For assembly/disassembly
09442–1011 Piston ring expander
of piston ring
For assembly/disassembly
09402–1530 Press sub-assembly of connecting rod small end
bushing
For assembly/disassembly
of connecting rod small end
9233–10360 Wing nut
bushing (together with
09402–1530)
For assembly/disassembly
of connecting rod small end
09481–1130 Guide
bushing (together with
09402–1530)
For assembly/disassembly
09402–1540 Spindle of connecting rod small end
bushing
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KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
For assembly/disassembly
09481–1340 Guide
of flywheel
09420–1100
For main/sub idle gear
Sliding hammer assembly and cam idle gear
09420–1442
shaft removal
For assembly/disassembly
09411–1300 Socket wrench
of Torx bolt
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KSS-SMJ5-E111E.book 6 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Instruments
JP31199030901005
Name Remark
Lubricant, etc.
JP31199030901006
Name Remark
Lubrication
Special tool
JP31199030901007
Lubricant, etc.
JP31199030901008
Name Remark
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KSS-SMJ5-E111E.book 7 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
This is used for assembly of bearing. Reference dimensions are shown in the figures below:
Jig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}
φ23{20.827} φ25{0.984}
1C{0.039}
35{1.378}
50{1.964}
70{2.756}
50{1.964}
1C{0.039}
10 - 20 φ50{1.969}
+0.5{0.0196} {0.394 - 0.787}
φ19{0.748}
0
φ30{1.181}
Jig C Jig D
φ34{1.339} φ41{1.614}
20{0.787} 20{0.787}
40{1.575} 40{1.575}
10{0.394} 10{0.394}
φ54{2.126} φ64{2.520}
φ60{2.362} φ70{2.756}
SAPH311990300034
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KSS-SMJ5-E111E.book 8 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Instruments
JP31199030901010
Alternator
Name Remark
Starter
Name Remark
Lubricant, etc.
JP31199030901011
Name Remark
Kyodo Yushi Multemp AC-N For lubrication of parts
Turbocharger
Special tool
JP31199030901012
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KSS-SMJ5-E111E.book 9 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
• Operating
system(OS):Windows95,
Windows98(IE5.0 or
later),
Windows2000(SP3,
IE5.0 or later),
WindowsXP(SP1a, IE6.0
– Personal computer (DOS-V) or later)
• CPU and memory:
Conditions that assure
operation of the above
operating system
• Display: 800 x 600, 256
colors or more
This is installed as
interruption between vehicle
09049–1080 Signal check harness harness and the ECU.
Tester inspection is allowed
in energized status.
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ENGINE
4 ENGINE ASSEMBLY/DISASSEMBLY
Service procedure
Overhaul item
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
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.
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Compression pressure:
Unit MPa {kgf/cm2,lbf/in.2}
Difference between
0.3{3, 44} or less
cylinders
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Engine Body
Removal
JP31199040702002
(2) Drain engine oil from the oil pan drain plug as required.
SAPH311990400003
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KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(1) Remove the fuel hoses (feed side and return side). Wrap
the removed hose with a plastic sheet with its end facing
upward to prevent spill of fuel.
SAPH311990400004
Clip ! CAUTION • Wipe off spilled water and engine oil with
waste.
SAPH311990400005
SAPH311990400006
(3) When the wire is completely tense, make sure that the
Image drawing wire is firmly engaged with the engine hanger. Then, lift
the engine slowly.
SAPH311990400007
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KSS-SMJ5-E111E.book 6 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Installation
JP31199040702003
SAPH311990400008
! CAUTION • Please use Hino genuine engine oil
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ENGINE
5 FUEL SYSTEM
Setup layout
Layout
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Fuel System
Fuel system diagram
JP31199050402001
Common rail
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Supply pump
Fuel tank
Fuel filter
SAPH31ZZZ0500001
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Part layout
JP31199050402003
SAPH31ZZZ0500002
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH31ZZZ0500003
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KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH31ZZZ0500004
Tightening torque
23390 Refer to the main text.
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KSS-SMJ5-E111E.book 6 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH31ZZZ0500005
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KSS-SMJ5-E111E.book 7 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
4. Operate the priming pump and bleed the air from the
system.
! CAUTION • 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.
SAPH31ZZZ0500007
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KSS-SMJ5-E111E.book 8 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
! CAUTION • 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 an original fuel filter element.
• Complete the work for removal and installation quickly to prevent entry of foreign matter to
the fuel system.
! CAUTION • 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.
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KSS-SMJ5-E111E.book 9 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(1) The soiling and the foreign material of the clamp face are removed.
(2) Install the fuel filter element with according to tightening angle in the table below of a turn after the O-ring
of the fuel filter element comes into contact with the fuel filter head.
NOTICE • The cross-section shape of the O-ring on the side of the fuel filter element has been
changed.
! CAUTION • Tighten after confirming whether the O-ring is a new or an old one.
• As the O-ring is included in the element kit, do not use an O-ring again after it has been
removed once.
• Install the O-ring after applying fuel to the surface of the O-ring.
• Do not use a tool, but tighten by hand.
Old New
Old New
3/4
11/2 1/2
SAPH31ZZZ0500008
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KSS-SMJ5-E111E.book 10 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
عTightening angleع
(Image with the fuel filter seen from below)
O-ring
SAPH31ZZZ0500011
(1) Install the fuel filter element with 1/2 to 3/4 of a turn after the O-ring of the water cup comes into contact
with the fuel filter element.
(2) Tighten the fuel filter drain valve.
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KSS-SMJ5-E111E.book 11 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
! CAUTION • 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 an original fuel filter element.
• Complete the work for removal and installation quickly to prevent entry of foreign matter to
the fuel system.
! CAUTION • 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 with according to tightening angle in the table below of a turn after the O-ring
of the fuel filter element comes into contact with the fuel filter head.
! CAUTION • Tighten after confirming whether the O-ring is a new or an old one.
• As the O-ring is included in the element kit, do not use an O-ring again after it has been
removed once.
• Do not use a tool, but tighten by hand.
عTightening angleع
(Image with the fuel filter seen from below)
3/4
SAPH31ZZZ0500012
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KSS-SMJ5-E111E.book 12 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Priming pump
SAPH31ZZZ0500013
! CAUTION • 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.
! CAUTION • After work, wipe off spilled water or fuel. After start of the engine, make sure that there is
no fuel leak.
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KSS-SMJ5-E111E.book 13 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Close
contact
Raised
SAPH31ZZZ0500015
SAPH31ZZZ0500016
Bolt
SAPH31ZZZ0500017
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KSS-SMJ5-E111E.book 14 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(2) Secure the supply pump, install the injection pump drive
gear on the shaft, and use a vice or similar to prevent
turning while tightening the nut.
SAPH31ZZZ0500018
SAPH31ZZZ0500019
(2) Install a new O-ring and mount the air compressor and
Supply pump O-ring
supply pump assembly on the flywheel housing.
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KSS-SMJ5-E111E.book 15 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
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KSS-SMJ5-E111E.book 16 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Replacement of injector
JP31199050704005
1. Removal of injector
(1) Remove the fixing bolt and remove the plate and the
injection pipe oil seal.
(2) Remove the nozzle clamp holder and remove the injector.
2. Installation of injector
(1) Attach a new O-ring to the groove of the cylinder head and
insert the injector.
Fixing bolt
Injector ! CAUTION • Apply engine oil to the O-ring and be careful
to prevent pinching of the O-ring.
Injection pipe (2) Install the nozzle clamp holder and tack weld the injector
temporarily.
Nozzle clamp ! CAUTION • Do not fix the nozzle holder until the injection
holder pipe is tack welded.
(3) Put a new injection pipe oil seal on the injector and install
the plate.
Injection pipe
oil seal
! CAUTION • Install the injection pipe oil seal to prevent
O-ring undue force to the injection nozzle. (Offset
position between the injection pipe oil seal
and the injection nozzle may cause oil leak or
poor assembly of the injection pipe.)
SAPH31ZZZ0500022
(4) Assemble the injection pipe temporarily and tighten the
fixing bolt of the nozzle clamp holder.
Tightening torque : 25 N⋅m {250 kgf⋅cm, 1.8 lbf⋅ft}
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PC
QR Code reader
Hino-Bowie
Engine-use code
QR code
Connector
New injector
ECU
SAPH31ZZZ0500024
Inspection of injector
JP31199050704006
(4) If the resistance value in (2) and (3) exceeds the standard
value, replace the injector assembly.
2. Cleaning of injector
Upper body
(1) Remove sludge at or around the terminal, if any.
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KSS-SMJ5-E111E.book 18 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH31ZZZ0500027
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ELECTRICAL 7–1
ENGINE
7 ELECTRICAL
Setup layout
Layout
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
7–2 ELECTRICAL
Electrical System
Part layout
JP31199070402001
SAPH311990700001
Tightening torque
9190-06121 4N⋅m{40kgf⋅cm, 3lbf⋅ft}
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ELECTRICAL 7–3
SAPH311990700002
Tightening torque
9069A 154N⋅m{1,570kgf⋅cm, 114lbf⋅ft} 9241-10107 51N⋅m{520kgf⋅cm, 38lbf⋅ft}
9011-64401 83N⋅m{850kgf⋅cm, 61lbf⋅ft} 9241-14147 154N⋅m{1,570kgf⋅cm, 114lbf⋅ft}
9189A 5.9N⋅m{60kgf⋅cm, 4lbf⋅ft}
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
7–4 ELECTRICAL
SAPH311990700003
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KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ELECTRICAL 7–5
Layout of components
JP31199070402003
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KSS-SMJ5-E111E.book 6 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
7–6 ELECTRICAL
Engine main
revolution sensor
Boost pressure sensor Suction control valve (SCV) Fuel temperature sensor
Upper view
SAPH311990700005
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KSS-SMJ5-E111E.book 7 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ELECTRICAL 7–7
Front view
SAPH311990700006
Service procedure
Overhaul item
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KSS-SMJ5-E111E.book 8 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
7–8 ELECTRICAL
Inspection of components
JP31199070702001
At 39kPa
SAPH311990700007 Without continuity
{0.4kgf/cm2 ,5.6565lbf/in.2}
39.2 - 58.8kPa
2 2
{0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in } ON
2
2.9kPa{0.3kgf/cm ,
2
4.7lbf/in }
Within
OFF Toward pressure increase
SAPH311990700008
Connector color: Dark (1) Heat the coolant temperature sender gauge using hot
water.
A (2) Measure the resistance between terminals using a circuit
tester. If it is faulty, replace the gauge.
Between A and C
C
B Temperat
-20 20 80 110
SAPH311990700009
ure
{-68} {68} {176} {230}
(°C{°F})
Resistanc
13.84 - 2.32 - 0.31 - 0.1399 -
e value
16.33 2.59 0.326 0.1435
(Ω)
Temperat
75 100
ure
{167} {212}
(°C,°F)
Resistanc
35.5 -
e value 79 - 92
42.5
(Ω)
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ELECTRICAL 7–9
Standard value
Resistance value :
Ω(Normal temperature 2.59 - 3.29
20°C{68°F})
SAPH311990700010
SAPH311990700011
SAPH311990700012
6. Inspection of injector
(1) For inspection and replacement of the injector, refer to
the chapter of "J05E FUEL SYSTEM".
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7–10 ELECTRICAL
Installation of component
JP31199070702002
O-ring
SAPH311990700013
Installation of starter
JP31199070702003
SAPH311990700014
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KSS-SMJ5-E111E.book 11 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ELECTRICAL 7–11
Installation of alternator
JP31199070702004
1. Installation of alternator
(1) Tighten the alternator temporarily using through bolts and
nuts.
(2) Tighten the adjusting bolts and fixing bolts temporarily.
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
INTAKE 8–1
ENGINE
8 INTAKE
Setup layout
Layout
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
8–2 INTAKE
Intake Manifold
Part layout
JP31199080402001
SAPH311990800001
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
INTAKE 8–3
SAPH311990800002
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
8–4 INTAKE
Replacement
JP31199080704001
Protrusion
SAPH311990800003
(3) Install the intake manifold and tighten it with bolts and
nuts.
SAPH311990800004
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ENGINE
9 ENGINE MECHANICAL
Setup layout
Layout
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Cylinder Head
Part layout
JP31199090402001
SAPH311990900001
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900002
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900003
(3) Remove the cylinder head using a special tool and hoist.
Figure is an Special tool : 09433–1070 Eye bolt
example of work.
short 126.5{4.9803}
Underhead length
Service limit (mm{in.}) middle 156.5{6.1614}
long 187.5{7.3819}
SAPH311990900005
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KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(2) Install the cylinder head gasket on the cylinder block and
the flywheel housing.
Too small
Clearance Clearance
SAPH311990900007
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KSS-SMJ5-E111E.book 6 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(3) Align the dowel pins of the cylinder block using a special
Figure is an tool and hoist and mount the cylinder head.
example of work.
Special tool : 09433–1070 Eye bolt
90° 1,2,7,8,9,10,15,16,17
135° 4,5,12,13
180° 3,6,11,14,18
SAPH311990900009
(9) Make sure the head bolts that have the same tightening
Paint mark angle markings have the same orientation.
SAPH311990900010
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SAPH311990900012
Liquid gasket 3. Temporarily install the cylinder head cover with the gasket
application region attached, and execute a parallel adjustment of the
SAPH311990900013 semicircular plugs.
SAPH311990900014
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KSS-SMJ5-E111E.book 8 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(3) Coat the semicircular plugs with liquid gasket (Three Bond
TB 1207B-Black or equivalent) just before you install the
cylinder head cover.
SAPH311990900015
(4) Put the cylinder head cover on the cylinder head and
Cylinder
Head cover Bolt tighten bolts.
Silent block
Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
Cylinder head
SAPH311990900016
Overhaul item
SAPH311990900017
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KSS-SMJ5-E111E.book 9 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(2) Put a backup metal (e.g. brass bar) at the valve stem
head and pull out the valve seat using a press.
(3) Remove welding spatter or dirt on the valve seat surface.
(4) Heat the cylinder head to approx. 80 to 100 °C and strike
the cooled valve seat into the mounting area of the
cylinder head.
SAPH311990900020
(6) Strike gently while turning the valve using a special tool
for adjustment.
Special tool : 09431–1020 Valve lapping tool
SAPH311990900021
(1) Tap the nozzle seat from the cylinder head lower part.
Then, put an appropriate bolt inside.
(2) Hit the bolt head using a hammer and pull out the nozzle
seat toward the the cylinder head upper part.
(3) Remove the O-ring from the cylinder head.
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KSS-SMJ5-E111E.book 10 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(4) After attaching a new O-ring into the nozzle seat hole of
Cylinder head the cylinder head, apply the liquid gasket [Threebond
O-ring
TB1211 (white) or equivalent] at the lower part of a new
nozzle seat and assemble it on the cylinder head.
Nozzle sheet ! CAUTION • Be sure to replace the O-ring with a new part.
Reuse may cause water leak or gas leak,
resulting in overheat or crack of the cylinder
head.
SAPH311990900023
Cylinder
Head
Steel ball
SAPH311990900025
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KSS-SMJ5-E111E.book 11 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Cylinder Block
Part layout
JP31199090402002
SAPH311990900026
Tightening torque
11521 69N⋅m{700kgf⋅cm, 51lbf⋅ft}+90°+45° 15605 22N ⋅m{220kgf⋅cm, 16lbf⋅ft}
Service procedure
Overhaul item
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Overhaul
JP31199090702002
SAPH311990900027
(2) Pull out the cylinder liner toward the cylinder block upper
part using a special tool.
(3) Apply engine oil to the inner bore of the cylinder block.
(4) Align the match mark of the cylinder liner with that of the
cylinder block. Install the cylinder liner using a special tool.
Special tool : 09471–1490 Guide
SAPH311990900029
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KSS-SMJ5-E111E.book 13 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Block front
Front of engine
SAPH311990900030
Cylinder liner
A, B and C marking
position
SAPH311990900031
0.01 - 0.08
Standard value (mm{in.})
{0.0004 - 0.0031}
SAPH311990900032
(1) Remove the standard oil check valve and install the
cooling jet on the cylinder block using a special tool.
Special tool : 9001–24262 Check bolt
Check bolt
SAPH311990900033
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KSS-SMJ5-E111E.book 14 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(2) Connect the injection test oil hose from the lower part of
the cylinder block to the special tool check bolt.
Check bolt
Oil hose
SAPH311990900034
Cylinder liner
Cooling jet
SAPH311990900035
(4) Inject oil from the nozzle of the cooling jet at the hydraulic
Oil injection unit (example)
Pressure pressure of 196kPa{2kgf/cm2, 28lbf/in.2}.
Regulator
Oil
Hose NOTICE • Refer to the drawing for the oil injection unit.
Air tank
(Oil tank) Compressed
Air gauge air
Air hose
SAPH311990900036
(5) When the injection center hits within the specified line of
the gauge, it is considered normal.
Injection Gauge target circle
! CAUTION • Oil is susceptible to combustion due to
spread. Do not use fire near around.
• Work at well ventilated place.
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KSS-SMJ5-E111E.book 15 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(7) If injection does not hit the target circle, correct it with a
special tool.
SAPH311990900039
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KSS-SMJ5-E111E.book 16 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900040
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KSS-SMJ5-E111E.book 17 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900041
SAPH311990900044
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KSS-SMJ5-E111E.book 18 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Flywheel housing
SAPH311990900045
SAPH311990900046
(2) Hook the special tool oil seal puller with the tab of the front
oil seal and install the hook on the plate of the special tool
oil seal puller with accompanying bolts.
SAPH311990900047
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KSS-SMJ5-E111E.book 19 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(3) Remove two bolts which installed the plate of the special
tool oil seal puller on the crankshaft.
(4) Attach the accompanying center bolt to the special tool oil
seal puller and tighten it. Pull out the front oil seal.
SAPH311990900048
SAPH311990900049
(3) Apply small amount of engine oil to the seal area of the
front oil seal.
(4) Install the oil seal press guide inserting a new front oil seal
with accompanying guide bolts on the crankshaft.
SAPH311990900050
(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.
(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the front oil seal.
SAPH311990900051
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KSS-SMJ5-E111E.book 20 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(1) Install the plate of the special tool oil seal puller on the
crankshaft using two flywheel assembly mounting bolts.
Special tool : 09420–1742 Oil seal puller
! CAUTION • Align the large hole of the plate with the collar
dowel of the crankshaft.
SAPH311990900052
(2) Hook the oil seal puller with the tab of the rear oil seal and
install the hook on the plate of the oil seal puller with
accompanying bolts.
(3) Remove two bolts which installed the plate of the oil seal
puller on the crankshaft.
SAPH311990900053
(4) Attach the accompanying center bolt to the oil seal puller
and tighten it. Pull out the rear oil seal.
SAPH311990900054
Guide of oil seal press (1) Insert a new rear oil seal into the guide of the oil seal
press.
Special tool : 09407–1040 Oil seal press
SAPH311990900055
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KSS-SMJ5-E111E.book 21 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(3) Apply small amount of engine oil to the seal area of the
rear oil seal.
(4) Install the oil seal press guide inserting a new rear oil seal
with accompanying guide bolts on the crankshaft.
(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.
SAPH311990900057
(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the rear oil seal.
Setup layout
Layout
SAPH311990900058
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KSS-SMJ5-E111E.book 22 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900059
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KSS-SMJ5-E111E.book 23 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
1. Removal of piston
Figure is an
example of work. (1) Remove bolts and remove the connecting rod cap.
SAPH311990900061
(4) Hit the connecting rod from underneath the engine using
a handle of a hammer. Remove the piston together with
the connecting rod.
SAPH311990900062
SAPH311990900063
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SAPH311990900064
SAPH311990900066
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KSS-SMJ5-E111E.book 25 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(3) Face the side with the piston ring identification print
upward and install in the order of the oil ring, second ring
and top ring using a special tool.
(4) Connect the joint of the coil expander and fit the oil ring
Lower surface
inside the ring. Offset the coil expander joint with the ring
Oil ring joint Clearance
joint by 180 deg for installation.
(5) Allocate the joints of the piston ring with uniform intervals
as shown in the figure.
Coil expander Ring
Second ring
SAPH311990900067
SAPH311990900069
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KSS-SMJ5-E111E.book 26 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(4) Insert the piston carefully so that the connecting rod may
not come in contact with the cooling jet.
Bearing
SAPH311990900071
(6) Align the match mark of the connecting rod cap with that
of the connecting rod and fix it with a dowel pin.
Match mark
Stamp ! CAUTION • Do not change the combination between the
connecting rod and the connecting rod cap.
1234 1234
SAPH311990900072
SAPH311990900073
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(9) Tighten the connecting rod bolt and mark the bolt head in
Paint mark the same direction with paint.
112{4.4095} 112.15{4.4153}
SAPH311990900075
Standard value
111.9±0.006{4.4055±0.0002}
(mm{in.})
Standard value
0.088 - 0.112{0.0035 - 0.0044}}
(mm{in.})
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Second
0.75 - 0.9 {0.0295 - 0.0354} 1.2{0.0472}
ring
37 {1.4567} 36.96{1.4551}
SAPH311990900080
(2) Measure the piston boss inner diameter using a cylinder gauge.
37 {1.4567} 37.05{1.4587}
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SAPH311990900083
Groove
Spindle
Special tool : 09402–1540 Spindle
Connecting rod ! CAUTION • Align the press sub-assembly groove with the
special tool spindle groove for installation.
Press
Sub-assembly
SAPH311990900084
SAPH311990900085
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SAPH311990900086
(2) Align the connecting rod oil hole with the bushing oil hole
assembled on the special tool. Make sure that the groove
of the special tool spindle is in alignment with the groove
of the special tool press sub-assembly.
Groove
Oil hole ! CAUTION • Place the connecting rod so that the chamfer
side of the connecting rod small end inner
diameter may be the bushing side
• Apply engine oil to the inner diameter surface
SAPH311990900088 of the connecting rod.
SAPH311990900089
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KSS-SMJ5-E111E.book 31 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Replacement of crankshaft
JP31199090704007
1. Removal of crankshaft
(1) Remove the main bearing cap and the main shaft bearing.
Remove the crankshaft using a hoist.
SAPH311990900090
2. Installation of crankshaft
(1) Face the groove side (front) of the thrust bearing toward
the crankarm and the part number side (back) toward the
main bearing cap or the cylinder block. Install it on the
cylinder block and the main bearing cap.
(2) Install the main bearing on the cylinder block and each
bearing cap.
SAPH311990900091
(4) Align the main bearing cap which has the thrust bearing
Stamp number and the main bearing with the cylinder block.
Front of engine
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KSS-SMJ5-E111E.book 32 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900073
(6) Apply engine oil to the bolt seat and the bolt thread of the
bearing cap bolt.
Paint mark (14) Make sure that all paint marks are in the same direction.
45ࠑ (15) After tightening, hit the front/rear ends of the crankshaft
90ࠑ
gently with a plastic hammer for initial fit.
0.050 - 0.219
{0.0020 - 0.50{0.0197} 1.219{0.0480}
0.0086}}
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KSS-SMJ5-E111E.book 33 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Inspection of crankshaft
JP31199090703002
SAPH311990900096
Measure two (1) Measure the outer diameter of the crankshaft journal
places. using a micrometer. If it is faulty, grind or replace the
90ࠑ
crankshaft. When the crankshaft is ground, use the
undersize bearing.
SAPH311990900097
Eccentric wear
Regrind for correction.
0.10{0.0039}
Wear of 0.20{0.0079} or
Regrind
more
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KSS-SMJ5-E111E.book 34 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900098
80{3.1496} 79.3{3.1221}
SAPH311990900099
SAPH311990900100
Standard value (mm{in.}) Repair limit (mm{in.})
0.051 - 0.102
0.2{0.0079}
{0.0020 - 0.0040}
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KSS-SMJ5-E111E.book 35 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Crank pin
Radius is
incomplete. Radius is 2.5 to 3.0mm {0.0984 to 0.1181 in.}
small. Step Step
R
Journal
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Good Poor
SAPH311990900101
SAPH311990900102
SAPH311990900103
SAPH311990900104
Wear value (mm{in.}) Action
Eccentric wear
Regrind for correction.
0.10{0.0039}
Wear of 0.20{0.0079} or
Regrind
more
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KSS-SMJ5-E111E.book 36 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900105
(1) Apply engine oil to the bolt seat and the bolt thread of the
1 crankshaft pulley mounting bolt.
6 3 (2) Install the crankshaft pulley on the crankshaft and tighten
it according to the figure.
4 5 Tightening torque : 118 N⋅m {1,200 kgf⋅cm, 87 lbf⋅ft}
2
NOTICE • Insert a large flat tip screwdriver into the
flywheel gear from the flywheel housing
SAPH311990900106 inspection hole to prevent turning of the
crankshaft.
Replacement of flywheel
JP31199090704009
1. Removal of flywheel
Engine revolution sensor
Flywheel
(1) Remove the engine revolution sensor.
Mounting bolt (2) Remove bolts fixing the flywheel.
SAPH311990900107
(3) Install a special tool into the bolt hole of the crankshaft to
remove the flywheel.
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KSS-SMJ5-E111E.book 37 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(1) Heat the entire ring gear circumference with a burner until
it is about 200 °C(392°F).
SAPH311990900109
SAPH311990900110
(1) Heat the entire ring gear circumference with a burner until
it is about 200 °C(392°F).
SAPH311990900111
(2) Face the chamfered side toward the flywheel and install it
on the flywheel quickly.
SAPH311990900112
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KSS-SMJ5-E111E.book 38 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
4. Installation of flywheel
(1) Make sure that there is no burr or dirt on the joint surface
of the crankshaft and the flywheel and the screw hole.
(2) Install the special tool into the bolt hole of the crankshaft.
Special tool : 09481–1340 Guide
(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 and the bolt thread of the
flywheel mounting bolt.
SAPH311990900114
SAPH311990900115
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KSS-SMJ5-E111E.book 39 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900117
Tightening torque
900124 59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90° 900125 172N⋅m {1, 750 kgf⋅cm, 127lbf⋅ft}
900124A 108N⋅m {1, 100 kgf⋅cm, 80lbf⋅ft}
Service procedure
Overhaul item
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KSS-SMJ5-E111E.book 40 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Removal of camshaft
JP31199090702006
(1) Loosen the lock nut and turn the adjusting screw
completely.
Rock nut
SAPH311990900118
(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm and the rocker arm
shaft.
SAPH311990900119
Disassembly of camshaft
JP31199090702007
1. Disassembly of camshaft
(1) Fix the camshaft gear using a vice to disassemble the
camshaft.
SAPH311990900120
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KSS-SMJ5-E111E.book 41 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
0.04{0.0016} 0.1{0.0039}
SAPH311990900122
40{1.5748} 39.85{1.5689}
40{1.5748} 40.15{1.5807}
0.020 - 0.063
Standard value (mm{in.})
{0.0008 - 0.0025}
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KSS-SMJ5-E111E.book 42 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Assembly of camshaft
JP31199090702009
Underhead length
SAPH311990900124
2. Fix the camshaft gear using a vice. Apply engine oil to the
seat and the bolt thread of the camshaft gear mounting
bolt.
3. Set the dowel pin to the camshaft and the camshaft gear
and tighten the camshaft gear mounting bolt.
Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft}
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KSS-SMJ5-E111E.book 43 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Installation of camshaft
JP31199090702010
(2) Coat the bearing parts with engine oil and then install the
camshaft bearing caps in numerical order 1-2-3-4-5 from
the front of the engine, making sure the five-sided mark on
Engine Foreword
SAPH311990900127
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KSS-SMJ5-E111E.book 44 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(6) Apply engine oil to the cam threads and set the rocker
arm in position, making sure it is correctly laid on the
crosshead. Then, tighten the bolts in the sequence
shown in the figure, making several passes and gradually
tightening them each time.
SAPH311990900129
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KSS-SMJ5-E111E.book 45 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900130
Service procedure
Overhaul item
SAPH311990900131
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KSS-SMJ5-E111E.book 46 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Standard value
(mm{in.})
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KSS-SMJ5-E111E.book 47 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900134
SAPH311990900135
Lubricating
hole
Cylinder
Block
SAPH311990900136
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KSS-SMJ5-E111E.book 48 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(3) Face the lubricating hole of the idle gear shaft toward the
oil pan (downward). Install A in the figure by adjusting the
Sub-idle gear timing of the crankshaft gear and the main idle gear as in
the detailed drawing.
Oil pump
gear
A
Main idle gear
Crankshaft gear
SAPH311990900137
(4) Apply engine oil to the bolt seat and the bolt thread of the
idle gear shaft mounting bolt.
SAPH311990900138
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KSS-SMJ5-E111E.book 49 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900139
(4) Remove the sub-idle gear shaft mounting bolt and pull out
the idle gear shaft using a sliding hammer.
SAPH311990900140
SAPH311990900141
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KSS-SMJ5-E111E.book 50 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900142
0.025 - 0.075
Standard value (mm{in.})
{0.0010 - 0.030}
SAPH311990900143
SAPH311990900144
SAPH311990900145
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KSS-SMJ5-E111E.book 51 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(1) Insert a large flat tip screwdriver into the cam idle gear
from the side of the camshaft gear of the camshaft
housing to prevent turning of the cam idle gear.
SAPH311990900146
0.030 - 0.253
0.30{0.0118}
{0.0012 - 0.0100}
SAPH311990900147
0.100 - 0.178
Standard value (mm)
{0.0039 - 0.0070}
SAPH311990900148
SAPH311990900149
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KSS-SMJ5-E111E.book 52 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(3) Measure backlash between the main idle gear and the air
compressor idle gear using a dial gauge and a magnet
stand. If it is beyond the service limit, replace each gear.
(4) Measure backlash between the idle gear and the supply
pump drive gear using a dial gauge and a magnet stand. If
it is beyond the service limit, replace each gear.
0.020 - 0.083
0.10{0.0039}
{0.0008 - 0.0033}
SAPH311990900151
(1) Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.
SAPH311990900152
(2) Measure backlash between the main idle gear and the
sub-idle gear using a dial gauge and a magnet stand. If it
is beyond the service limit, replace each gear.
0.030 - 0.113
0.30{0.0118}
{0.0012 - 0.0044}
SAPH311990900153
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KSS-SMJ5-E111E.book 53 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(1) Insert a large flat tip screwdriver into the sub-idle gear to
prevent turning of the sub-idle gear.
SAPH311990900154
(2) Measure backlash between the sub-idle gear and the oil
pump gear using a dial gauge and a magnet stand. If it is
beyond the service limit, replace each gear.
0.030 - 0.131
0.30{0.0118}
{0.0012 - 0.0005}
SAPH311990900155
0.114 - 0.160
Main idle gear {0.0045 - 0.30{0.0118}
SAPH311990900156
0.0063}
0.040 - 0.095
Sub-idle gear {0.0016 - 0.30{0.0118}
0.0037}
SAPH311990900157
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KSS-SMJ5-E111E.book 54 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(2) Measure backlash between the cam idle gear and the
sub-idle gear using a dial gauge. If it is beyond the service
limit, replace each gear.
0.050 - 0.218
0.30{0.0118}
{0.0020 - 0.0086}
Setup layout
Layout
SAPH311990900158
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KSS-SMJ5-E111E.book 55 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Valve System
Part layout
JP31199090402007
SAPH311990900159
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KSS-SMJ5-E111E.book 56 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
22{0.8661} 20.08{0.7905}
0.03 - 0.101
0.15{0.0059}
{0.0012 - 0.0039}
SAPH311990900161
SAPH311990900162
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KSS-SMJ5-E111E.book 57 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900163
22.5 - 23.0
Standard value (mm{in.})
+0.1{0.0039in.}
{0.8858 - 0.9055}
22.9mm{0.9022in.}
-0.4{0.0157in.}
SAPH311990900164
(1) Install the valve spring upper seat on the valve spring.
(2) Compress the valve spring using a special tool and install
the valve spring retainer.
Special tool : 09470–1170 Valve spring press
SAPH311990900165
• Be sure to assemble each valve at the original
cylinder position.
• When the valve spring is compressed, avoid
contact of the valve spring upper seat with the
valve stem seal.
• Since the valve spring has equal spacing,
vertical direction is not specified for assembly.
• Check for scratch on the valve stem seal
when the valve is reused.
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KSS-SMJ5-E111E.book 58 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311990900166
(2) Measure the free length of the valve spring using a vernier
calipers. If it is out of the service limit, replace the valve spring.
SAPH311990900168
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KSS-SMJ5-E111E.book 59 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(3) Loosen the adjusting screw and the lock nut of the
Adjusting screw of rocker arm
Roller crosshead completely.
Cam base
circle Lock nut
Adjusting screw of
crosshead ! CAUTION • Provide the adjusting screw protrusion of 10
10 mm or more
mm or more from the top surface of the
crosshead. If the adjusting screw is not
completely separated from the valve stem,
Clearance correct adjustment is not allowed.
Close contact
Lock Nut
SAPH311990900170
(4) Insert a thickness gauge between the rocker arm and the
Rocker arm Thickness gauge crosshead and adjust the clearance with the adjusting
screw of the rocker arm. Tighten the lock nut.
SAPH311990900172
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KSS-SMJ5-E111E.book 60 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Close contact
Close contact
SAPH311990900173
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
EXHAUST 10–1
ENGINE
10 EXHAUST
Setup layout
Layout
10
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
10–2 EXHAUST
Exhaust Manifold
Part layout
JP31199100402001
SAPH311991000001
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
EXHAUST 10–3
SAPH311991000002
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
10–4 EXHAUST
Replacement
JP31199100704001
Black side
SAPH311991000003
When a new exhaust manifold is used Tightening torque : 53 N⋅m {540 kgf⋅cm, 40 lbf⋅ft}
12 11 10 9 8 7 6 5
! CAUTION • When nuts are tightened, prevent each
spacer from riding on the counterbore area of
4
the manifold flange.
1 2 3
• The tightening sequence of the exhaust
When exhaust manifold is reused
manifold varies between use of a new part
8 9 2 3 5 6 11 12 and reuse.
(3) Tighten the same nuts again according to the order in the
7 1 4 10 figure.
Tightening torque : 53 N⋅m {540 kgf⋅cm, 40 lbf⋅ft}
Spacer
! CAUTION • Be sure to retighten it.
SAPH311991000004
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
COOLING 11–1
ENGINE
11 COOLING
System drawing
11
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
11–2 COOLING
Cooling System
Cooling system drawing
JP31199110803001
Reservoir
Water temperature
Thermostat case
Cylinder head
Thermostat
Radiator
Cylinder block
Turbo charger
Car
heater
Drain cock
Drain cock
SAPH311991100001
Setup layout
Layout
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
COOLING 11–3
Part layout
JP31199110402002
SAPH311991100002
[S5LQ0017E03] [0811CsCshWbYs]
11–4A COOLING
(2) Remove the O-ring from the groove on the coolant pump.
SAPH3125H1100003
SAPH3125H1100011
(3) Install the new O-ring on the groove of the coolant pump.
SAPH3125H1100005
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KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
COOLING 11–5
Inspection of thermostat
JP31199110703001
SAPH311991100006
13mm
Thermostat valve opening
{0.5122in.} 74.5 - 78.5
temperature standard value :
{166.1 - 173.3}
Valve lift
T1(°C{°F})
0°C{32°F}
T1°C{°F}
10°C
T2°C{°F}
Temperature NOTICE • The thermostat valve opening temperature
{50°F}
(T1) is stamped on the thermostat seat.
SAPH311991100007
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KSS-SMJ5-E111E.book 6 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
11–6 COOLING
SAPH311991100009
(3) Install the coolant pump to the dowel pin of the cylinder
block.
SAPH311991100009
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
LUBRICATION 12–1
ENGINE
12 LUBRICATION
System drawing
12
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
12–2 LUBRICATION
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
Supply
pump
drive
Main idle
gear shaft
: Lubrication
: Return
SAPH311991200001
Setup layout
Layout
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
LUBRICATION 12–3
Part layout
JP31199120402001
SAPH311991200002
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
12–4 LUBRICATION
SAPH311991200003
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KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
LUBRICATION 12–5
(1) Remove bolts and hose joint, and remove the oil cooler.
SAPH311991200004
SAPH311991200005
! CAUTION • Face the D-ring flat area toward the oil cooler.
Flat area
SAPH311991200006
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KSS-SMJ5-E111E.book 6 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
12–6 LUBRICATION
(3) Insert the positioning stud into the screw hole of the
cylinder block and install the oil cooler.
Tightening torque :
44.1±4.9 N⋅m {450±50 kgf⋅cm, 33±4 lbf⋅ft}
SAPH311991200009
Overhaul item
SAPH311991200011
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KSS-SMJ5-E111E.book 7 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
LUBRICATION 12–7
SAPH311991200012
SAPH311991200013
Tightening torque :
24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft} (M14, M20)
29.4±4.9 N⋅m {300±50 kgf⋅cm, 22±4 lbf⋅ft} (M22)
34.3±4.9 N⋅m {350±50 kgf⋅cm, 25±4 lbf⋅ft} (M24)
SAPH311991200011
(3) Install the soft washer in (2) and the oil pressure warning
switch.
SAPH311991200012
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KSS-SMJ5-E111E.book 8 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
12–8 LUBRICATION
Tightening torque :
24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft}
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KSS-SMJ5-E111E.book 9 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
LUBRICATION 12–9
SAPH311991200014
(3) Tighten the oil pump according to the order in the figure.
Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
SAPH311991200015
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KSS-SMJ5-E111E.book 10 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
12–10 LUBRICATION
SAPH311991200016
SAPH311991200017
(1) Measure the outer diameter of the drive gear and the
inner diameter of the pump chamber at cylinder block.
Standard value
Measuring area
(mm{in.})
Outer diameter of drive gear 54{2.1260}
0.100 - 0.202{0.0039 -
0.30{0.0118}
0.0080} (reference)
SAPH311991200019
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 11 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
LUBRICATION 12–11
(1) Measure the drive gear width and the pump chamber
depth at the cylinder block using a depth gauge.
Standard value
Measuring area
(mm{in.})
SAPH311991200021
(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the cylinder block hole
diameter using a cylinder gauge.
Standard value
Measuring area
(mm{in.})
0.040 - 0.099
Standard value (mm{in.})
{0.0016 - 0.0039}
SAPH311991200023
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KSS-SMJ5-E111E.book 12 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
12–12 LUBRICATION
(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.
Standard value
Measuring area
(mm{in.})
0.030 - 0.075
Standard value (mm{in.})
{0.0012 - 0.0030}
SAPH311991200025
(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.
Standard value
Measuring area
(mm{in.})
SAPH311991200026
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 13 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
LUBRICATION 12–13
0.072 - 0.277
0.30{0.0118}
{0.0028 - 0.0109}
SAPH311991200027
SAPH311991200017
SAPH311991200016
SAPH311991200028
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 14 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
12–14 LUBRICATION
Oil Pan
Part layout
JP31199120402003
SAPH311991200029
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 15 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
LUBRICATION 12–15
Replacement
JP31199120704004
(1) Cut the gasket of the rear end plate to be flush to the
cylinder block lower surface using a scraper.
(2) Make sure that there is no deformation, dirt or oil on the
joint surface between the cylinder block and the oil pan.
Protrusion
Apply liquid gasket [Threebond TB1207D (silver) or
equivalent] to the front rear end of the cylinder block lower
surface.
(3) Insert several stud bolts (70 mm{2.7559 in.} or larger) for
Bolt tightening
attaching direction
positioning into the cylinder block screw hole.
(4) Position the oil pan gasket protrusion at the intake side
and the flywheel housing (printed seal surface at cylinder
block). Align the new oil pan gasket and oil pan to the
cylinder block lower surface and tighten bolts in the arrow
order of the figure.
Tightening torque :
Liquied gasket application position 19.6 - 24.5 N⋅m {200 - 250 kgf⋅cm, 14 - 18 lbf⋅ft}
(5) Remove positioning stud bolts and install the correct bolts.
Engine front side (6) Tighten bolts in the arrow order of the figure.
SAPH311991200030
Tightening torque : 30 N⋅m {300 kgf⋅cm, 22 lbf⋅ft}
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 16 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
12–16 LUBRICATION
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ENGINE
Starter........................................................................ 13-2
Part layout (typical example)................................. 13-2
Disassembly.......................................................... 13-3
Inspection of components..................................... 13-9
Assembly ............................................................ 13-14
Alternator (50A) ...................................................... 13-21
Part layout (typical example of 50A) ................... 13-21
Circuit drawing (50A) .......................................... 13-22
Disassembly........................................................ 13-23
Inspection of components................................... 13-26
Assembly ............................................................ 13-29
Inspection after assembly ................................... 13-33
13
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Starter
Part layout (typical example)
JP31199130402001
SAPH311991300001
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Disassembly
JP31199130702001
SAPH311991300002
Commutator end
frame
SAPH311991300003
(2) Remove two set bolts and remove the commutator end
frame.
Set bolt
! CAUTION • Hold the M lead wire and remove the
commutator end frame by lifting.
SAPH311991300004
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Brush lead
Clamp
SAPH311991300005
! CAUTION • Do not hold the M lead wire and hold the yoke
assembly outer diameter for removal.
Center bracket
assembly
SAPH311991300006
5. Removal of packing
Yoke assembly (1) Remove the packing from the centering parts at both ends
of the yoke assembly.
Packing Packing
SAPH311991300007
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KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311991300008
Puller
SAPH311991300009
8. Removal of cover
Packing Cover (1) Remove the cover from the center bracket assembly.
(2) Remove the packing.
SAPH311991300010
Planetary gear ! CAUTION • Make sure that the gear is not damaged or
chipped.
Carrier pin
SAPH311991300011
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 6 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Center bracket
SAPH311991300012
Shim
SAPH311991300013
SAPH311991300015
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KSS-SMJ5-E111E.book 7 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311991300016
Holder
Lever assembly
SAPH311991300017
(2) Turn and pull out the lever assembly using the clutch as
the axis.
Lever assembly
SAPH311991300018
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 8 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311991300019
Brake plate
SAPH311991300020
SAPH311991300021
SAPH311991300022
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 9 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Packing
SAPH311991300023
Inspection of components
JP31199130703001
SAPH311991300024
(3) Measure the resistance between the coil lead wire and the
Tester rod yoke with a circuit tester and check insulation.
When the value is below the service limit, replace it.
Feed coil
Service limit 1kΩor less
SAPH311991300025
SAPH311991300026
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 10 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Growler tester
SAPH311991300027
SAPH311991300028
Commutator
Standard value Service limit
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KSS-SMJ5-E111E.book 11 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
8.98{0.3535} or
Area 9{0.3543}
SAPH311991300032 less
Brush
SAPH311991300034
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KSS-SMJ5-E111E.book 12 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
25.90{1.0197} or
Area 26{1.0236}
less
SAPH311991300035
12.04{0.4740} or
Area 12.1{0.4764}
less
SAPH311991300036
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 bushing.
1
Standard value (mm{in.}) Service limit (mm{in.})
25{0.9843} 25.2{0.9921} or more
SAPH311991300037
2 26{1.0236} 26.2{1.0315}
SAPH311991300038
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KSS-SMJ5-E111E.book 13 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
9{0.3543} 9.2{3.6220}
SAPH311991300040
Body
Standard value(Ω) 1.13 - 1.25
SAPH311991300041
B terminal
SAPH311991300042
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KSS-SMJ5-E111E.book 14 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(2) Push the end of the start magnet switch assembly (close
the internal contact) and make sure that there is electric
continuity between the B terminal and the M terminal
using a circuit tester.
SAPH311991300043
Overhaul item
Assembly
JP31199130702002
1. Installation of packing
(1) Install a new packing on the center bracket assembly.
Packing
SAPH311991300023
SAPH311991300044
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 15 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Brake plate
SAPH311991300045
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
SAPH311991300018
SAPH311991300016
7. Installation of pinion
(1) Lubricate parts (refer to the lubrication point drawing and
Pinion stopper the lubrication list) and install the pinion and the pinion
stopper.
Pinion
SAPH311991300015
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KSS-SMJ5-E111E.book 16 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(2) Install the retainer clip using a tool such as snap ring
pliers.
Retainer clip
Pinion stopper
Pinion
SAPH311991300014
SAPH311991300013
Internal gear
Center bracket
SAPH311991300012
SAPH311991300011
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 17 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311991300010
SAPH311991300008
Packing Packing
SAPH311991300007
Center bracket
assembly
SAPH311991300006
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 18 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Spring
Brush
Brush lead
Clamp
SAPH311991300005
Tightening torque :
15.7 - 17.6 N⋅m {160 - 179 kgf⋅cm, 12 - 13 lbf⋅ft}
Commutator end
frame
SAPH311991300003
SAPH311991300004
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 19 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311991300002
19. Lubrication
Refer to the following figure and table for lubricant to be applied.
! CAUTION • There shall be no lubricant on the commutator surface, brush and contact.
SAPH311991300046
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 20 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Table of lubricant
Amount Lubricant
Code Lubricating point Lubricant used Remark
(g{oz}) manufacturer
0.5 - 1
4 Armature front metal 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}
Clutch case lever 1-2 Nippon Oil
10 Pyroknock No.2
shifter {0.04 - 0.07} Corporation
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}
Setup layout
Layout
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 21 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Alternator (50A)
Part layout (typical example of 50A)
JP31199130402002
SAPH311991300047
Tightening torque
27317 7.8-9.8 N m{80-99 kgf⋅cm, 6-7lbf⋅ft} 27317C 1.9-2.5 N⋅m{20-25 kgf⋅cm, 1-2lbf⋅ft}
27317A 1.9-2.5 N⋅m{20-25 kgf⋅cm, 1-2lbf⋅ft} 27391 127 - 157 N⋅m{1, 300 - 1, 600 kgf⋅cm, 94-
116lbf⋅ft}
27317B 2.9 - 3.9 N⋅m{30 - 39 kgf⋅cm, 2-3lbf⋅ft} 27391A Internal nut : 4.9-5.9 N m{50-60 kgf⋅cm,
3.6-4.3lbf⋅ft}
System drawing
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 22 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Capacitor
Diode
Fuse Load
L Lamp 1.4 to 3W
R
Starter switch
P
Feed coil
N
Regulator
Battery 24V
Stator coil
Alternator
SAPH311991300048
Service procedure
Overhaul item
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 23 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Disassembly
JP31199130702003
SAPH311991300050
(3) Remove three through bolts and disconnect the front from
the rear.
SAPH311991300051
2. Disassembly of front
(1) Remove nuts and remove the pulley, fan and collar.
SAPH311991300052
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 24 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311991300053
SAPH311991300054
(4) Remove the ball bearing from the front bracket using a
press or jig C.
Jig C
! CAUTION • Place jig C at the inner race of the front
bearing.
• Removed bearing must not be reused.
SAPH311991300055
3. Disassembly of rear
(1) Remove solder of the lead wire connecting the stator coil
and the diode using a soldering bit and suction line or a
solder suction device
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 25 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311991300057
SAPH311991300058
Terminal
Lead wire
Regulator assembly
SAPH311991300059
SAPH311991300060
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 26 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311991300061
SAPH311991300062
(8) Remove the roller bearing from the rear bracket using a
press, jig A and jig B.
SAPH311991300063
Inspection of components
JP31199130703002
SAPH311991300064
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 27 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(2) Measure the resistance between the stator coil core and
each terminal using a megger tester.
SAPH311991300065
(4) Measure the resistance between the core and the coil
using a megger tester.
SAPH311991300067
(1) Measure the outer diameter of the shaft at the ball bearing
insertion area of the rotor assembly using a micrometer.
SAPH311991300068
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 28 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
SAPH311991300069
Standard value
SAPH311991300070
SAPH311991300071
Standard value
Forward resistance value Approx. 10 Ω
Overhaul item
SAPH311991300072
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 29 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Assembly
JP31199130702004
1. Assembly of front
(1) Press fit a new ball bearing into the front bracket using a
press and jig C.
SAPH311991300074
SAPH311991300075
(4) Install the space 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}
SAPH311991300076
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 30 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
2. Assembly of rear
(1) Press fit a new roller bearing into the rear bracket using a
Jig A
press, jig A and jig B.
Jig B
SAPH311991300077
Tightening torque :
2.9 - 3.9 N⋅m {30 - 39 kgf⋅cm, 2 - 3 lbf⋅ft}
SAPH311991300078
SAPH311991300079
Tightening torque :
1.9 - 2.5 N⋅m {20 - 25 kgf⋅cm, 1 - 2 lbf⋅ft}
SAPH311991300080
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 31 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
(5) Solder the lead wire connecting the regulator and the field
coil, and connecting the stator coil and the diode using a
soldering bit.
Terminal
Lead wire
Regulator assembly
SAPH311991300082
Tightening torque :
4.9 - 5.9 N⋅m {50 - 60 kgf⋅cm, 3.6 - 4.3 lbf⋅ft}
SAPH311991300083
SAPH311991300084
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 32 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Tightening torque :
1.9 - 2.5 N⋅m {20 - 25 kgf⋅cm, 1 - 2 lbf⋅ft}
SAPH311991300085
(3) Align the tab and install the cover. Fix it with bolts.
Tightening torque :
3.3 - 4.4 N⋅m {34 - 44 kgf⋅cm, 2 - 3 lbf⋅ft}
SAPH311991300086
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 33 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
1. Inspection of rotation
(1) Turn the pulley with hand to check if there is no
interference with internal parts and if rotation is smooth.
SAPH311991300087
B E Approx. 20 Ω
SAPH311991300088
E B Infinite
P E Approx.7 Ω
E P Infinite
R L
N P
E
Connector details
SAPH311991300089
[S5LQ0017E03] [0811CsCshWbYs]
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
TURBOCHARGER 14–1
ENGINE
14 TURBOCHARGER
Setup layout
Layout
14
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
14–2 TURBOCHARGER
Turbocharger Assembly
Part layout
JP31199140402001
SAPH311991400001
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
TURBOCHARGER 14–3
Inspection
JP31199140501001
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
14–4 TURBOCHARGER
Replacement
JP31199140704001
1. Removal
(1) Remove the boost pipe and U-turn pipe.
(2) Disconnect all pipes connected to the turbocharger.
(3) Remove the bolts fixing the exhaust pipe and the
turbocharger and remove the turbocharger.
2. Installation
(1) Install the turbocharger in the reverse order of
disassembly. When the turbocharger is installed on the
engine or after installation, observe the following
precautions for work. Pay special attention to entry of
foreign matter inside the turbocharger.
Tightening torque :
56 N⋅m {570 kgf⋅cm, 41 lbf⋅ft}
(Turbocharger to exhaust manifold)
(2) Lubrication and cooling system
a. 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.
b. Clean the oil pipe, oil hose, coolant pipe and hose.
Check for pipe deformation, hose crack or dirt or
foreign matter in the pipe or hose.
c. Do not use sealant at the installation surface of the oil
pipe and the coolant pipe or joint between the coolant
hose and the coolant pipe to prevent failures such as
damage due to clogging or loosening of tightened
areas.
d. Be sure to use new soft washers, O-rings and gaskets.
e. Be sure to install the oil pipe, oil hose, coolant pipe and
coolant hose correctly to prevent leak of oil or water
from connections.
[S5LQ0017E03] [0811CsCshWbYs]
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KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
TURBOCHARGER 14–5
[S5LQ0017E03] [0811CsCshWbYs]
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 1 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
ENGINE
16
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 2 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 3 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Insufficient engine power Piston, cylinder liner and piston Refer to Large engine oil
ring consumption.
Faulty engine start (electric unit) Faulty battery Check battery
Faulty wiring of starter Replace starter wiring
Loose battery cable Tighten battery terminal connection
or replace cable
Faulty operation of starter Replace starter assembly
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 4 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 5 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Alternator
JP31199160601002
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 6 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Starter
JP31199160601003
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 7 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
Turbocharger
JP31199160601004
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 8 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
[S5LQ0017E03] [0811CsCshWbYs]
App version: 123456.beta
KSS-SMJ5-E111E.book 9 ページ 2008年7月2日 水曜日 午後3時31分 Data version:
[S5LQ0017E03] [0811CsCshWbYs]
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–1
ENGINE
[S5LQ0017E03] [0811CsCshWbYs]
17–2 ENGINE DIAGNOSIS CODE
Engine ECU
Precautions
JP31199170102001
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–3
ACT Relay
Fuse
Each Sensor Power
Main relay
Key switch signal Fuse
Starter signal
- + Battery
OUTPUT
Glow relay
INPUT
Common rail T
Engine
P
SAPH311991700002
Service procedure
Inspection procedure item
[S5LQ0017E03] [0811CsCshWbYs]
17–4 ENGINE DIAGNOSIS CODE
Inspection
JP31199170703001
1. Pre-inspection
(1) If an error occurs on the system, The DTC code is
indicated in the console panel.
(2) Reading of failure code
a. Connection of Hino–DX
Failure diagnosis
connector
SAPH311991700003
Hino-Bowie
Connecting cable
Connect to the failure diagnosis
connector at the vehicle side.
SAPH311991700004
SAPH311991700005
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–5
NOTICE • For the system status by indication of DTC code in the table, refer to "1. Pre-inspection,
Inspection, Engine ECU".
"Reference : Inspection, Engine ECU, Engine diagnosis code"
a. Engine does not start P0335 Engine speed main sensor circuit
17-12
Engine stopped. malfunction
a. Low output (LOW idle 800rpm P2120 Accelerator sensor 1 and 2 malfunction
fixing)
17-35
[S5LQ0017E03] [0811CsCshWbYs]
17–6 ENGINE DIAGNOSIS CODE
a. Other problems P0182 Fuel temperature sensor circuit low input 17-23
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–7
Function, movement
Description of function
and operation
[S5LQ0017E03] [0811CsCshWbYs]
17–8 ENGINE DIAGNOSIS CODE
SAPH311991700006
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–9
Vehicle harness
Signal check harness
Test lead
SAPH311991700007
[S5LQ0017E03] [0811CsCshWbYs]
17–10 ENGINE DIAGNOSIS CODE
SAPH311991700008
Failure diagnosis list
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–11
1. Set the starter key to "OFF" and connect the signal check
# 㧭 # & 㧰 ' 㧱 ' harness.
#
2. Turn the starter key "ON" and measure voltage between
terminals A5, A6, A7 and terminals D1, E4, E5.
Standard value : 20 V or more
OK
Normal
1. Set the starter key to "OFF" and connect the signal check
D1 D E4 E E5 harness.
OK
Normal
[S5LQ0017E03] [0811CsCshWbYs]
17–12 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
B6 B B7 harness.
OK
SAPH311991700012
OK
Normal
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–13
SAPH311991700013
OK
[S5LQ0017E03] [0811CsCshWbYs]
17–14 ENGINE DIAGNOSIS CODE
Abnormal engine main rotation sensor pulse count (DTC code P0336)
JP31Z01170601013
1. Set the starter key to "OFF" and connect the signal check
B6 㧮 B7
harness.
OK
SAPH311991700015
NG Defective harness
SAPH311991700016
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–15
OK
[S5LQ0017E03] [0811CsCshWbYs]
17–16 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
harness.
GND +5V
2. Disconnect the connector of the sub-speed sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the sub-speed sensor
connector (at machine harness side).
OK
SAPH311991700019
OK
Harness failure
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–17
1. Set the starter key to "OFF" and connect the connector of the
D D19
sub-speed sensor.
D30
2. Start the engine and keep idling status.
OK
SAPH311991700021
NG Harness failure
OK
[S5LQ0017E03] [0811CsCshWbYs]
17–18 ENGINE DIAGNOSIS CODE
Abnormal engine auxiliary rotation sensor pulse count (DTC code P0341)
JP31Z01170601039
1. Set the starter key to "OFF" and connect the signal check
harness.
GND +5V
2. Disconnect the connector of the engine auxiliary rotation
sensor.
3. Set the starter key to "ON" and measure the voltage between
the +5 V terminal of the engine auxiliary sensor connector (unit
harness side) and the GND terminal.
OK
1. Set the starter key to "OFF" and connect the connector of the
SIG engine auxiliary rotation sensor.
D19
2. Measure the resistance between terminal SIG of the engine
auxiliary rotation sensor connector (unit harness side) and
terminal D19 of the signal check harness.
NG Defective harness
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–19
D19 2. Measure the waveform between terminals D19 and D30 of the
D30
signal check harness.
OK
OK
[S5LQ0017E03] [0811CsCshWbYs]
17–20 ENGINE DIAGNOSIS CODE
Engine speed main and sub sensor circuit malfunction (DTC code P0335)
JP31199170601006
1. Inspection item
(1) Take actions of (DTC code P0335) and (DTC code P0340).
"Reference : Engine speed main sensor circuit malfunction (DTC code P0335), Engine ECU, Engine
diagnosis code"
"Reference : Engine speed sub sensor circuit malfunction (DTC code P0340), Engine ECU, Engine
diagnosis code"
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–21
1. Set the starter key to "OFF" and connect the signal check
D E harness.
E19
D34 2. Disconnect the ECU side connector of the signal check
harness and measure the resistance between terminal E19
and terminal D34.
OK
OK
[S5LQ0017E03] [0811CsCshWbYs]
17–22 ENGINE DIAGNOSIS CODE
OK
1. This failure code is displayed when the engine speed of 2,700 r/min or more is detected. While this
failure code is detected, fuel injection is stopped. When the engine speed is lower than 2,600 r/min., fuel
injection is resumed.
NOTICE • The objective of this failure code is not to detect overrun due to failure of this system, but
to memorize high revolution of the engine.
• Engine speed may be incorrectly recognized with noise on the speed sensor signal due to
harness failure or modification, resulting in detection of overrun.
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–23
1. Set the starter key to "OFF" and connect the signal check
D34 E27 harness.
OK
OK
[S5LQ0017E03] [0811CsCshWbYs]
17–24 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
harness.
GND +5V
2. Disconnect the connector of the boost pressure sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the boost pressure
sensor connector (at machine harness side).
OK
SAPH311991700031
OK
Harness failure
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–25
1. Set the starter key to "OFF" and connect the connector of the
D D27
boost pressure sensor.
2. Set the starter key to "ON" and measure the voltage between
terminal D27 and terminal D33 of the signal check harness.
D33
SAPH311991700032
OK
SAPH311991700033
OK
Harness failure
[S5LQ0017E03] [0811CsCshWbYs]
17–26 ENGINE DIAGNOSIS CODE
SAPH311991700034
OK
Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237).
1. Set the starter key to "OFF" and connect the signal check
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33 of the signal check
harness.
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–27
Excessive common rail pressure, supply pump excess forced feed (DTC
code P0088)
JP31199170601014
1. Set the starter key to "OFF" and connect the signal check
㧰 D20 harness.
D31 2. Start and warm-up the engine until the coolant temperature
D33 gauge moves.
OK
2. Check the fuel injection timing of the supply pump. If the timing
is not set 0° for the top dead center, set it correctly.
3. When there is no error after the check above, delete the past
failure using the PC diagnosis tool and start the engine.
If the same code is output again, possible failures are the
supply pump, common rail pressure sensor system and engine
ECU. Perform more detailed diagnosis with failure diagnosis
tool (HinoDX) using PC.
[S5LQ0017E03] [0811CsCshWbYs]
17–28 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33.
OK
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–29
1. Set the starter key to "OFF" and connect the signal check
D33 D D20
harness.
D31 2. Set the starter key to "ON" and measure the voltage between
terminals D20/D31 and terminal D33 of the signal check
harness.
OK
2. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the common rail
pressure sensor connector (at machine harness side).
OK
[S5LQ0017E03] [0811CsCshWbYs]
17–30 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
D
D20
D31 2. Measure the resistance between terminals D20/D31 of the
signal check harness and the SIG terminal of the common rail
pressure sensor connector (at machine harness side).
SIG
Standard value : 2 Ω or less
NG Harness failure
SAPH311991700041
OK
1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
SAPH311991700042
NG Harness failure
D33
SAPH311991700043
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–31
1. Set the starter key to "OFF" and connect the signal check
harness.
2. Set the starter key to "ON" and measure the voltage between
terminal A21 and terminal B20 of the signal check harness.
B20
A21 Standard value : 0.7 - 1.5V (idle status)
OK
Standard value
OK
Harness failure
[S5LQ0017E03] [0811CsCshWbYs]
17–32 ENGINE DIAGNOSIS CODE
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Abnormal value
: 0.3 V or less
: 4.85 V or more
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–33
1. Set the starter key to "OFF" and connect the signal check
㧭 㧮 harness.
A22
B21
2. Set the starter key to "ON" and measure the voltage between
terminal A22 and terminal B21 of the signal check harness.
OK
Engine revolution
Measuring item Voltage(V)
(r/min)
Low idle 1,000 Approx.1.4
High idle 2,100 Approx.3.5
SAPH311991700045
OK
Harness failure
[S5LQ0017E03] [0811CsCshWbYs]
17–34 ENGINE DIAGNOSIS CODE
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Abnormal value
: 0.3 V or less
: 4.85 V or more
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–35
1 Inspection item
[S5LQ0017E03] [0811CsCshWbYs]
17–36 ENGINE DIAGNOSIS CODE
OK
SAPH311991700047
OK
Harness failure
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–37
$
# NG [4] Go to measurement of voltage between terminals.
SAPH311991700048
OK
OK
Harness failure
[S5LQ0017E03] [0811CsCshWbYs]
17–38 ENGINE DIAGNOSIS CODE
1. After deleting the past failures with the failure diagnosis tool
(HinoDX) using PC, check again if the same code (DTC code
P2228, P2229) is output.
Standard : Normal
SAPH311991700034
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–39
1. Set the starter key to "OFF" and connect the signal check
harness.
OK
1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
SAPH311991700034
[S5LQ0017E03] [0811CsCshWbYs]
17–40 ENGINE DIAGNOSIS CODE
Standard value : ∞ Ω
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the ground line may
have occurred.)
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–41
Injector common 1 power source line short (DTC code P1212), Injector
common 2 power source line short (DTC code P1215)
JP31199170601022
1. Set the starter key to "OFF" and connect the signal check
D5 D D6 harness.
ECU case ground
(ECU mounting bolt)
2. Disconnect the ECU side connector of the signal check
harness and set the starter key to "ON".
E6 E E7
3. Measure the voltage between each terminal of the signal check
harness and the ECU case ground.
OK
1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
SAPH311991700034
[S5LQ0017E03] [0811CsCshWbYs]
17–42 ENGINE DIAGNOSIS CODE
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the power line may
have occurred.)
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–43
1. Set the starter key to "OFF" and connect the signal check
harness.
Terminal to
E1 Failure area
E2
DTC code measure
(injector)
E6 resistance
SAPH311991700053
P0201 #1 D2 ↔ D5
P0202 #2 E2 ↔ E6
P0203 #3 E1 ↔ E7
P0204 #4 D3 ↔ D6
OK
1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
SAPH311991700034
[S5LQ0017E03] [0811CsCshWbYs]
17–44 ENGINE DIAGNOSIS CODE
OK
Machine harness disconnection (Check the harness between the ECU and the injector clustered connector.)
SAPH311991700055
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–45
SAPH311991700056
OK
[S5LQ0017E03] [0811CsCshWbYs]
17–46 ENGINE DIAGNOSIS CODE
SAPH311991700034
Failure area
DTC code
(Flow damper)
P0263 #1
P0266 #2
P0269 #3
P0272 #4
SAPH311991700057
1. Remove the flow damper from the common rail and run air from
one side of the flow damper. Check if the damper is not blocked
by release of air to the opposite side.
SAPH311991700058
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–47
[S5LQ0017E03] [0811CsCshWbYs]
17–48 ENGINE DIAGNOSIS CODE
SAPH311991700059
OK
1. Set the starter key to "OFF", connect the signal check harness
and disconnect the ECU side connector.
OK
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–49
E4
E E8
E9
2. Measure voltage between terminal E4 and terminals E8/E9 of
the signal check harness.
Standard value : Pulse waveform at 24V ↔ 0V
SAPH311991700061
OK
! CAUTION • After turning "ON" the starter key, take measurements within 40 seconds.
[S5LQ0017E03] [0811CsCshWbYs]
17–50 ENGINE DIAGNOSIS CODE
Supply pump SCV sticking (DTC code P2635), Supply pump malfunction
(DTC code P2635), Supply pump abnormal pressure record (DTC code
P2635)
JP31199170601026
OK
2. When there is no error after the check above, delete the past
failure and operate the engine.
If the same code is output again, possible failures are the
supply pump and engine ECU. Perform more detailed
diagnosis with failure diagnosis tool (HinoDX) - Hino–DX
SAPH311991700062 [Inspection Menu], using PC.
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–51
1. Set the starter key to "OFF" and connect the signal check
C2
C1 C D1 D E4 E E5
harness.
OK
SAPH311991700064
OK
[S5LQ0017E03] [0811CsCshWbYs]
17–52 ENGINE DIAGNOSIS CODE
1 Inspection of QR code
1. Read the QR code data with the failure diagnosis tool (HinoDX)
using PC.
SAPH311991700034
OK
2. After deleting the past failure, check if the same code (DTC
code P0605, P0606, P0607) is output again.
Standard : Normal
SAPH311991700034
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
[S5LQ0017E03] [0811CsCshWbYs]
ENGINE DIAGNOSIS CODE 17–53
1 Check of ECU
2. After deleting the past failure, check if the same code (DTC
code P0611, P0200) is output again.
Standard : Normal
SAPH311991700034
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
[S5LQ0017E03] [0811CsCshWbYs]
17–54 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
A6
A5 A A7 harness.
Standard value : 0 V
NG Defective harness
SAPH311991700065
OK
1. Set the starter key to "OFF" and connect the signal check
B B14 C C4 harness.
Standard value
: 0 V (when starter key is at "OFF")
: 24 V (when starter key is at "START")
NG Harness failure
OK
[S5LQ0017E03] [0811CsCshWbYs]