HYDRAULIC EXCAVATOR

MAINTENANCE SPECIFICATIONS
SHOP SK330-8
MANUAL model SK350LC-8

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.

Book Code No.S5LC0011E02

0-1
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:

2) WARNING- Indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury and is represented as
follows:

0-2
SAFETY PRECAUTIONS
The proper and safe lubrication and maintenance
for this machine, recommended by Manufacturer,
are outlined in the OPERATOR’S MANUAL for the
machine.
Improper performance of lubrication or mainte-
nance procedures are dangerous and could result
in injury or death. Read and understand the MAN-
UAL before performing any lubrication or mainte-
nance.
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it
important to use caution when performing service work.
A knowledge of the system and or components is im-
portant before the removal or disassembly of any com-
ponent.
Because of the size of some of the machine compo-
nents, the serviceman or mechanic should check the
weights noted in this manual. Use proper lifting proce-
dures when removing any components. Weight of com-
ponents table is shown in the section ;
SPECIFICATIONS.
The following is a list of basic precautions that must al-
ways be observed.
(1) Read and understand all Warning plates and decal
on the machine before Operating, Maintaining or
Repairing this machine.
(2) Always wear protective glasses and protective
shoes when working around machines. In particu-
lar, wear protective glasses when using hammers,
punches or drifts on any part of the machine or at-
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the
welding job being performed. Do not wear loose fit-
ting or torn clothing. Remove all rings from fingers,
loose jewelry, confine long hair and loose clothing
before working on this machinery.
(3) Disconnect the battery and hang a "Do Not Oper-
ate" tag in the Operators Compartment. Remove ig-
nition keys.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine
so it does not roll while working on or under the ma-
chine. Hang a "Do Not Operate" tag in the Opera-
tors Compartment.
(5) Do not work on any machine that is supported only
by lift, jacks or a hoist. Always use blocks or jack
0-3
stands, capable of supporting the machine, before
performing any disassembly.
Do not operate this machine unless you have
read and understand the instructions in the OP-
ERATOR’S MANUAL. Improper machine opera-
tion is dangerous and could result in injury or
death.
(6) Relieve all pressure in air, oil or water systems be-
fore any lines, fittings or related items are discon-
nected or removed. Always make sure all raised
components are blocked correctly and be alert for
possible pressure when disconnecting any device
from a system that utilizes pressure.
(7) Lower the bucket, dozer, or other attachments to
the ground before performing any work on the ma-
chine. If this cannot be done, make sure the bucket,
dozer, ripper or other attachment is blocked correct-
ly to prevent it from dropping unexpectedly.
(8) Use steps and grab handles when mounting or dis-
mounting a machine. Clean any mud or debris from
steps, walkways or work platforms before using.
Always face to the machine when using steps, lad-
ders and walkways. When it is not possible to use
the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
ations.
(9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
sure all chains, hooks, slings, etc., are in good con-
dition and are the correct capacity. Be sure hooks
are positioned correctly. Lifting eyes are not to be
side loaded during a lifting operation.
(10)To avoid burns, be alert for hot parts on machines
which have just been stopped and hot fluids in
lines, tubes and compartments.
(11)Be careful when removing cover plates. Gradually
back off the last two capscrews or nuts located at
opposite ends of the cover or device and carefully
pry cover loose to relieve any spring or other pres-
sure, before removing the last two capscrews or
nuts completely.
(12)Be careful when removing filler caps, breathers and
plugs on the machine. Hold a rag over the cap or
plug to prevent being sprayed or splashed by liq-
uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
can be hot.
(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
 INDEX SK330-8/SK350LC-8
Book Code No. Index
Title
Distribution Year–Month No.

MAINTENANCE SPECIFICATIONS
S5YN0118E01
2006-7
OUTLINE 1
S5LC0211E01
2006-7
SPECIFICATIONS 2
S5LC0311E02
ATTACHMENT DIMENSIONS 3
2007-2
S5LC1111E01
TOOLS 11
2006-7
S5LC1211E01 STANDARD MAINTENANCE
2006-7
12
TIME SCHEDULE
S5LC1311E02 MAINTENANCE STANDARDS
2007-2
13
AND TEST PROCEDURES
S5LC2111E02 MECHATRO CONTROL
2007-2
21
SYSTEM
S5LC2211E02
2007-2
HYDRAULIC SYSTEM 22
S5LC2311E02

SYSTEM
2007-2
ELECTRICAL SYSTEM 23
S5LC2411E02
2007-2
COMPONENTS SYSTEM 24
S5LC2511E02
2007-2
AIR-CONDITIONER SYSTEM 25
_

S5YN3118E01 DISASSEMBLING
DISASSEMBLING

2006-7 & ASSEMBLING

31
S5LC3211E01
ATTACHMENTS 32
2006-7
S5LC3311E02
2007-2
UPPER STRUCTURE 33
S5LC3411E02
2007-2
TRAVEL SYSTEM 34
E / G TROUBLESHOOTING

S5YN4618E02
2007-2
BY ERROR CODES 46
S5LC4711E02
2007-2
BY TROUBLE 47
S5YN4818E01
2006-7
TROUBLE DIAGNOSIS MODE 48
_

S5LC5111E02
ENGINE 51
2007-2
_

LC10-07001~
YC10-03501~ APPLICABLE MACHINES

0-5
NOTE:
This Manual is prepared as a technical material in
which the information necessary for the maintenance
and repairing services of our hydraulic excavators are
collected, and is categorized into 7 Chapters, Specifica-
tion, Maintenance, System, Disassembly, Trouble-
shooting, Engine, and Installation Procedures for
Optional Attachment.
This Manual may be properly revised due to the im-
provement of products, modification of specifications,
etc. And there are cases where the system on actual
machine and a part of the contents of this manual may
differ due to the variations of specification by countries.
For the section in which the description is hardly under-
stood, contact our distributor.

• The 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
 1

1. OUTLINE
TABLE OF CONTENTS

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3

1.1.1 PREPARATION BEFORE DISASSEMBLING..........................................................1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-3
1.1.4 ELECTRICAL EQUIPMENT .....................................................................................1-4
1.1.5 HYDRAULIC PARTS ................................................................................................1-5
1.1.6 WELD REPAIR .........................................................................................................1-5
1.1.7 ENVIRONMENTAL ISSUES.....................................................................................1-5
1.2 INTERNATIONAL UNIT SYSTEM .....................................................................................1-6

Book Code No. S5YN0118E01

1-1
1. OUTLINE

Issue Date of Issue Applicable Machines Remarks

SK330-8 : LC10-07001~ S5YN0118E01
First edition July, 2006 K
SK350LC-8 : YC10-03501~ (ASIA, OCE)
SK200-8 : YN11-45001~ ↑
↑ August, 2006 K
SK210LC-8 : YQ11-06001~ (ASIA, OCE)
SK250-8: LQ12-06001~ ↑
↑ October, 2006 K
SK260LC–8 : LL12-05001~ (ASIA, OCE)
↑ December, 2006 SK850LC: LY01-00101~ ↑ K
E235BSR : YF05-02001~ ↑
↑ February, 2007 K
E235BSR(N)LC : YU05-02001~ (NHK)

1-2
 1. OUTLINE

1.1 GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and
begin a meeting before starting the work.
MAKING REPAIRS
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

prepare for accidents and fire.

(1) Knowledge of operating procedure
Read Operator’s Manual carefully to understand
the operating procedure.
(2) Cleaning machines
Clean machines of soil, mud, and dust before
carrying into the service shop.
Carrying a soiled machine into the service shop,
causes making less efficient work and damage of
parts.
(3) Inspecting machines
Confirm the disassembling section before starting
work, determine the disassembly procedure taking
the conditions in work shop into account, and
request to procure necessary parts in advance.
(4) Recording
Record the following items to keep contact and
prevent malfunction from recurring.
1) Inspecting date, place
2) Model name, Serial number and Record on
hour meter
3) Trouble condition, place, cause
5) Choose a hard, lever and safe place, and put
attachment on the ground without fail.
6) Use hoist, etc. to remove parts of heavy weight
(23kg [50 lb] or more).
7) Use proper tools, and change or repair
defective tools.
8) Machine and attachment required to work in the
lifting condition should be supported with
supports or blocks securely.
1.1.3 DISASSEMBLING AND ASSEMBLING
HYDRAULIC EQUIPMENT
(1) Removing hydraulic equipment assy
1) Before removing pipes, release the pressure of
hydraulic oil tank, or open the cover on the
return side to tank, and take out the filter.
2) Drain the oil in the removed pipes into pan to
prevent the oil from spilling on the ground.

4) Visible oil leak, water leak and damage
5) Clogging of filters, oil level, oil quality, oil
contamination and looseness.
6) Examine the problems on the basis of monthly
operation rate with the last inspection date and
records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Tools required for repair work.
2) Prepare the places to put the disassembled
parts.
3) Prepare oil pans for leaking oil, etc.
1.1.2 SAFETY WHEN DISASSEMBLING AND
ASSEMBLING
WARNING
(1) Safety
1) Wear appropriate clothing, safety shoes, safety
helmet, goggles, and clothes with long sleeves.
3) Pipes with plugs or caps to prevent oil leaking,
entry of dust, etc.
4) Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
and gear oil before putting them on working
bench.
1) Since performance and function of hydraulic
equipment after disassembly and assembly
results in immunity from responsibility on the
manufacture’s side, disassembly, assembly
and modification without permission are strictly
prohibited.
2) If it is unavoidably necessary to disassemble
and modify, it should be carried out by experts
or personnel qualified through service training.
3) Make match mark on parts for reassembling.
4) Before disassembling, read Disassembling
Instruction in advance, and determine if the
disassembly and assembly are permitted or
not.

1-3
1. OUTLINE
5) For parts which are required to use jig and
tools, don’t fail to use the specified jig and tools.
6) For parts which can not be removed in the
specified procedure, never force removal. First
check for the cause.
7) The removed parts should be put in order and
tagged so as to install on proper places without
confusion.
8) For common parts, pay attention to the quantity
and places.
(3) Inspecting parts
1) Check that the disassembled parts are free
from adherence, interference and uneven
working face.
2) Measure the wear of parts and clearance, and
record the measured values.
3) If an abnormality is detected, repair or replace
the parts.
(4) Reassembling hydraulic equipment
1) During the parts cleaning, ventilate the room.
2) Before assembly, clean parts roughly first, and
then completely.
3) Remove adhering oil by compressed air, and
apply hydraulic oil or gear oil, and then
assemble them.
4) Replace the removed O-ring, back-up rings and
oil seal with new ones, and apply grease oil on
them before assembling.
5) Removes dirt and water on the surface on
which liquid sealant are applied, decrease
them, and apply liquid sealant on them.
6) Before assembling, remove rust preventives on
new parts.
7) Use special tools to fit bearings, bushing and oil
seal.
8) Assemble parts matching to the marks.
9) After completion, check that there is no
omission of parts.
(5) Installing hydraulic equipment
1) Confirm hydraulic oil and lubrication oil.
2) Air release is required in the following cases ;
1. Change of hydraulic oil
2. Replacement of parts on suction pipe side
3. Removing and attaching hydraulic pump
4. Removing and attaching swing motor
5. Removing and attaching travel motor
6. Removing and attaching hydraulic cylinder
1-4
If hydraulic oil and lubricating oil are not
filled and also air bleed is not performed,
the hydraulic equipment may be damaged.
3) For air bleed of hydraulic pump and swing
motor, loosen drain plug on the upper part, start
engine, and run in low idling, then bleed air until
hydraulic oil is comes out. After completion of
comes, tighten plug securely.
4) For air bleed of travel motor and hydraulic
cylinder, starts engine and operate it for 10
minutes or more at no-load and low speed.
For cylinder, don’t move it to the stroke end
at beginning.
5) Air in pilot circuit can be bleed out by only
operating digging, swing and traveling motions
thoroughly.
6) Check hydraulic oil level.
Move attachments to hydraulic oil check
position, and check hydraulic oil level of tank.
Refill oil if the oil level is lower than the specified
level.
How to check oil level of hydraulic oil tank



 
LEVEL GAUGE
Oil level of hydraulic oil tank.
If the indicator is within
level marks, the oil quantity
is acceptable.
1.1.4 ELECTRICAL EQUIPMENT
(1) The disassembly of electrical equipment is not
allowed.
(2) Handle equipment with care so as not to drop it or
bump it.
(3) Connector should be removed by unlocking while
holding the connector.
Never stress in tension to the caulked section by
pulling wire.
(4) Check that connector is connected and locked
completely.
(5) Engine key off before removing and connecting
connector.

(6) Engine key off before touching terminals of starter
and alternator.
(7) Remove battery grounding terminal before
beginning work close to battery and battery relay
with tools.
(8) Wash machine with care so as not to splash water
on electrical equipment and connector.
(9) When water has entered in the waterproofed
connector, the removing of water is not easy. So
check the removed waterproofed connector with
care to protect it from entry of water. If moisture
adheres on it, dry it completely before connecting.
Battery fluid is dangerous.
The battery fluid is dilute sulfuric acid, and causes
scald and loss of eyesight by adhering on eyes,
skin and clothes. When the fluid has adhered on
them, take an emergency measure immediately and
see a doctor for medical advice.
• When it has adhered on skin ;
Wash with soap and water.
• When it has got in eyes ;
Wash in water for 10 minutes or more
immediately.
• When it has spilled out in large quantity ;
Use sodium bicarbonate to neutralize, or wash
away with water.
• When it was swallowed ;
Drink milk or water.
• When it has adhered on clothes ;
Wash it immediately.
1.1.5 HYDRAULIC PARTS
(1) O-ring
• Check that O-ring is free from flaw and has
elasticity before fitting.
• Even if the size of O-ring is equal, the usage
differs, for example in dynamic and static
sections, the rubber hardness also differs
according to the pressure force, and also the
quality differs depending on the materials to be
seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and
bend.
• Floating seal should be put in pairs.
1-5
1. OUTLINE
(2) Flexible hose (F hose)
• Even if the connector and length of hose are the
same, the parts differ according to the
withstanding pressure. Use proper parts.
• Tighten it to the specified torque, and check that
it is free from twist, over tension, interference,
and oil leak.
1.1.6 WELD REPAIR
(1) The weld repair should be carried out by qualified
personnel in the specified procedure after
disconnecting the grounding cable of battery. If the
grounding cable is not disconnected, the electrical
equipment may be damaged.
(2) Remove parts which may cause fire due to the
entry of spark beforehand.
(3) Repair attachments which are damaged, giving
particular attention to the plated section of piston
rod to protect it from sparks, and don’t fail to cover
the section with flame-proof clothes.
1.1.7 ENVIRONMENTAL ISSUES
(1) Engine should be started and operated in the place
where air can be sufficiently ventilated.
(2) Waste disposal
The following parts follows the regulation.
Waste oil, waste container and battery
(3) Precautions for handling hydraulic oil
Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
• When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
• When it was swallowed ;
Don’t force him to vomit it, but immediately
receive medical treatment.
• When it has adhered on skin ;
Wash with soap and water.
(4) Others
For spare parts, grease and oil, use KOBELCO
genuine ones.
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 µ 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
 1. OUTLINE

(6) Unit Conversion Table

QUANTITIES JIS SI REMARKS

Mass kg kg
Force kgf N 1kgf=9.807N
Torque kgf•m N•m 1kgf•m=9.807N•m
Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa
Motive power PS kW 1PS=0.7355kW
Revolution r.p.m min –1 1r.p.m=1min–1

1-7
1. OUTLINE

[MEMO]

1-8
 2

2. SPECIFICATIONS
TABLE OF CONTENTS

2.1 NAME OF COMPONENTS................................................................................................2-3

2.2 GENERAL DIMENSIONS ..................................................................................................2-4
2.2.1 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+3.30m (10ft-10in) Standard Arm+1.40m3 (1.83cu•yd) Bucket] ..........2-4

2.2.2 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+2.60m (8ft-6in) Short Arm+1.60m3 (2.09cu•yd) Bucket] .................2-5

2.2.3 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+4.15m (13ft-7in) Long Arm+1.20m3 (1.57cu•yd) Bucket] ................2-5
2.3 WEIGHT OF COMPONENTS............................................................................................2-6
2.4 TRANSPOTATION ............................................................................................................2-8
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................................2-8
2.4.2 DIMENSIONS OF ATTACHMENT ...........................................................................2-9
2.5 SPECIFICATIONS AND PERFORMANCE .......................................................................2-11
2.5.1 SPEED AND CLIMBING CAPABILITY.....................................................................2-11
2.5.2 ENGINE ....................................................................................................................2-11
2.5.3 HYDRAULIC COMPONENTS ..................................................................................2-11
2.5.4 WEIGHT ...................................................................................................................2-11
2.6 TYPE OF CRAWLER.........................................................................................................2-12
2.6.1 SK330-8....................................................................................................................2-12
2.6.2 SK350LC-8 ...............................................................................................................2-12
2.7 TYPE OF BUCKET ............................................................................................................2-13
2.8 COMBINATIONS OF ATTACHMENT................................................................................2-14
2.9 ENGINE SPECIFICATIONS ..............................................................................................2-15
2.9.1 SPECIFICATIONS....................................................................................................2-15
2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-TM) ..........................................2-16

Book Code No. S5LC0211E01

2-1
2. SPECIFICATIONS

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC0211E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)

2-2
 2. SPECIFICATIONS

2.1 NAME OF COMPONENTS

ARM
ARM CYLINDER

BOOM

BOOM CYLINDER
BUCKET
CYLINDER
CAB

SLEWING BEARING

IDLER LINK
SLEWING MOTOR

FUEL TANK

CONTROL VALVE
BUCKET LINK
HYDRAULIC TANK

HYDRAULIC
PUMP

BUCKET GUARD
MONITOR PANEL

SHOE

FRONT IDLER

IDLER ADJUST

UPPER ROLLER ENGINE

AIR CLEANER
COUNTER WEIGHT

LOWER ROLLER
RADIATOR AND OIL COOLER
BATTERY
TRAVEL MOTOR

2-3
2. SPECIFICATIONS

2.2 GENERAL DIMENSIONS

2.2.1 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+3.30m (10ft-10in) Standard Arm+1.40m3 (1.83cu•yd)
Bucket]

1500(4'11") 1450(4'9")

2950(9'8")
50(2")

R35
00(1
1'6"
)

11200(36'9")
3500(11'6")
3420(11'3")

3160(10'4")
1190*
(3'11")

(19.7")
500*
Q'TY OF LOWER ROLLER:7SETS[9SETS]
4650 (15'3") [4980(16'4")] (23.6") 600 3200(10'6")
5830 (19'2") [5990(19'8")]

Dimensions marked * do not include the height of the shoe lug.

[ ] include LC specifications.

2-4
 2. SPECIFICATIONS

2.2.2 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+2.60m (8ft-6in) Short Arm+1.60m3 (2.09cu•yd)

Bucket]

11280(37')
4750(15'7")
3500(11'6")
3640(11'11")

1190*
(3'11")
Q'TY OF LOWER ROLLER:7SETS[9SETS] 4650(15'3") [4980(16'4"))

5830(19'2") [5990(19'8")]

2.2.3 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+4.15m (13ft-7in) Long Arm+1.20m3 (1.57cu•yd)

Bucket]
11230(36'10")

4750(15'7")

3500(11'6")
3590(11'9")

1190*
(3'11")

Q'TY OF LOWER ROLLER:7SETS[9SETS]

4650(15'3") [4980(16'4"))
5830(19'2") [5990(19'8")]

Dimensions marked * do not include the height of the shoe lug.

[ ] include LC specifications.

2-5
2. SPECIFICATIONS

2.3 WEIGHT OF COMPONENTS

Unit ; kg (lb)
Model
SK330 - 8 SK350LC - 8
Item
Machine complete 33,800 (74,500) 34,600 (76,300)
1. Upper frame assy (Assembly of following :) 15,800 (34,840) ←
1.1 Upper frame 2,950 (6,500) ←
1.2 Counter weight
Counter weight (Semi-weighted) 8,130 (17,920) ←
Counter weight (weighted) 9,700 (21,380) ←
1.3 Cab 235 (520) ←
1.4 Engine *699 (1,540) ←
1.5 Hydraulic oil tank *189 (420) ←
1.6 Fuel tank *199 (440) ←
1.7 Slewing motor (including reduction unit) *456 (1,000) ←
1.8 Control valve *231 (510) ←
1.9 Boom cylinder *266 (590) × 2 ←
1.10 Pin (for mounting boom) 83 (180) ←
1.11 Pump *155 (340) ←
1.12 Radiator (including intercooler) *206 (450) ←
2. Lower frame assy (Assembly of following :) 11,300 (24,900) 12,000 (26,460)
2.1 Lower frame 4,070 (8,970) 4,300 (9,480)
2.2 Slewing bearing 545 (1,200) ←
2.3 Travel motor (including reduction unit) 397 (880) × 2 ←
2.4 Upper roller 40 (90) × 2 ←
2.5 Lower roller 57 (125) × 14 57 (125) × 18
2.6 Front idler 176 (390) × 2 ←
2.7 Idler adjuster 186 (410) × 2 ←
2.8 Sprocket 75 (165) × 2 ←
2.9 Swivel joint *24 (50) ←
2.10 Track guide 39 (86) × 2 39 (86) × 6
2.11 Track link with 600mm (23.6in) shoes assy 1,870 (4,120) × 2 2,000 (4,410) × 2
Track link with 800mm (31.5in) shoes assy 2,450 (5,400) × 2 2,610 (5,760) × 2
2.11.1 Track link assy 840 (1,850) × 2 900 (1,980) × 2
3. Attachment (Assembly of following / STD :) 6,590 (14,530) ←
{6.50m (21ft-4in) Boom + 3.30m (10ft-10in) Arm + 1.40m (1.83cu•yd)
3

Bucket}
3.1 Bucket assy (STD) 1,080 (2,380) ←
3.2 STD Arm assy (Assembly of following :) 1,900 (4,190) ←
3.2.1 STD Arm 1,250 (2,760) ←
3.2.2 Bucket cylinder *266 (590) ←
3.2.3 Idler link 33 (73) × 2 ←
3.2.4 Bucket link 142 (313) ←
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket) 102 (225) ←
3.3 Boom assy (Assembly of following :) 3,610 (7,960) ←
3.3.1 Boom 2,670 (5,890) ←
3.3.2 Arm cylinder *539 (1,190) ←
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 75 (165) ←

2-6
 2. SPECIFICATIONS

Unit ; kg (lb)
Model
SK330 - 8 SK350LC - 8
Item
4. Lubricant and water (Assembly of following :) 862 (1,900) ←
4.1 Hydraulic oil 310 (684) ←
4.2 Engine oil 28 (62) ←
4.3 Fuel 484 (1,070) ←
4.4 Water 44 (97) ←

Marks * show dry weight.

2-7
2. SPECIFICATIONS

2.4 TRANSPOTATION
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER
(1) 6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm+1.40m3 (1.83cu•yd) Bucket

Model
SK330-8 SK350LC-8
Item
Width 600mm (23.6in) shoes 3,200 (10ft-6in) 3,200 (10ft-6in)
Weight 33,800kg (74,500 lbs) 34,200kg (75,400 lbs)

6")
.7(4.
116

(16.5")
420.1

SECTION AA

11218(36'10") 1800(5'11")

219.5(8.6")

4179(13'9")
660 1020(3'4")
100
(4")

(26")
528
(21")

2-8
 2. SPECIFICATIONS

2.4.2 DIMENSIONS OF ATTACHMENT

(1) BOOM

Type
6.50m (21ft-4in) Boom
Item
Length×Height×Width 6.75 × 1.84 × 0.83
m (ft-in)
L×H×W (22'2"× 6'0"× 2'9")
Weight kg (lbs) 3,290 (7,250)

H
L

(2) ARM AND BUCKET

Type 2.6m (8ft-6in) Arm + 3.30m (10ft-10in) Arm + 4.15m (13ft-7in) Arm +
1.6m 3(2.09cu•yd) Bucket 1.40m 3 (1.83cu•yd) Bucket 1.20m 3 (1.57cu•yd) Bucket
Item
Length×Height×Width 5.41 × 1.13 × 1.57 6.07 × 1.12 ×1.42 6.94 × 1.10 × 1.24
m (ft-in)
L×H×W (17'9"×3'8"×5'2") (19'11"×3'8"×4'8") (22'9"×3'7"×4'1")
Weight kg (lbs) 2,870 (6,330) 2,960 (6,530) —
H

(3) Arm

Type
2.6 m (8ft-6in) Arm 3.30 m (10ft-10in) Arm 4.15 m (13ft-7in) Arm
Item
Length×Height×Width 3.82 × 1.09 × 0.62 4.48 × 0.97 × 0.62 5.35 × 0.99 × 0.63
m (ft-in)
L×H×W (12'6"×3'7"×2'2") (14'8"×3'2"×2'2") (17'7"×3'3"×2'1")
Weight kg (lbs) 1,660 (3,660) 1,830 (4,040) —
H

2-9
2. SPECIFICATIONS

(4) Bucket

Type Hoe bucket

Length×Height×Width 1.64 × 1.46× 1.24 1.62 × 1.47× 1.42 1.62 × 1.42× 1.57 1.67 × 1.46× 1.68
m (ft-in)
L×H×W (5'5"×4'9"×4'1") (5'4"×4'10"×4'8") (5'4"×4'8"×5'2") (5'6"×4'9"×5'6")
Weight kg (lbs) 930 (2,050) 1070 (2,360) 1140 (2,510) 1170 (2,580)
m3
Bucket capacity 1.2 (1.57) 1.40 (1.83) STD 1.60 (2.09) 1.80 (2.35)
(cu•yd)

HOE BUCKET

L H

2-10
 2. SPECIFICATIONS

2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY

Area & Model

SK330-8 SK350LC-8
Item
Swing speed min-1 {rpm} 10.0 {10.0}
Travel speed (1-speed/2-
km/h (mile/h) 3.3 / 5.6 (2.05 / 3.5)
speed)
Gradeability % (degree) 70 (35)

2.5.2 ENGINE

Engine model HINO J08E-TM

Water-cooled, 4-cycle direct injection type engine
Type
with inter cooler turbo charger
6 -ø112 mm × 130 mm
Number of cylinders—Bore×Stroke
(4.41 in × 5.12 in)
Total displacement 7.684 L (468.9 cu•in)
Rated output / Engine speed 197 kW (268 PS) / 2,100 min-1
Maximum torque / Engine speed 998 N•m (736 lbf•ft)/ 1,600 min-1
Starter 24 V / 5.0kW
Alternator 24 V / 60A

2.5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

Hydraulic motor (swing) Axial piston motor × 1
Variable displacement axial piston motor × 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve × 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type

2.5.4 WEIGHT

Unit : kg (lbs)
SK330-8 SK350LC-8
Fully equipped weight 33,800 (74,500) 34,600 (76,300)
Upper structure 15,800 (34,840) ←
Lower machinery 11,300 (24,900) 12,000 (26,460)
Attachment
6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm 6,590 (14,530) ←
+1.40m3 (1.83cu•yd) Bucket

2-11
2. SPECIFICATIONS

2.6 TYPE OF CRAWLER

2.6.1 SK330-8

Overall width of crawler Ground pressure kPa

Shape Shoe width mm (in)
mm (ft-in) (psi)
Grouser shoe
600 (23.6) 3,200 (10'6") 68 (9.86)

800 (31.5) 3,400 (11'2") 53 (7.69)

45 LINKS

2.6.2 SK350LC-8

Overall width of crawler Ground pressure kPa

Shape Shoe width mm (in)
mm (ft-in) (psi)
Grouser shoe
600 (23.6) 3,200 (10'6") 64 (9.28)

800 (31.5) 3,400 (11'2") 50 (7.25)

48 LINKS

Use 600mm (23.6in) grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate
with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)

2-12
 2. SPECIFICATIONS

2.7 TYPE OF BUCKET

Heaped Outer width mm (ft-in) Availability
Struck Number W or W/O Weight
Hoe bucket capacity With side Without side of face
m3(cu•yd) of tooth side cutter kg (lbs)
m3(cu•yd) cutter cutter shovel
0.84 930
1.20 (1.57) 1,240 (4'1") 1,110 (3'8") 4 W YES
(1.10) (2,050)
1.40 (1.83) 1.00 1,070
1,420 (4'8") 1,300 (4'3") 5 W YES
STD (1.31) (2,360)
1.20 1,140
1.60 (2.09) 1,565 (5'2") 1,450 (4'9") 5 W YES
(1.57) (2,510)
1.40 1,170
1.80 (2.35) — 1,670 (5'6") 5 W/O YES
(1.83) (2,580)

2-13
2. SPECIFICATIONS

2.8 COMBINATIONS OF ATTACHMENT

Bucket Available Arm
Heaped capacity Struck 3.3m (10ft-10in) Arm 4.15m (13ft-7in) 2.6m (8ft-6in) Arm
Type
m3 (cu•yd) m3 (cu•yd) (STD) Arm (Long) +Arm (Short)
1.20 (1.57) 0.84 (1.10)
1.40 (1.83) STD 1.00 (1.31)
Hoe bucket
1.60 (2.09) 1.02 (1.57)
1.80 (2.35) 1.40 (1.83)
Breaker — —
Nibbler — —

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.

• Use the attachments recommended by KOBELCO.

The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our
responsibility

If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.

2-14
 2. SPECIFICATIONS

2.9 ENGINE SPECIFICATIONS

2.9.1 SPECIFICATIONS

Applicable machine SK330-8, SK350LC-8

Engine model HINO J08E-TM
Water-cooled, 4 cycle 6 cylinder direct injection type
Type
diesel engine with intercooler turbo-charger
Number of cylinder×Bore×Stroke mm (in) 6 × 112 × 130 (4.41 × 5.12)
Total displacement cc (cu•in) 7,684 (469)
Compression ratio 18.0
Rated output kW (PS) at min -1
197 (268) at 2,100
N•m (lb•ft) at
Maximum torque 998 (736) at 1,600
min-1
High idling min-1 2,310 ± 30
Low idling min -1
1,000 ± 30
Injection starting pressure MPa (psi) 3.2 (464)
Start/Full open
Thermostat action 350 (170) / 363 (194)
K (°F)
Firing order 1-4-2-6-3-5
Compression pressure MPa (psi)at min -1 3.4~3.7 (493~537) at 280
Fuel injection timing 0° before top dead point
Valve clearance Open Close
14° before top 30° after bottom
Intake valve 0.3 mm at cool
Valve clearance dead point dead point
54° before bottom 13° after top dead
Exhaust valve 0.45 mm at cool
dead point point
Starter capacity V × kW 24 × 5.0
Generator capacity (Alternator) V×A 24 × 60
ø850 (33.5") × suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.80
Full level 26.0 (6.87)
Engine oil quantity L (gal) Low level 20.0 (5.28)
Total 28.5 (7.53)
Dry weight kg (lbs) 680 (1,500)
Fuel consumption ratio g/kW•h (g/ps•h) 225 (165)
Allowable inclination
Front / Rear and Right / Left : 35°
(Limited by E/G lubrication)
Dimension (L×W×H) {without fan} mm (in) 1,294 × 868 × 987 (4ft-2.95in × 34.2in × 38.9in)
Rotating direction Counterclockwise seeing from flywheel side

2-15
2. SPECIFICATIONS

2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-TM)

Condition to be measured: The net value is indicated, measuring it without cooling fan.
marks show the rated point

SHAFT TORQUE
SHAFT OUTPUT

FUEL CONSUMPTION RATE

ENGINE SPEED (min-1)

Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
225g/kW.h
X 209kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
56.3
Fuel consumption in regular operation
(load factor 0.70~0.80)
39.4 L/h~45.1 L/h

2-16
 3
3. ATTACHMENT DIMENSION
TABLE OF CONTENTS

3.1 BOOM ................................................................................................................................3-3

3.1.1 BOOM DIMENSIONAL DRAWING...........................................................................3-3
3.1.2 BOOM MAINTENANCE STANDARD.......................................................................3-4
3.2 ARM ...................................................................................................................................3-7
3.2.1 ARM DIMENSIONAL DRAWING..............................................................................3-7
3.2.2 ARM MAINTENANCE STANDARD ..........................................................................3-8
3.3 BUCKET ............................................................................................................................3-12
3.3.1 BUCKET DIMENSIONAL DRAWING .......................................................................3-12
3.3.2 BUCKET DIMENSIONAL TABLE .............................................................................3-12
3.3.3 LUG SECTION DIMENSIONAL DRAWING .............................................................3-13
3.3.4 BOSS SECTION DIMENSIONAL DRAWING...........................................................3-14

Book Code No. S5LC0311E02

3-1
3. ATTACHMENT DIMENSION

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC0311E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC0311E02
Revision February, 2007 ↑ K
(ASIA, OCE)

3-2
 3. ATTACHMENT DIMENSION

3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING

d4
J

I
d3 K
d1

D C
H G B

E
F
K

A
J

d2

SECTION K-K

Fig. 3-1 Boom dimensional drawing

Unit : mm (ft-in)
STD
6.50M (21ft-4in) BOOM
LC02B00164F1
No NAME DIMENSION
A Boom length 6,500 (21'4")
B Boom foot width 826 (32.5")
C Boom end inner width 405.8 (16.0")
D Boom end outer width 577 (22.7")
E Height of boom cylinder rod pin 1,115 (3'8")
F Height of arm cylinder (head side) pin 1,460.8 (4'9.5")
G Distance between pins of boss R2,955 (9'8")
H Distance between pins of bracket R3,390.5 (11'1.5")
I Arm cylinder (head side) inner width 146 (5.75")
J Outer width of bracket on the boom cylinder (rod side) mounting 564 (22.2")
d1 Boom foot pin dia. ø 125 (4.92")
d2 Boom cylinder (rod side) pin dia. ø 110 (4.33")
d3 Pin dia. of boom end. ø 110 (4.33")
d4 Arm cylinder (head side) pin dia. ø 110 (4.33")

3-3
3. ATTACHMENT DIMENSION

3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section ASIA, OCEANIA

A
C

Fig. 3-2 Clearance of pin and bushing on boom section

ASIA 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
+ 0.020 + 0.226 + 0.246
ø 110 (+0.0008) (+0.0089) (+0.0097)
A Boom foot LC02B01373P1
(4.331) - 0.020 + 0.098 + 0.078
(-0.0008) (+0.0039) (+0.0031)
+ 0.222 + 0.262
0
Boom cylinder ø 100 - 0.040
(+0.087) (0.0103)
B LC02B01344P1
(Head side) (3.937) + 0.105 + 0.0105 More
(-0.0016) Replace
(+0.0041) (+0.0041) than 3.0
bushing
+ 0.020 + 0.230 + 0.250 2.5 (0.12)
or pin
Boom cylinder (+0.0008) (+0.0091) (+0.0098) (0.10)
C LC02B01345P1
(Rod side) - 0.020 + 0.105 + 0.085
ø 110 (-0.0008) (+0.0041) (+0.0033)
(4.331) + 0.030 + 0.250 + 0.280
Arm cylinder (+0.0012) (+0.0098) (+0.0110)
D LC02B01444P1
(Head side) - 0.030 + 0.050 + 0.020
(-0.0012) (+0.0020) (+0.0008)

3-4
 3. ATTACHMENT DIMENSION

OCEANIA 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
+ 0.020 + 0.226 + 0.246
ø 110 (+0.0008) (+0.0089) (+0.0097)
A Boom foot LC02B01373P1
(4.331) - 0.020 + 0.098 + 0.078
(-0.0008) (+0.0039) (+0.0031)
+ 0.222 + 0.262
0
Boom cylinder ø 100 - 0.040
(+0.087) (0.0103)
B LC02B01344P1
(Head side) (3.937) + 0.105 + 0.0105 More
(-0.0016) Replace
(+0.0041) (+0.0041) than 3.0
bushing
+ 0.230 + 0.250 2.5 (0.12)
or pin
Boom cylinder (+0.0091) (+0.0098) (0.10)
C LC02B01345P1
(Rod side) + 0.020 + 0.105 + 0.085
ø 110 (+0.0008) (+0.0041) (+0.0033)
(4.331) - 0.020 + 0.226 + 0.246
Arm cylinder (-0.0008) (+0.0089) (+0.0097)
D LC02B01337P1
(Head side) + 0.098 + 0.078
(+0.0039) (+0.00031)

3-5
3. ATTACHMENT DIMENSION

(2) Clearance in thrust direction on the boom cylinder installation section

D
D C

A
L3 L3' X3

B A

PL3
X1 L1
SECTION C-C
X4

L4 PL4
PL2 PL2

PL1

SECTION D-D SECTION A-A

X2 L2 L2 X2

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
826
Boom
(32.5) 0.5 (0.02) 1.0 1.5 1,026
A-A Boom foot L1 PL1
832 or less (0.04) (0.06) (3'4.4")
Upper frame
(32.8)
130
Boom cylinder
Boom cylinder (5.12) 0.6~1.0 2.0 2.5 286
B-B L2 PL2
(Head side) 136 (0.02~0.04) (0.08) (0.10) (11.26)
Upper frame Shim
(5.35)
adjust
130
Boom cylinder L3 ment
Boom cylinder (5.12) 0.6~2.0 3.0 4.0 877
C-C PL3
(Rod side) 564 (0.02~0.08) (0.12) (0.16) (34.5)
Boom L3'
(22.2)
140
Arm cylinder
Arm cylinder (5.51) 0.6~1.0 2.0 2.5 309
D-D L4 PL4
(Head side) 146 (0.02~0.04) (0.08) (0.10) (12.2)
Boom
(5.75)

3-6
 3. ATTACHMENT DIMENSION

3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING

VIEW J

SECTION X-X

SECTION Y-Y SECTION Z-Z

Fig. 3-4 ARM DIMENSIONAL DRAWING

3.30m (10ft-10in) LC12B00457F1 (ASIA)

ARM LC12B00383F1 (OCE) Unit : mm (ft-in)
Code NAME DIMENSION Code NAME DIMENSION
C Arm length 3,300 (10'10") N Bracket inner width 146 (5.75")
Distance between pins of boss
D R1,010 (3'4") O Bracket inner width 136 (5.35")
and bracket
D1 I.D of boss ø120 (4.72") P Idler link dimension 696 (27.4")
D2 I.D of boss ø95 (3.74") Q Bucket link dimension 686 (27.0")
Height between pins of boss and
D4 I.D of boss ø125 (4.92") R 44 (1.73")
center
Distance between pins of boss
E R2,429.5 (7'12") d1 Pin dia. ø90 (3.54")
and bracket
Distance between pins of boss
F R515 (20.3") d2 Pin dia. ø80 (3.15")
and boss
Height between pins of boss and
G 735.5 (29.0") d3 Pin dia. ø110 (4.38")
bracket
Height between pins of boss and
H 280 (11.0") d4 Pin dia. ø110 (4.33")
bracket
K Arm top end boss width 368 (14.5") d5 Pin dia. ø90 (3.54")
L Arm link section boss width 390 (15.4")
M Boss width 400 (15.75")

3-7
3. ATTACHMENT DIMENSION

3.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing ASIA, OCEANIA

E F
D, D'
B

C
G

Fig. 3-5 Clearance of pin and bushing on arm section

ASIA 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
+0.272 +0.332
(+0.0107) (+0.0131)
A Arm point
–0.020 +0.095 +0.115
ø90 (-0.0008) (+0.0037) (+0.0045)
LC12B01783P1
(3.5433) –0.060 +0.298 +0.358
Bucket link (-0.0024) (+0.0117) (+0.0141)
B
(Bucket side) +0.168 +0.188
(+0.0066) (+0.0074)
0 +0.229 +0.269
Idler link
ø80 (0) (+0.0090) (+0.0106)
C (Connected part LC12B01784P1
(3.1496) –0.040 +0.158 +0.158
of arm) (+0.0062) (+0.0062)
(-0.0016)
+0.299 +0.359
Bucket link (+0.0118) (+0.0141) Replace
D 2.5 3.0
(Idler link side) 0 +0.170 +0.170 bushing
(0.10) (0.01)
(0) (+0.0067) (+0.0067) or pin
LC12B01789P1
ø90 –0.060 +0.310
Bucket cylinder (3.5433) (-0.0024) (+0.0122)
D'
(Rod side) +0.250 +0.050
(+0.0098) (+0.0020)
Bucket cylinder +0.030 +0.050 +0.280
E LC12B01790P1
(Head side) (+0.0012) (+0.002) (+0.0110)
Arm cylinder –0.030 +0.020
F LC02B01444P1 (+0.0008)
(Rod side) (-0.0012)
ø110 +0.020 +0.288 +0.308
Arm foot
(4.331) (+0.0008) (+0.0113) (+0.0121)
G (Connected part LC12B01468P1
–0.020 +0.190 +0.170
of boom)
(-0.0008) (+0.0075) (+0.0067)

3-8
 3. ATTACHMENT DIMENSION

OCEANIA 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
+0.272 +0.332
(+0.0107) (+0.0131)
A Arm point
–0.020 +0.095 +0.115
ø90 (-0.0008) (+0.0037) (+0.0045)
LC12B01657P2
(3.5433) –0.060 +0.217 +0.277
Bucket link (-0.0024) (+0.0085) (+0.0109)
B
(Bucket side) +0.071 +0.091
(+0.0028) (+0.0036)
+0.222 +0.262
Idler link
ø80 (+0.0087) (+0.0103)
C (Connected part LC12B01613P1
(3.1496) +0.079 +0.079
of arm) (+0.0031) (+0.0031)
0 +0.219 +0.259
Bucket link (0) (+0.0086) (+0.0102)
D
(Idler link side) –0.040 +0.034 +0.034
Replace
(-0.0016) (+0.0013) (+0.0013) 2.5 3.0
LC12B01614P1 bushing
+0.235 +0.275 (0.10) (0.01)
or pin
Bucket cylinder ø90 (+0.0093) (+0.0108)
D'
(Rod side) (3.5433) +0.074 +0.074
(+0.0029) (+0.0029)
+0.238 +0.258
Bucket cylinder (+0.0094) (+0.0102)
E LC12B01461P1
(Head side) +0.077 +0.057
(+0.0030) (+0.0022)
+0.020 +0.226 +0.246
Arm cylinder (+0.0008) (+0.0089) (+0.0097)
F LC02B01337P1
(Rod side) –0.020 +0.098 +0.078
ø110 (-0.0008) (+0.0039) (+0.0031)
(4.331) +0.200 +0.220
Arm foot
(+0.0079) (+0.0087)
G (Connected part LC12B01468P1
+0.099 +0.079
of boom)
(+0.0039) (+0.0031)

3-9
3. ATTACHMENT DIMENSION

(2) Clearance of arm and cylinder installing sections in thrust direction

E
D, D'
B
F
E
B C
D, D' F
A A

C G
G
L3
L1 X3
X1
X5

L5 PL5
X6 L6

PL1
SECTION E-E
PL3
SECTION A-A
SECTION C-C

L2 X4 L4
X2
PL6

SECTION F-F

PL2 X7 L7
X4' L4'
SECTION B-B PL4 PL7
SECTION D-D,D'-D' SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction

3-10
 3. ATTACHMENT DIMENSION

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
380
Arm
(14.96) 1.0 (0.04) 2.0
A-A Arm point L1 PL1
381 or less (0.08)
Bucket
(15.10) 576
380 (22.7)
Link side
(14.96)
B-B Bucket link L2 — — PL2
382
Bucket
(15.04)
390 With in 2.5
Idler link Arm 1.0
C-C L3 (15.35) 0.5 (0.10) PL3
(Arm connection) (0.04)
Link side — (0.02)
Bucket link Rod side —
D-D (Idler link L4 390 505
Link side
connection) (15.35) (19.9)
0.6~1.0 2.0 Shim
130 PL4
Rod side (0.024~0.04) (0.08) adjust
Bucket link (5.12)
D’-D’ L4’ -ment
(Rod side) 136
Link side
(5.35)
130
Head side
Bucket cylinder (5.12) 299
E-E L5 PL5
(Head side) 136 (11.8)
Arm
(5.35) 0.6~2.0 3.0 4.0
140 (0.024~0.08) (0.12) (0.16)
Rod side
Arm cylinder (5.51) 309
F-F L6 PL6
(Rod side) 146 (12.2)
Arm
(5.75)
400
Arm With in
(15.75) 1.0 2.5 577
G-G Arm foot L7 0.5 PL7
405.8 (0.04) (0.10) (22.7)
Boom (0.02)
(15.98)

3-11
3. ATTACHMENT DIMENSION

3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket

 




 
  

 



Fig. 3-7 Bucket dimensional drawing

No. NAME No. NAME

A Distance between pin and bracket G Outer width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug Io Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.

3.3.2 BUCKET DIMENSIONAL TABLE

Unit : mm (ft-in)
Type GD bucket (General Duty)
[STD]
1.20 m3 1.60 m3 1.80 m3
Capacity 1.40 m3
(1.57 cu•yd)) (2.09 cu•yd)) (2.35 cu•yd))
(1.83 cu•yd)
Part No. LC61B00115F1 LC61B00052F1 LC61B00118F1 LC61B00057F1
A R517 (20.4") ← ← ←
B R1,690 (5'7") ← ← ←
C 1,238 (4'1") 1,060 (3'6") 1,388 (4'7") 1,620 (5'4")
D 444 (17.5") ← ← ←
E 382 (15.0") ← ← ←
F 1,415 (4'8") 1,240 (4'1") 1,565 (5'2") 1,683 (5'6")
G 1,122 (3'8") 936 (36.9") 1,272 (4'2") 1,496 (4'11")
H 1,238 (4'1") 1,060 (3'6") 1,388 (4'7") 1,620 (5'4")
I 280.5 (11") 316 (12.4") 318 (12.5") 377 (14.8")
IO 280.5 (11") 315 (12.4") 318 (12.5") 376 (14.8")
d1 ø 105 (4.13") ← ← ←
d2 ø 90 (3.54") ← ← ←

3-12
 3. ATTACHMENT DIMENSION

3.3.3 LUG SECTION DIMENSIONAL DRAWING

LS12B01054P1

28 (1.10")

19
(0.748")

VIEW I

SHIM t=1
(Five shims are installed
at shipping) Insert this pin flush with surface

SECTION AA
Fig. 3-8 Dimension of lug section

Unit : mm (ft-in)
Lug plate thickness

Screw hole P.C.D

Boss outer radius

Plate thickness

Boss outer dia.

Spring pin dia.
Pin hole dia.

Boss width.
Screw dia.

Capacity of
Hole dia.

Type of Part No. of

bucket
bucket bucket
m3 (cu.yd)

A B D E F G H J M N
1.40 (1.83) LC61B00115F1
1.20 (1.57) LC61B00052F1 90 28 105 16 105 19 190 12 150
GD bucket M20
1.60 (2.09) LC61B00118F1 (3.54") (1.10") (4.13") (0.63") (4.13") (0.748") (7.48") (0.472") (5.91")

1.80 (2.35) LC61B00057F1

3-13
3. ATTACHMENT DIMENSION

3.3.4 BOSS SECTION DIMENSIONAL DRAWING

)
gh
ou
thr
rill
(D
G

Fig. 3-9 Dimension of boss section

Unit : mm (ft-in)
Capacity of
Type of Part No. of Part No.
bucket øA øB E F øG
bucket bucket of boss
m3 (cu•yd)
1.40 (1.83) LC61B00115F1
1.20 (1.57) LC61B00052F1 139.8 103.8 15 40 21
GD bucket LS12B01054P1
1.60 (2.09) LC61B00118F1 (5.50") (4.09") (0.591") (1.58") (0.827")
1.80 (2.35) LC61B00057F1

3-14
 11. TOOLS
11
TABLE OF CONTENTS

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS............................................11-3

11.2 SCREW SIZE...................................................................................................................11-5
11.2.1 CAPSCREW (BOLT) ..............................................................................................11-5
11.2.2 CAPSCREW (SOCKET BOLT) ..............................................................................11-5
11.2.3 SOCKET SET SCREW...........................................................................................11-5
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING .......................................................11-6
11.3.1 JOINT (O-RING TYPE)...........................................................................................11-6
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ................................................................11-6
11.3.3 JOINT (ORS TYPE)................................................................................................11-6
11.3.4 SPLIT FLANGE ......................................................................................................11-6
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES...................................................11-7
11.5 PLUG ...............................................................................................................................11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ...................................................................11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................................11-9
11.6 SPECIAL SPANNER FOR TUBE ....................................................................................11-11
11.7 SPECIAL TOOLS.............................................................................................................11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND
SEALING COMPOUND ...................................................................................................11-14
11.9 SUCTION STOPPER.......................................................................................................11-15
11.9.1 COMPONENTS ......................................................................................................11-15
11.9.2 DIMENSION ...........................................................................................................11-15
11.9.3 APPLICABLE MODEL ............................................................................................11-15
11.10 UPPER FRAME LIFTING JIG..........................................................................................11-16
11.11 ENGINE MOUNTING PEDESTAL...................................................................................11-17

Book Code No. S5LC1111E01

11-1
11. TOOLS

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC1111E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)

11-2
 11. TOOLS

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Tables Table11-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given.
Overtightening of bolts may result in a twist-off and a fracture under load.
Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques.
Table11-1 Tightening torque for metric coarse threads (not plated)
Unit : N•m (lbf•ft)
Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
(3.2±0.4) (2.7±0.3) (7.1±0.7) (6.0±0.6) (12.8±1.3) (10.8±1.1)
10.7±1.1 9.0±0.9 23.5±2.0 19.6±2.0 42.2±3.9 35.3±3.9
M8 P=1.25
(7.9±0.8) (6.6±0.7) (17.3±1.5) (14.5±1.5) (31.1±2.9) (26.0±2.9)
21.6±2.0 17.9±1.8 46.1±4.9 39.2±3.9 83.4±8.8 70.6±6.9
M10 P=1.5
(15.9±1.4) (13.2±1.3) (34.0±3.6) (28.9±2.9) (61.5±6.5) (52.1±5.1)
36.3±3.9 31.4±2.9 79.4±7.8 66.7±6.9 143±15 121±12
M12 P=1.75
(26.8±2.9) (23.2±2.1) (58.6±5.8) (49.2±5.1) (105±11) (89.2±8.9)
57.9±5.9 49.0±4.9 126±13 106±10 226±20 191±19
M14 P=2
(42.7±4.4) (36.1±3.6) (92.9±9.6) (78.2±7.4) (167±15) (141±14)
88.3±8.8 74.5±6.9 191±20 161±16 343±39 284±29
M16 P=2
(65.1±6.5) (55.0±5.1) (141±15) (119±12) (253±29) (209±21)
122±12 103±10 265±29 226±20 481±49 402±39
M18 P=2.5
(90.0±8.9) (75.8±7.2) (195±21) (167±15) (355±36) (297±29)
172±17 144±14 373±39 314±29 667±69 559±59
M20 P=2.5
(127±13) (106±10) (275±29) (232±21) (492±51) (412±44)
226±20 192±20 500±49 422±39 902±88 755±78
M22 P=2.5
(167±15) (142±15) (369±36) (311±29) (665±65) (557±58)
294±29 235±29 637±69 520±49 1160±118 941±98
M24 P=3
(217±21) (173±21) (470±51) (383±36) (856±87) (694±72)
431±39 353±39 941±98 765±78 1700±167 1370±137
M27 P=3
(318±29) (260±29) (694±72) (564±58) (1250±123) (1010±101)
588±59 490±49 1285±127 1079±108 2300±235 1940±196
M30 P=3.5
(434±44) (361±36) (948±94) (796±80) (1700±173) (1430±145)
794±78 667±69 1726±177 1451±147 3110±314 2610±265
M33 P=3.5
(586±58) (492±51) (1270±131) (1070±108) (2290±232) (1930±195)
1030±98 863±88 2226±226 1863±186 4010±402 3360±333
M36 P=4
(760±72) (637±65) (1640±167) (1370±137) (2960±297) (2480±246)

11-3
11. TOOLS

Table11-2 Tightening torques for metric fine threads (not plated)

Torque value Unit : N•m (lbf•ft)
Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1.0
(8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9)
22.6±2.0 18.7±1.9 48.1±4.9 41.2±3.9 87.3±8.8 73.5±6.9
M10 P=1.25
(16.7±1.5) (13.8±1.4) (35.5±3.6) (30.3±2.9) (64.4±6.5) (54.2±5.1)
39.2±3.9 33.3±2.9 85.3±8.8 71.6±6.9 154±16 129±13
M12 P=1.25
(28.9±2.9) (24.6±2.1) (62.9±6.5) (52.8±5.1) (114±12) (95.2±9.6)
92.2±8.8 77.5±7.8 196±20 169±17 363±39 304±29
M16 P=1.5
(68.0±6.5) (57.2±5.8) (145±15) (125±13) (268±29) (224±21)
186±19 155±16 402±39 333±29 726±69 608±59
M20 P=1.5
(137±14) (114±12) (297±29) (246±21) (535±51) (448±44)
314±29 265±29 686±69 569±59 1240±118 1030±98
M24 P=2
(232±21) (195±21) (506±51) (420±44) (915±87) (760±72)
637±59 530±49 1390±137 1157±118 2500±255 2080±206
M30 P=2
(470±44) (391±36) (1030±101) (853±87) (1840±188) (1530±152)
853±88 706±70 1860±186 1550±155 3350±334 2790±275
M33 P=2
(629±65) (521±52) (1370±137) (1140±114) (2470±246) (2060±203)
1070±108 892±88 2330±226 1940±196 4200±422 3500±353
M36 P=3
(789±80) (658±65) (1720±167) (1430±145) (3100±311) (2580±260)

11-4
 11. TOOLS

11.2 SCREW SIZE

11.2.1 CAPSCREW (BOLT)

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

11.2.2 CAPSCREW (SOCKET BOLT)

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

11.2.3 SOCKET SET SCREW

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
11. TOOLS

11.3 TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE)

Size Wrench Tightening torque

(PF) (mm) N•m (lbf•ft) O-RING O-RING
1/8 14 17±2 (13±1.5)
1/4 19 36±2 (27±1.5)
3/8 22 74±5 (55±4)
1/2 27 108±9.8 (80.0±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)

11.3.2 HYDRAULIC HOSE (30° FLARE TYPE)

Size Tightening torque

Wrench(mm) UNION NUT
(PF) N•m (lbf•ft)
1/8 17 15±2.0 (11±1.5)
1/4 19 29±4.9 (21±3.6)
3/8 22 49±4.9 (36±3.6)
1/2 27 78±4.9 (58±3.6)
3/4 36 118±9.8 (87±7.2)
1 41 137±15 (101±11)

11.3.3 JOINT (ORS TYPE)

Tightening Torque CONNECTOR O-RING FITTING

Unified screw size Opposing flats
N•m (lbf•ft)
1-14 UNS 30, 32 137±14 (101±10)
36 177±18 (131±13)
1 3 / 16-12 UN
41 206±26 (152±15)
41 206±26 (152±15)
1 7/ 16-12 UN
46 206±26 (152±15) NUT

11.3.4 SPLIT FLANGE

Tightening torque N•m (lbf•ft)

 
 

Standard pressure Hi pressure
Size Bolt Bolt
series series
size size
20.6 MPa 41.2 MPa
3/4 33.9±5.6 (25±4) M10 39.5±5.6 (29±4) M10
1 42.4±5.6 (31±4) M10 62.2±5.6 (46±4) M12
11/4 55.1±7.1 (41±5) M10 93.3±8.4 (69±6) M14
11/2 70.6±8.4 (52±6) M12 169±11 (125±8) M16
2 81.9±8.4 (60±6) M12 282±11 (208±8) M20

11-6
 11. TOOLS

11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table11-3 indicates standard tightening torques applicable to cases where no particular note is given.
Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe
connections.
Always tighten nuts and sleeves to proper torques.
Table11-3
Working Tube size Opposing Tightening torque
pressure OD × thickness flats N•m (lbf•ft)
Manufacturer's name
MPa (psi) mm (in) (HEX)
mm
ø10×1.5
19 49.0±9.8 (36±7.2)
(0.394×0.059)
ø15×2.0
27 118±12 (87±8.7)
(0.591×0.079)
ø18×2.5
Nippon A.M.C. 29.4 (4270) 32 147±15 (110±11)
(0.709×0.098)
ø22×3.0
36 216±22 (160±16)
(0.866×0.118)
ø28×4.0
41 275±27 (200±20)
(1.10×0.157)
ø35×5.0
Ihara Koatu 29.4 (4270) 55 441±44 (330±33)
(1.38×0.197)

SLEEVE NUT
B

d
d

Tube size Parts No. Tube size Opposing Parts No.

ød Ihara Koatu Nippon A.M.C. ød flats Ihara Koatu Nippon A.M.C.
(HEX) mm
6 ZF93S06000 — 6 14 ZF93N06000 —
8 ZF93S08000 — 8 17 ZF93N08000 —
10 ZF93S10000 ZA93S10000 10 19 ZF93N10000 ZA93N10000
12 ZF93S12000 — 12 22 ZF93N12000 —
15 ZF93S15000 ZA93S15000 15 27 ZF93N15000 ZA93N15000
18 ZF93S18000 ZA93S18000 18 32 ZF93N18000 ZA93N18000
22 ZF93S22000 ZA93S22000 22 36 ZF93N22000 ZA93N22000
28 ZF93S28000 ZA93S28000 28 41 ZF93N28000 ZA93N28000
32 ZF93S32000 — 32 50 ZF93N32000 —
35 ZF93S35000 ZA93S35000 35 55 ZF93N35000 ZA93N35000
38 ZF93S38000 — 38 60 ZF93N38000 —

11-7
11. TOOLS

11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)

Applicable Cap nut parts Opposing flats

A
tube T screw
No.
O. D : A H1 H
6 ZF83H06000 M12 X 1.5 14 14
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
H1 T screw H 15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
28 ZF83H28000 M36 X 1.5 38 41

(2) Plug (Tube 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

d screw tube Nut parts No. d screw Opposing flats

O. D : A
6 ZF93N06000 M12 X 1.5 14
8 ZF93N08000 M14 X 1.5 17
10 ZF93N10000 M16 X 1.5 19
12 ZF93N12000 M18 X 1.5 22
15 ZF93N15000 M22 X 1.5 27
18 ZF93N18000 M26 X 1.5 32
22 ZF93N22000 M30 X 1.5 36
28 ZF93N28000 M36 X 1.5 41
32 ZF93N32000 M42 X 1.5 50
35 ZF93N35000 M45 X 1.5 55
38 ZF93N38000 M48 X 1.5 60

11-8
 11. TOOLS

11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw

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

(3) Plug for (F) flare hose

PF screw

PF screw Plug parts No. B mm

PF1/4 2444Z2728D1 14
60

PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36

PF screw Plug parts No. E mm F mm

PF PF1/4 2444Z2729D1 14 19
60

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
11. TOOLS

(4) Plug for ORS joints

Male


#  $  %   ()     
  !  
   ,  -+./0   
 
 
&#  *+(   " 
 '
&  *+(    " 
 '
&  *+(   " 

Female

 



$

  
  % &"'()
   !" 
    !"# 
    !" 

(5) Plug for half clamp

4-oH For standard pressure : 20.6 MPa (2990 psi)

Plug O-ring
Size part No. C mm D mm G mm H mm part No.
25.53~
1/2 ZE12Q08000 38.10 17.48 9 45Z91D2
C 25.40
31.88~
3/4 ZE12Q12000 47.63 22.23 31.75 11 ZD12P02600

ZE12Q16000 52.37 39.75~ ZD12P03400

1 26.19 11
39.62
44.58~
D 1 1/4 ZE12Q20000 58.72 30.18 44.45 11 ZD12P03800

For high pressure : 41.2 MPa (5970 psi)

Plug O-ring
G Size part No. C mm D mm G mm H mm part No.
25.53~
1/2 ZE13Q08000 40.49 18.24 9 2445Z831D1
25.40
31.88~
3/4 ZE13Q12000 50.80 23.80 11 ZD12P02600
31.75
ZE13Q16000 57.15 39.75~ ZD12P03400
1 27.76 39.62 13
44.58~
1 1/4 ZE13Q20000 66.68 31.75 44.45 15 ZD12P03800

11-10
 11. TOOLS

11.6 SPECIAL SPANNER FOR TUBE

Applicable tube
diameter Part No. HEX (mm) Drawing of a special spanner mm (in)
mm (in)

70(2.76)

16 22
15 (0.591) 2421T160 27 (0.630) (0.315) (0.866)

40(1.57) 12.7 (0.500 )

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)

35 (1.38) 2421T314 55 41 PART-No. 45

(1.61) (1.77)

HEX55 19.05 (0.750 )

11-11
11. TOOLS

11.7 SPECIAL TOOLS

Table11-4
No. Tools name Tools No. Shape Applicable
Spanner or
Pump
1 socket ZT22A17000 General tools
install
Nominal B : 17
CUT

Spanner ZT12A36000 Swing motor

2
Nominal S : 36 A,B port

Commercial tool outer width (D) - cut length = Required length

81 (3.19") - 16 (0.63") = 65 (2.56")

Additional M10 X 22
threading
for M10 eye bolt For slinging the
Plug ZE72X16000
3 swing motor
PF1
(M port)

O-ring
PF1

M12 Eye bolt

ZS91C01200 For slinging the

Eye bolt
or swing motor
4 M12×22
commercial &
equivalent Flare hose
22

M12

M8 Eye bolt

Plug
ZF83P22000
(Nominal
tube dia. 22)
5 Reference nut Flare hose
Reference
ZS91C00800
Eye bolt
ZF93N22000 M8 X 18
Nut Addtional
threading for
M8 Eye bolt

M8 Eye bolt

M8 X 18
Plug YN01H01001P1
Additional
threading
Nominal
6 1-14UNS HEX 27 Flare hose

Eye bolt ZS91C00800

1-14UNS

11-12
 11. TOOLS

Table11-4

M8 Eye bolt
M8 X 18
Additional
Plug YN01H01002P1 threading
Nominal
7 1 3/16-12UN HEX 36 Flare hose

Eye bolt ZS91C00800

1 3/16-12UN

M12 Eye nut

Plug ZE25F08000
PF1/2 For slinging the
8 Weld
Coupling swivel joint
half Coupling half

PF 1/2

TORX driver 5.49

(with tamper
For instrument
9 proof) — Point shape
panel cover (RH)
T30
(For M6)

11-13
11. TOOLS

11.8 APPLICATION OF SCREW LOCKING COMPOUND AND

SEALING COMPOUND
(1) For general use

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

(2) For specific location

No. Use Manufacturer Name Equivalent Applicable

(Manufacturer ; Loctite)
# 1901 Anti-seizure Cylinder
Three-Bond # 1215 gray # 5699 Swing motor
# 1211 white # 5301J Swing motor
# 1303B # 211 Main pump
(Manufacturer ; Three-
Bond)
Sealing Loctite
# 222 # 1344N Main pump
compound
1 # 277 # 1307N Pilot valve
&
adhesive (Manufacturer ; Three-
Bond)
Loctite Parmatex 98D # 1121 Hydraulic oil tank :
Sumitomo
Chemical Co., Cyano Bond PO-1 Hose
Ltd.
Shell
Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease bath
petroleum

11-14
 11. TOOLS

11.9 SUCTION STOPPER

11.9.1 COMPONENTS

No. NAME PARTS No. Q'TY

SUCTION STOPPER ASSY 24100P978F2
1 ROD 2420T4660D1 1
1 Rod
2 NUT ZN16C08007 1
3 COVER 2414T2123D2 1
4 O-RING 45Z91D6 1

2 Nut
3 Cover

4 O-ring

Fig. 11-1 Components of suction stopper

11.9.2 DIMENSION

50
(1.97")

R8
O113 (4.45")
2
M8 NUT

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

11.9.3 APPLICABLE MODEL

SK200-6ES

Applicable
SK115SR

SK135SR

SK235SR

SK200-6E
SK100-2

SK120-2

SK100-3

SK120-3

SK200-6

SK200-8

SK330-8

model
SK100

SK120

Part No.

24100P978F2

11-15
11. TOOLS

11.10 UPPER FRAME LIFTING JIG

No. NAME Q'TY TYPE

1 MASTER LINK L 1 KITO HL050

2 HIGH COUPLING HC 9 KITO HC020

3 CHAIN 1 8 4.4m(14' 5")

4 CHAIN 2 8 1.5m(4' 11")

5 GRAB HOOK H 1 KITO HH020

6 HOOK 2 KITO HJ050

Fig. 11-3 Upper frame lifting jig

11-16
 11. TOOLS

11.11 ENGINE MOUNTING PEDESTAL

Material : Wood
Unit : mm(inch)

5
1
6

3
2

6 6

4
6
6

1X1 set

5X1 set

4X1 set 2X1 set

3X1 set

6X5 sets

Fig. 11-4 Engine stand

11-17
11. TOOLS

[MEMO]

11-18
 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) ................................................................................................12-15
12.2.1 MEASURING METHOD .........................................................................................12-15
12.2.2 WORKING CONDITION .........................................................................................12-15
12.2.3 STANDARD TIME CONSTITUENT ........................................................................12-15
12.2.4 MEANING OF WORDS IN USE .............................................................................12-17

Book Code No. S5LC1211E01

12-1
12. STANDARD MAINTENANCE TIME TABLE

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC1211E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)

12-2
 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 time×Preparation 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
12. STANDARD MAINTENANCE TIME TABLE

12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF

EXCAVATOR
(1) Standard maintenance time table
1) Units of working time : 6 minutes = 0.1 hour
2) Calculating method of standard maintenance time :
Maintenance time=Working time×Number of workers
(Working time=Maintenance time÷Number of workers)
3) When more than one operation is going on :
Add each standard service time. A pure time (readily started) is given except covers easily removed by hand.
Assy works include the following works marked with black dot •.
4) O/H : The removing and attaching time is not included.
5) Abbreviations in the table.

A/C : Air conditioner C/V : Control valve O/H : Over haul

ASSY : Assembly Cyl : Cylinder SOL : Solenoid
ATT : Attachment E/G : Engine SW : Switch
BRG : Bearing F hose : Flexible hose V : Valve

(2) Classification of working code

No. Group Remarks

01 Attachment Indicates installing, removing, replacement and overhaul.
02 Cab & Guard
03 Swing frame
04 Travel system
Electric Indicates the installing, removing and replacement of single items.
06
equipments
09 E/G relation Indicates overhaul of the single engine.
(Materials prepared by manufacturer )

(3) Conditions for standard service time of the engine

1) Tools designated by E/G maker are used
2) Genuine parts are changed
3) Correct working procedures are observed.
• The time required for works specified in this Chapter shows the total time for maintenance.

12-4
 12. STANDARD MAINTENANCE TIME TABLE

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. 0.9
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.2
04 • Bucket drive pin Detach/attach 1 0.2
05 • Bucket sling and movement Preparation 1 pc. 0.3
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 3.6
07 • Tooth Replace 1 pc. 0.9
08 • Side cutter Replace 1 pc. 1.8
09 • Bushing Replace 1 pc. 0.9

10 Arm relation See 32.1.3

11 Arm ASSY Detach/attach 1 pc. 1.9
12 • Bucket cylinder attaching and Preparation 1 pc. 0.6
detaching position and piping
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.2
14 • Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin 0.2
15 • Bucket cylinder assy Detach/attach 1 pc. 0.2
16 • Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.2
17 • Boom top pin Detach/attach 1 pc. Include wire stop pin. 0.2
01 Attachment

18 • Arm sling and movement Detach/attach 1 pc. 0.3

30 Boom relation See 32.1.4

31 Boom ASSY Detach/attach 1 pc. 2.1
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.3
34 • Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.3
35 • Boom cylinder piping Detach/attach 2 pc. 0.3
36 • Arm & bucket piping Detach/attach 1 pc. 0.3
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include stopper pin. 0.3
39 • Boom assy slinging Detach/attach 1 pc. 0.2
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.7
41 • Arm cylinder piping Detach/attach 1 pc. 0.3
42 • Arm cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.2
43 • Arm cylinder slinging Detach/attach 1 pc. 0.2
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 1.0
51 • Boom cylinder piping Detach/attach 2 0.4
52 • Boom cylinder head pin Detach/attach 2 pcs. 0.3
53 • Boom cylinder slinging Detach/attach 2 0.3
60 Bucket cylinder O/H 1 4.0
61 • Pin bushing Replace 1 Include seal. 1.5
70 Arm cylinder O/H 1 4.0

12-5
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
71 • Pin bushing Replace 1 set Include seal. 1.5
80 Boom cylinder O/H 2 8.0
01

81 • Pin bushing Replace 1 set Include seal. 1.5

10 Cab relation See 33.1.2

11 Cab ASSY Detach/attach 1 pc. 1.4
12 • Front lower glass, floor mat Detach/attach 1 pc. each 0.1
13 • Seat rear cover top, bottom Detach/attach 4 places 0.2
14 • Seat rear cover top, bottom Detach/attach 1 pc. each 0.2
15 • Right side panel (include A/C duct) Detach/attach 3 0.3
16 • Cable and harness (electric) Detach/attach 6 0.2
17 • Cab mounting bolt Detach/attach 8 pcs. 0.2
18 • Cab slinging Detach/attach 3 places 0.2

20 Guard relation See 33.1.4

21 Bonnet assy (11) Detach/attach 1 pc. 0.3
22 Guard (7) Detach/attach 1 pc. 0.2
23 Guard (8) Detach/attach 1 pc. 0.2
24 Guard assy (5) Detach/attach 1 pc. 0.2
25 Stay (3) Detach/attach 1 pc. 0.2
02 Cab & Guard

26 Guard (2) Detach/attach 1 pc. 0.2

27 Panel assy (21) Detach/attach 1 pc. 0.2
28 Panel assy (23) Detach/attach 1 pc. 0.2
29 Panel assy (22) Detach/attach 1 pc. 0.2
30 Guard (15) Detach/attach 1 pc. 0.2
31 Guard assy (17) Detach/attach 1 pc. 0.2
32 Guard (16) Detach/attach 1 pc. 0.2
33 Beam (11) Detach/attach 1 pc. 0.2
34 Pillar (10) Detach/attach 1 pc. 0.2
35 Panel (4) Detach/attach 1 pc. 0.2
36 Beam (6) Detach/attach 1 pc. 0.2
37 Pillar (9) Detach/attach 1 pc. 0.2
38 Pillar (12) Detach/attach 1 pc. 0.2
39 Plate (49) Detach/attach 1 pc. 0.2
40 Guard assy (13) Detach/attach 1 pc. 0.2
41 Cover assy (2) Detach/attach 1 pc. 0.2
42 Guard assy (1) Detach/attach 1 pc. 0.2
43 Guard assy (4) Detach/attach 1 pc. 0.2
44 Guard (3) Detach/attach 1 pc. 0.2
45 Plate (18) Detach/attach 1 pc. 0.2
46 Cover assy (1) Detach/attach 1 pc. 0.2
Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.

12-6
 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

56 Cover (6) Detach/attach 1 pc. 0.1

57 Cover (7) Detach/attach 1 pc. 0.1
58 Cover (8) Detach/attach 1 pc. 0.1

60 Counterweight relation See 33.1.11

61 Counterweight ASSY Detach/attach 1 pc. 0.9
62 • Counterweight temporary slinging Preparation 1 pc. 0.3
63 • Counterweight mounting bolt Detach/attach 1 pc. 0.3
64 • Counterweight slinging Detach/attach 1 pc. 0.2

10 Intake relation See 33.1.9

11 Air cleaner ASSY Detach/attach 1 pc. 0.4
12 • Hose (3) Detach/attach 1 0.1
13 • Air cleaner mounting bolt Detach/attach 1 set 0.2
14 • Element Replace 1 0.1

20 Exhaust relation See 33.1.10

21 Muffler ASSY Detach/attach 1 pc. 0.5
22 • U bolt Detach/attach 1 pc. 0.2
23 • Clamp ASSY Detach/attach 1 pc. 0.2
03 Swing frame

30 Radiator relation See 33.1.12

31 Radiator ASSY Detach/attach 1 pc. 5.0
32 • Coolant (LLC) Replace 1 pc. 0.3
33 • • Concentration of coolant Measuring 1 pc. 0.2
34 • A/C condenser Detach/attach 1 pc. 0.3
35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.3
37 • Sub tank hose Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.3
39 • Water hose (radiator ~ E/G) Detach/attach 2 0.6
40 • Radiator mounting bolts removing Detach/attach 1 set 0.2
41 • Under cover Detach/attach 1 pc. 0.1
42 • Hydraulic oil tank suction stopper Detach/attach 1 pc. 0.2
43 • Hydraulic oil piping Detach/attach 1 pc. 0.6
Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.

12-7
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

50 Fuel relation See 33.1.6

51 Fuel tank ASSY Detach/attach 1 pc. 1.8
52 • Fuel Replace 1 pc. 0.4
53 • Hose (water separator side) Detach/attach 2 0.1
54 • Tube (tank side) Detach/attach 1 0.1
55 • Fuel tank installing bolts Detach/attach 1 pc. 0.3
56 • Tank slinging Detach/attach 1 pc. 0.3
Other necessary works Detach/attach 1 pc. Removing and installing guard 0.4

60 Hydraulic oil tank relation See 33.1.7

61 Hydraulic oil tank ASSY Detach/attach 1 pc. 3.0
65 • Cover Detach/attach 1 pc. 0.2
03 Swing frame

66 • Hydraulic oil Replace 1 pc. 0.6

68 • Pilot drain hose Detach/attach 1 pc. 0.2
69 • Pump suction hose Detach/attach 1 pc. 0.5
70 • Mounting bolt Detach/attach 1 pc. 0.2
71 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.3
72 • Return filter Replace 1 0.2
73 • Suction filter Cleaning 1 0.2

80 Pump relation See 33.1.8

81 Pump ASSY Detach/attach 1 pc. 3.2
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.3
83 • Strainer & stopper Detach/attach 1 pc. 0.3
84 • Piping Detach/attach 1 set 1.0
85 • Guard Detach/attach 5 pcs. 1.0
86 • Pump slinging Detach/attach 1 pc. 0.5
87 • Cleaning Cleaning 1 pc. 0.1
88 • Vent air Adjust 1 pc. 0.1
89 Pump ASSY O/H 1 pc. 4.0

90 Swing motor unit relation See 33.1.19

91 Swing motor ASSY Detach/attach 1 pc. 2.4
92 • Piping Detach/attach 1 set 1.0
93 • Mounting bolt Detach/attach 1 pc. 0.7
94 • Unit slinging Detach/attach 1 pc. 0.5
95 • Cleaning and sealant Cleaning 1 set 0.2

12-8
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
96 Swing motor O/H 1 pc. 4.0
97 Swing reduction gear O/H 1 pc. 5.0

100 Swivel joint relation See 33.1.20

101 Swivel joint ASSY Detach/attach 1 2.6
102 • Piping (Top part only) Detach/attach 1 set 0.5
103 • Whirl stop bolt Detach/attach 1 0.2
104 • Cover Detach/attach 1 0.4
105 • Joint & elbow Detach/attach 1 set 0.4
106 • Mounting bolt Detach/attach 1 set 0.4
107 • Swivel joint slinging Detach/attach 1 0.4
108 • Cleaning Cleaning 1 set 0.3
109 Swivel joint O/H 1 set Removing and installing guard 3.6
Other necessary works Detach/attach 1 set Lower piping 0.6

110 Multi control valve (For Oceania) See 33.1.15

111 • Multi C/V ASSY Detach/attach 1 After removing guard 1.7
112 Write hose name on multi C/V connecting hose Detach/attach 1 set 0.3
03 Swing frame

113 • Piping Detach/attach 1 set 0.5

114 • Mounting bolt Detach/attach 1 set 0.3
115 • Cleaning Cleaning 1 set 0.2
Other necessary works Detach/attach 1 set Guard 0.4

120 Main control valve See 33.1.16

121 Main control valve ASSY Detach/attach 1 pc. 2.5
122 • Attach tag to port name of pipe Preparation 1 pc. 0.6
123 • Piping Detach/attach 1 set 1.7
124 • Bracket mounting bolt Detach/attach 1 pc. 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY Detach/attach 1 set 6.0
Other necessary works Detach/attach 1 set Guard 0.4

130 Valve relation OPT

131 Solenoid valve ASSY Detach/attach 1 1.0
132 • Attach tag to port name of pipe Preparation 1 0.2
133 • Piping Detach/attach 1 set 0.5
134 • Mounting bolt Detach/attach 1 0.3

140 Engine (E/G) mounting relation See 33.1.13

141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 2.0
142 • Harness connector & grounding & Detach/attach 1 pc. 0.3
cable connection
143 • Fuel hose Detach/attach 1 pc. 0.1

12-9
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
144 • Others Detach/attach 1 set 0.5
145 • Mounting bolt Detach/attach 1 pc. 0.5
146 • Engine slinging Detach/attach 1 set 0.3
147 • Cleaning Cleaning 1 pc. 0.5
148 Engine O/H 1 set Reference for engine (Chapter 51)
Other necessary works Detach/attach 1 set Removing and installing guard 0.6
Detach/attach 1 set Removing and installing counterweight 0.9
Detach/attach 1 set Removing and installing pump 3.2
Detach/attach 1 set Removing and installing air cleaner 0.4
1 set Removing and installing muffler 0.4
03 Swing frame

Detach/attach

Detach/attach 1 set Removing and installing radiator 4.0

150 Upper frame See 33.1.21

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 0.9
Detach/attach 1 set Boom 2.1

00 Travel relation See 34.1.2

01 Track link ASSY Detach/attach One side Include adjustment of tension 2.0
02 • Track link attaching and detaching position Preparation One side 0.1
03 • Master pin Detach/attach One side 0.7
04 • Track link extending and winding Detach/attach One side 0.7
05 Shoe plate Replace 1 pc. 0.4
04 Travel system

10 Upper roller relation See 34.1.3

11 Upper roller ASSY Detach/attach 1 After removing track link 0.3
12 Upper roller O/H 1 1.0

20 Lower roller relation See 34.1.4

21 Lower roller ASSY Detach/attach 1 0.3
22 Lower roller O/H 1 1.5

30 Front idler relation See 34.1.5

31 Front idler ASSY Detach/attach One side After removing track link 0.8
32 Front idler ASSY slinging Detach/attach One side 0.3
33 Front idler ASSY Detaching One side 0.5
34 Idler ASSY O/H One side 1.5

12-10
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
40 Sprocket See 34.1.6
41 Sprocket Replace One side After removing track link 0.9

50 Travel motor relation See 34.1.7

51 Travel motor ASSY Detach/attach One side After removing track link 2.4
52 • Motor cover Detach/attach One side 0.1
53 • Hydraulic piping Detach/attach One side 1.3
54 • Motor mounting bolt Detach/attach One side 0.6
04 Travel system

55 • Motor slinging Detach/attach One side 0.2

56 Motor cleaning Cleaning One side 0.2
57 Travel motor O/H One side 4.0
58 Travel reduction gear O/H One side 4.0

60 Swivel joint relation

61 Pipe on swivel joint travel side Detach/attach 1 pc. Include bonnet assy removing and installing. 0.6
62 Swivel joint O/H 1 pc. See 33.2.6 3.6

70 Swing bearing See 34.1.8

71 Swing bearing ASSY Detach/attach 1 pc. After removing upper frame 0.8
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.6
73 Swing bearing slinging Detach/attach 1 pc. 0.4

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
06 Electric equipments

D-6 Diode Replace 1 0.3

D-9 Diode Replace 1 0.3
D-10 Diode Replace 1 0.3
D-12 Diode Replace 1 0.3
D-13 Diode Replace 1 0.3
D-14 Diode Replace 1 0.3
D-15 Diode Replace 1 0.3
D-16 Diode Replace 1 0.3
D-17 Diode Replace 1 0.3
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
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-7 Tuner AM & FM (OPT) Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right 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-13 Travel alarm (OPT) Replace 1 0.3
E-14 Cigarette lighter Replace 1 0.3
E-15 Fusible link Replace 1 0.2
E-27 Accel emergency mode volume Replace 1 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
06 Electric equipments

L-6 Boom cylinder work light (right) Replace 1 0.2

Motor
M-1 Starter motor Replace 1 Include counterweight removing and installing. 1.2
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

12-12
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
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
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
SE-2 Pressure sensor : Bucket dump
SE-3 Pressure sensor : Boom up
SE-4 Pressure sensor : Boom down
SE-5 Pressure sensor : Swing
SE-7 Pressure sensor : Arm in
SE-8 Pressure sensor : Arm out
06 Electric equipments
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3
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
SE-13 Engine speed sensor Replace 1 Include under cover removing and installing 0.5
SE-15 Fuel 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

12-13
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
SW-20 Attachment power boost switch (right) Replace 1 0.3
06

SW-27 Engine cooling coolant level switch Replace 1 0.3

12-14
 12. STANDARD MAINTENANCE TIME TABLE

12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST

(TEMPORARY EDITION)
Preface
This standard working time is based on the work time required for service of engine like disassembly, check,
adjustment and assembly and so on under a following condition.
This standard working time is provided under the following conditions.

12.2.1 MEASURING METHOD

(1) The time from the worker beginning working at the regular position of machine to the returning to the regular
position after completion of the work is counted as working time.
(2) The measuring unit is in 0.1 minute, and then round up the fractions.
(3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two workers is counted
as the working time. But light work which can be carried out easily by a person and the efficient is higher is
counted as a workman.

12.2.2 WORKING CONDITION

12.2.2.1 TOOLS, INSTRUMENT

(1) Hand tool ;
Tools which are commercially available and each workman usually carries
(2) Common tool ;
Tools which are commercially available and each workman do not usually carry but the storing place is specified
(3) Special tool ;
Tools especially prepared by HINO Motor’s Ltd. and the storing place is specified
(4) Machine tool ;
When measuring equipment and instrument are used, the time required to move parts to the specified place is
included but the time waiting for tool is not included as a general rule

12.2.2.2 WORKING PROCEDURE

The disassembly and assembly should be carried out according to working procedure prepared by HINO Motor’s
Ltd. Service Technical Dept. Training Group.

12.2.2.3 STANDARD WORKMAN QUALIFICATION

Workmen shall basically acquire 2~3 years of maintenance experience of HINO

12.2.3 STANDARD TIME CONSTITUENT

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.

12-15
12. STANDARD MAINTENANCE TIME TABLE

12.2.3.2 ALLOWANCE RATE, STANDARD PREPARATION TIME

12.2.3.2.1 HINO allowance rate (0.15~0.75)

(1) Basic rate : 0.10
(2) Working posture allowance (Fatigue coefficient) : Take any one of the followings according to the work contents.
Standing work : 0.05
Work in bent posture : 0.10
Work while lying : 0.15
(3) Difficult work allowance : 0.30
(4) Seized rusted section (For new vehicle) : 0.50
Take any one of above (3) and (4).
Min. allowance rate = Basic allowance + standing work allowance = 0.1+ 0.05 = 0.15
Max. allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 + 0.5=0.75

12.2.3.2.2 STANDARD WORKING TIME

(1) Working standard time : 3 minutes
(One time for a set of works)
(2) Special tool standard time : 3 minutes
(One time for a set of works)
(3) Standard time of non-portable machine : 3 minutes
(For single work)
(4) Part standard time : 6 minutes (up to 10 items), 10 minutes (10 items or more)
(One time for a set of works)
(5) Test : 15 minutes
(One time for a set of works)
(6) Preparation time for chain block, measuring instrument, piston, heater and so on : 3 minutes
(One time for a set of works)
(7) General cleaning : 2 minutes
(One time for a set of works)
(8) Safety treatment like wheel stopper, and so on : 3 minutes
(9) Visual checks : 2 minutes
The preparation time is classified into as described above, and only items required for the every work are
selected, calculated and counted as preparation time of the work.

12-16
 12. STANDARD MAINTENANCE TIME TABLE

12.2.4 MEANING OF WORDS IN USE

• Completed machine :
When detaching, replacing and adjusting the specified parts, it means the time which is determined by
addition of the preparation time, net working time and standard allowance time of the work.
• Single unit :
When detaching, replacing and adjusting the specified parts, it means the time in which the preparation time
of the work is omitted and which is determined by addition and subtraction to/from the work for "Completed
machine".
• Removal and installation :
The work to remove specified parts from machine and to attach the parts, and then to perform necessary
adjustment
• Simultaneous replacement :
The work to remove specified parts in 2 types or more from machine and to attach the spare parts, and then
to perform necessary adjustment
• Adjustment :
The work to carry out necessary adjustment with the specified parts removed or attached :
• Overhaul :
The work to remove specified assembled parts from machine, disassemble and check them, and then to
attach the spare parts to machine and to perform necessary adjustment
• Include :
Explains the contents of work to make the specified work range clear
• Exclude :
Shows the work which is not included in the specified primary work
• Unit :
Time is shown by hour.

12-17
12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

Completed Timing adjustment

1 00101 Engine adjustment A set 2.3 2.5
machine Valve clearance adjustment
Completed
2 00103 Engine adjustment B set A set and nozzle adjustment — —
machine
Include; Engine warm-up, valve clearance
Completed
3 00111 Compression measuring adjustment, removing air cleaner element 3.4 4.3
machine
and battery specific gravity measurement
Replacing cylinder, block, piston, ring
8 99012 Single unit From engine is removed condition 27.4 31.6
and liner simultaneously
Replacing crank shaft, piston, ring
9 99013 Single unit From engine is removed condition 20.8 25.8
and liner simultaneously
From engine is removed condition
Include; Valve clearance adjustment
Replacing cylinder block Single unit 24.4 30
Exclude; Installing expansion plug knock
pin
11 00126 Replacing crank shaft Single unit From engine is removed condition 18.4 22.8
12 00127 Replacing crank shaft main bearing Single unit From engine is removed condition 18.4 22.8
From engine is removed condition
Include; Adjustment of water pump, oil
pump, valve clearance, valve lapping and
15 00151 Engine overhaul Single unit measurement/cleaning 38.5 44.3
Exclude; Replacing of injection pump,
electrical equipment, water pressure test,
clutch overhaul and valve guide
16 00152 Compression measuring Single unit 2.3 3.1
From piston & connecting rod are
17 00153 Replacing piston Single unit 0.5 0.5 0.5 0.5
removed conditions
From piston & connecting rod are
18 00154 Replacing piston ring Single unit 0.2 0.2 0.2 0.2
removed conditions
From piston & connecting rod are
19 00155 Replacing cylinder liner Single unit 0.4 0.4 0.4 0.4
removed conditions
From piston & connecting rod are
20 00157 Replacing connecting rod Single unit 0.3 0.3 0.3 0.3
removed conditions
From connecting rod is a single unit
21 00158 Replacing piston pin bushing Single unit condition 0.4 0.4 0.4 0.4
Include; Reaming
26 00165 Replacing expansion plug Single unit 0.4 0.4 0.4 0.4
Completed
41 00302 Valve clearance adjustment 1.7 2.0
machine
Replacing rocker chamber cover
42 00305 One set 1.3 1.4
upper
Replacing rocker chamber cover
43 00306 One set Include; Removal and installing upper — 4.3
lower
Replacing rocker chamber cover
44 00304 One set 1.3 1.4
gasket
Removal and installing rocker arm Completed
45 00312 2.6 3.3
and support machine
Completed
46 00313 Replacing rocker arm 2.6 3.4
machine
Completed
47 00314 Replacing rocker arm support 2.6 3.4
machine
Completed
48 00315 Replacing rocker arm shaft 2.6 3.4
machine
Completed Excluding; Removal and installing of nozzle
50 00322 Removal and installing cylinder head 8.2 10.4
machine holder or injector and injector sub harness
Completed Include; Valve lapping
51 00323 Replacing cylinder head 11.5 16.9
machine Exclude; Replacing of valve guide

12-18
 12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

Include; Valve lapping

Completed Exclude; Replacing of valve guide,
52 00324 Overhaul of cylinder head 13.3 18.8
machine water pressure test and replacing
valve seat
Completed
53 00325 Replacing cylinder head gasket 8.2 10.4
machine
Completed
54 00326 Replacing valve Include; Valve lapping 10.2 15.6
machine
Completed Exclude; Removal and installing of
55 00327 Replacing valve spring 4.9 8.8
machine cylinder head
Completed Exclude; Removal and installing of
57 00328 Replacing valve stem seal 5.3 9.4
machine cylinder head
Removal and installing camshaft
61 00376 One set 1.2 0.2 1.6 0.2
housing plug
Removal and installing camshaft (with Completed
62 00377 2.6 3.4
camshaft gear) machine
With manifold and nozzle holder
Include; Valve lapping
Replacing cylinder head
Excluding; Removal and installing of
63 00352 (one piece and one set require same Single unit 6.1 6.5
cylinder head, replacing valve guide,
hour)
water pressure test and replacing
valve seat
Unit of 1
66 00355 Replacing valve guide 1.0 0.8 1.0 0.8
cylinder
72 00361 Replacing expansion plug Single unit 0.4 0.4 0.4 0.4
Replacing rocker arm
Unit of 1
73 00371 (one piece and one set require same 0.1 0.1
cylinder
hour)
Replacing rocker arm support
Unit of 1
74 00372 (one piece and one set require same 0.1 0.1
cylinder
hour)
Unit of 1
75 00373 Replacing rocker arm bushing 0.3 0.1 0.3 0.1
cylinder
From cylinder head is removed
Unit of 1
76 00374 Replacing valve condition 0.5 0.5 0.5 0.5
cylinder
Include; Valve lapping
Unit of 1 From cylinder head is removed
77 00375 Replacing valve spring 0.2 0.2 0.2 0.2
cylinder condition
Unit of 1 From cylinder head is removed
78 00330 Replacing valve stem seal 0.3 0.3 0.3 0.3
cylinder condition
81 00406 Removal and installing supply pump One set Include; Function check 2.3 2.3
84 00411 Tightening oil pan Single unit From engine is removed condition 0.5 0.5
85 00412 Removal and installing oil pan Single unit From engine is removed condition 0.5 0.5
86 00413 Replacing oil pan Single unit From engine is removed condition 0.7 0.7
87 00414 Replacing oil pan gasket Single unit From engine is removed condition 0.7 0.7
88 00421 Replacing oil pan drain cock Single unit From engine is removed condition 0.5 0.5
89 00422 Replacing oil pan drain cock gasket Single unit From engine is removed condition 0.5 0.5
92 00443 Replacing breather hose Single unit From engine is removed condition 0.3 0.2 0.3 0.2
93 00444 Replacing oil level gauge Single unit From engine is removed condition 0.1 0.1
94 00445 Replacing oil level gauge guide Single unit From engine is removed condition 0.2 0.2
95 00446 Replacing oil level gauge bracket Single unit From engine is removed condition 0.2 0.2
102 00512 Replacing fly wheel housing Single unit From engine is removed condition 3.4 3.4
103 00541 Replacing fly wheel housing gasket Single unit From engine is removed condition 5.4 5.4
104 00542 Replacing rear end plate Single unit From engine is removed condition 5.4 5.4
105 00543 Replacing rear end plate gasket Single unit From engine is removed condition 5.4 5.4
106 00515 Replacing crank shaft rear oil seal Single unit From engine is removed condition 5.4 5.4

12-19
12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

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

Completed Include; Replacing stud bolt with new

144 00644 Replacing exhaust manifold 3.0 3.4
machine one and insulator (TI system)
Completed
145 00645 Replacing exhaust manifold gasket 2.8 3.2
machine
One side of
Removal and installing of turbo
146 00646 Replacing exhaust heat insulator completed 2.4 2.6
charger
machine
147 00651 Replacing exhaust pipe One set 0.8 0.8
148 00653 Replacing exhaust pipe gasket One set 0.6 0.6
164 00686 Removal and installing turbo charger One set 2.9 2.5
165 00687 Replacing turbo charger One set Include; Replacing stud bolt 2.6 2.5
Replacing turbo charger oil return Include; Removal and installing of
167 00689 One set 0.9 0.9
pipe lower insulator
Replacing air intake pipe upper
174 00624 One set 0.4 0.4
(cooler to manifold)
Removal and installing engine and From engine is removed condition
188 00701 timing gear cover Single unit Include; Removal and installing of 5.4 5.4
(fly wheel housing) cylinder head
From engine is removed condition
Replacing timing gear cover
189 00711 Single unit Include; Removal and installing of 5.4 5.4
(fly wheel housing)
cylinder head
Replacing timing gear cover gasket From timing gear cover is removed
190 00712 Single unit 0.7 0.7
(fly wheel housing) condition
Replacing timing gear cover plate From timing gear cover is removed
191 00713 Single unit 1.0 1.0
(rear end plate) condition
Replacing timing gear cover plate
From timing gear cover is removed
192 00714 gasket Single unit 1.0 1.0
condition
(rear end plate gasket)
From timing gear cover is removed
193 00725 Replacing idler gear (main) Single unit 0.2 0.2
condition
From timing gear cover is removed
194 00736 Replacing idler gear (sub) Single unit 0.1 0.1
condition
From timing gear cover is removed
195 00726 Replacing idler gear shaft (main) Single unit 0.2 0.2
condition
From timing gear cover is removed
196 00737 Replacing idler gear shaft (sub) Single unit 0.1 0.1
condition
197 00724 Replacing crank shaft gear rear Single unit 0.4 0.4
From timing gear cover is removed
201 00738 Replacing cam idle gear Single unit 0.4 0.4
condition

12-20
 12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

From timing gear cover is removed

202 00739 Replacing cam idle gear shaft Single unit 0.4 0.4
condition
From timing gear cover is removed
203 00731 Replacing camshaft Single unit 0.8 0.8
condition
From timing gear cover is removed
204 00732 Replacing camshaft gear Single unit 0.8 0.8
condition
205 00751 Replacing crank pulley One set 1.9 1.9
206 00754 Replacing crank dumper One set 2.8 2.8
207 00755 Replacing crank shaft front oil seal One set 2.2 2.2
Replacing crank shaft front oil seal
208 00757 One set 2.8 2.8
retainer
Replacing crank shaft front oil seal
209 00758 One set 2.8 2.8
retainer gasket
Completed
211 00801 Checking injection timing 0.3 0.3
machine
226 00834 Replacing priming pump One set 0.4 0.4
227 00835 Cleaning fuel feed pump strainer One set 0.4 0.4
228 00836 Replacing through feed valve One set 0.4 0.4
230 00838 Replacing fuel injection pipe One set 2.5 0.1 2.5 0.1
236 00851 Replacing fuel filter assembly One set 0.5 0.5
237 00857 Replacing fuel filter cartridge One set 0.3 0.3
253 00875 Replacing fuel hose One set 0.8 0.8
254 00876 Replacing fuel leakage pipe One set 0.8 0.8
276 00912 Replacing oil filter cartridge One set 0.4 0.4
Replacing oil filter relief valve (oil filter
277 00907 One set 0.3 0.3
regulator valve)
Replacing oil filter relief valve spring
278 00908 One set 0.3 0.3
(oil filter regulator valve)
279 00909 Replacing oil filter safety valve One set 0.3 0.3
280 00910 Replacing oil filter safety valve spring One set 0.3 0.3
00961(tim Removal and installing fly wheel
294 ing gear housing Single unit From engine is removed condition 6.1 6.1
cover) (timing gear cover)
295 00942 Replacing oil pump Single unit From engine is removed condition 6.3 6.3
296 00944 Replacing oil pump gear Single unit From engine is removed condition 6.5 6.5
297 00943 Overhaul of oil pump Single unit From engine is removed condition 6.5 6.5
298 00946 Replacing suction strainer One set 0.1 0.1
299 00947 Replacing suction strainer O-ring One set 0.1 0.1
301 00951 Replacing oil pipe One set 0.4 0.4 0.4 0.4
302 00954 Replacing oil hose One set 0.4 0.4 0.4 0.4
303 00971 Replacing cooling oil jet 1 0.2 0.2 0.2 0.2
327 01028 Removal and installing water pump One set Include; Filling engine coolant up 4.0 4.0
328 01029 Replacing water pump One set Include; Filling engine coolant up 4.0 4.0
329 01030 Overhaul of water pump Single unit 0.8 0.8
330 01031 Replacing water pump pulley Single unit 0.6 0.6
331 01032 Replacing water pump casing gasket One set Liquid gasket 4.0 4.0
332 01036 Replacing cooling fan One set 0.9 0.9
333 01037 Replacing fluid fan coupling One set 0.9 0.9
334 01044 Replacing thermostat casing One set Include; Filling engine coolant up 1.3 1.3
336 01046 Replacing thermostat casing cover One set Include; Filling engine coolant up 1.0 1.0
Replacing thermostat casing cover
337 01047 One set Include; Filling engine coolant up 1.0 1.0
gasket
Include; Checking for temperature at
338 01048 Replacing thermostat One set 1.0 1.0
valve start opening

12-21
12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

Include; Checking for temperature at

339 01049 Checking thermostat One set 1.0 1.0
valve start opening
341 01053 Replacing coolant hose One set 0.3 0.2 0.3 0.2
342 01054 Replacing radiator hose One set 0.3 0.2 0.3 0.2
343 01071 Replacing fluid fan coupling 1 0.3 0.3
344 01072 Replacing cooling fan 1 0.3 0.3
345 01073 Replacing water pump 1 From cooling fan is removed condition 1.7 1.7
346 01074 Overhaul of water pump 1 0.8 0.8
402 01401 Removal and installing alternator One set 0.8 0.8
403 01402 Replacing alternator One set 0.9 0.9
404 01406 Replacing alternator support bracket One set 1.0 1.0
405 01408 Replacing V-belt One set 0.3 0.3
438 01801 Removal and installing supply pump One set Include; Function check 3.0 3.0
439 01802 Replacing supply pump One set Include; Function check 3.0 3.0
Removal and installing common rail
assembly
440 01830 One set Include; Function check 3.8 3.8
(with pressure sensor, pressure
limiter)
Replacing common rail assembly
441 01804 (with pressure sensor, pressure One set Include; Function check 3.8 3.8
limiter)
Removal and installing injector Completed
442 01805 Include; Function check 2.9 3.5
assembly machine

Completed Include; Function check and

443 01806 Replacing injector assembly 3.4 4.0
machine reprogramming
Removal and installing injector
444 01807 One set Include; Function check 1.9 0.2 1.9 0.2
assembly
Include; Function check and
445 01808 Replacing injector assembly One set 2.4 0.2 2.4 0.2
reprogramming
Removal and installing injector sub
446 01809 One set Include; Function check 1.9 1.9
harness assembly
Replace injector sub harness
447 01810 One set Include; Function check 1.9 1.9
assembly
448 01811 Removal and installing flow dumper One set Include; Function check 1.2 0.3 1.2 0.3
449 01812 Replacing flow dumper One set Include; Function check 1.2 0.3 1.2 0.3
Removal and installing pressure
450 01813 One set Include; Function check 1.2 1.2
limiter
451 01814 Replacing pressure limiter One set Include; Function check 1.2 1.2
Replacing common rail pressure
452 01815 One set Include; Function check 1.2 1.2
sensor
453 01816 Replacing main engine speed sensor One set Include; Function check 1.2 1.2
454 01817 Replacing sub engine speed sensor One set Include; Function check 1.2 1.2
Replacing coolant temperature
455 01818 One set Include; Function check 1.2 1.2
sensor
456 01819 Replacing fuel temperature sensor One set Include; Function check 1.2 1.2
457 01820 Replacing accel sensor One set Include; Function check 1.5 1.5
Removal and installing pressure
460 01823 1 Include; Function check 0.3 0.3
sensor
Removal and installing pressure
461 01824 1 Include; Function check 0.3 0.3
limiter
463 01826 Replacing injection pipe One set Include; Function check 1.2 0.1 1.2 0.1
Replacing fuel pipe
464 01827 One set Include; Function check 1.2 0.1 1.2 0.1
(common rail to supply pump)
465 01828 Replacing fuel leakage pipe One set Include; Function check 1.7 1.7
469 01840 Checking leakage of pressurized fuel One set Include; Function check 1.2 1.2

12-22
 12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

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

12-23
12. STANDARD MAINTENANCE TIME TABLE

[MEMO]

12-24
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

Book Code No. S5LC1311E02

13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC1311E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC1311E02
Revision February, 2007 ↑ K
(ASIA, OCE)

13-2
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE

EXERCISED
(1) Application
1) When the machine is new ;
Confirm that the performances are in accordance with standard specifications as compared to the
performance standards.
2) At specific self inspection ; (Rule by country)
Use the data for the criterion, for the purpose of correction, adjustment and replacement.
3) When performances are deteriorated ;
Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for
safety and economical considerations.
4) When main components are replaced ;
For example, use data to restore performances of pumps and others.
(2) Terminology
1) Standard values ;
Values to be used to condition or assemble a new machine. Where special notes are not given, these values
represent standard specifications (machine with standard attachments and standard shoes).
2) Reference values for remedy ;
Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited
to use the machine over the specified values.
3) Service limit ;
This is the limit value at which reconditioning is impossible without replacement of parts. If the value is
expected to exceed the service limit before next inspection and correction are performed, replace the parts
immediately. The operation over the specified values causes increase of damage and requires the down time
of machine, and also causes safety problems.
(3) Cautions to be Exercised at Judgment
1) Evaluation of measured data ;
Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors
are to be evaluated. Determine generally at what levels measured values are located, instead of determining
whether or not values fall within or run out of the reference values.
2) Determining correction, adjustment or replacement ;
Machine performances deteriorate with time as parts wear and some deteriorated performances may be
restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the
operating hours, kind of work and circumstances in which the machine is placed, and condition the machine
performances to its most desirable levels.
(4) Other Cautions to be Exercised
1) Parts liable to degrade ;
Rubber products, such as, hydraulic hoses,
O rings, and oil seals deteriorate with time ; replace them at regular intervals or at overhauls.
2) Parts requiring regular replacement ;
Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and
recommend that they should be replaced regularly.
3) Inspection and replacement of oils and greases ;
In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine
safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as
well.

13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.2 PERFORMANCE INSPECTION STANDARD TABLE

The mode is already "S" mode when power is thrown.

Unless otherwise specified, measure it on "H" mode.

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
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — 50°C~-10°C (122°F~14°F)

H mode Lo idle 1000 + 25 - 25 LOW throttle

Engine speed

H mode Hi idle 2100 + 30 - 70 Full throttle (HI idle)

not required
Adjustment
Measure the engine
B mode Hi idle 2100 + 30 - 70 Perform all
speed at multi display on min-1
A mode Hi idle 2100 + 30 - 70 measurement with
the gauge cluster.
Decel 1050 + 25 - 25 the air-conditioner
S mode Hi idle 1900 + 30 - 70 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure

P1 a1
Main relief

ATT 34.3 (4970) + 0.7 (+100) - 0.5 (-73) MR1 Boom up

P2 a2
P1 a1
Boost 37.8 (5480) + 1.0 (+145) - 0.5 (-73) MR1 Boom up
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
High pressure circuit

H 39.7 (5760) 0 - 5.9 (-855) OR3 Boom up

Over load relief valve pressure

R 39.7 (5760) 0 - 5.9 (-855) OR8 Arm out

Main pump

Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-580) (psi) OR2 Bucket dump
Bucket a1
H 39.7 (5760) 0 - 5.9 (-855) OR1 Bucket digging
RH 29.0 (4205) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 29.0 (4205) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 35.8 (5190) 0 - 2.0 (-290) Simultaneous
Travel

RV —
operation of travel
FW —
LH a2 35.8 (5190) 0 - 2.0 (-290) RH and LH
RV —

13-4
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

Standard
Inspection item Unit
value
1st speed 34.3 ~ 31.1
Track link revolution STD
2nd speed 20.4 ~ 18.4
(RH,LH) sec / 3 rev
1st speed 36.4 ~ 33.2
(H mode) LC
2nd speed 21.7 ~ 19.9
Up 2.7 ~ 3.3
Boom
Operating speed

Down 2.1 ~ 2.7

Operating time of
In 3.4 ~ 4.0
cylinder Arm sec (At no load)
Out 2.9 ~ 3.5
(At no load)
Digging 2.7 ~ 3.3
Bucket
Dumping 1.9 ~ 2.5
RH
Swing speed 17.1 ~ 19.1 sec / 3 rev
LH
1st speed Iron shoe 19.6 ~ 24.6
Travel speed sec / 20 m
2nd speed Iron shoe 12.3 ~ 14.3
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance

58 ~ 98 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 120
ATT amount of drift Boom cylinder 4.2 mm / 5min (At no load)
Arm cylinder 6
Amount of horizontal play at the bucket tooth 27 ~ 53 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
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED
(1) Warming up of engine
Start engine to raise the coolant temperature of
engine to 60 to 90° C (140 to 194° F) at surface of
radiator upper tank.
The E/G coolant tem-perature gauge is used to
measure. The range in white color shows the
temperature of approx. 65 to 105° C (149 to 221° F),
so confirm that the pointer indicates the
temperature within the white range.

(2) Engine speed measured value through service


 

diagnosis (See Fig. 13-2)
1) Turn "ON" the starter switch with the buzzer stop
switch pressed.
2) A program No. and an actual engine revolution
are displayed as the No.2 Item.
3) The screen advances like No.2, No.3....each
 
time the "Wiper switch" on the gauge cluster is  
pushed.
 
4) The screen returns like No.45, No.44....each  
time the "Washer switch" is pushed.
5) The display does not disappear unless the   
starter switch is turned to"OFF".
    
Fig. 13-1 Switch for E/G speed indication

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

Fig. 13-2 Service diagnosis for E/G speed

measuring (Example)

13-6
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge : 1unit
49 MPa (7100psi) pressure gauge : 2 units A3 a5
Pressure measuring equipment and instrument for
analysis : 1 set A2
PSV2 (A1)
(2) Measuring cleanliness of hydraulic oil (PSV1)
Dr3
B3

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.

13.4.2 PLACE TO INSTALL PRESSURE GAUGE

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

13-7
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve

PLUG FOR
OR8 : ARM (R) OPTIONAL RELIEF

MACHINE
FRONT

MR1 : MAIN RELIEF OR3 : BOOM (H) OR2 : BUCKET (R)

(ATT & TRAVEL)

VIEW FROM THE TOP OF THE MACHINE

OR4 : BOOM (R) OR1 : BUCKET (H)

MACHINE
FRONT

OR7 : ARM (H) PLUG FOR OPTIONAL RELIEF

VIEW FROM THE BOTTOM OF THE MACHINE

Fig. 13-4 Relief valve position on main control valve

13-8
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

(2) Pilot relief valve

The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.

A3

a5

Dr3

B3
PR1 ADJUST SCREW
FOR PILOT RELIEF

Fig. 13-5 Pilot relif valve position

(3) Swing over load relief
The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is carried out
using gauge ports (a1) and (a2). (See Fig. 13-3)

  



 
 
 
 







  



 


 
Fig. 13-6 Swing over load relief position

13-9
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).

: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)

: 6 mm

No. of turns of adjust screw Pressure change MPa (psi)

LOCK NUT HEX24
1 turn Approx. 2.1 (305) 311
Fig. 13-7 Pilot relief valve
(2) 2-stage main relief valve
(Commom for travel and ATT sections) 0-:! 0-:'
Start from the boosting side, first. Loosen nut (1),

adjust the pressure with adjusting screw (2) and
tighten nut (1) after completion of the adjustment on
the boosting side.
Then, loosen nut (3), adjust the pressure on the
standard side with adjusting screw (4) and tighten
" !
nut (3) after completion of the adjustment. 0-:
: 32 mm, Fig. 13-8 Main relief valve
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft) (Travel section, ATT common section)

: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)

: 19 mm, Adjust screw

: 6 mm

No. of turns of adjust screw Pressure change MPa (psi)

Boosting side 1 turn Approx. 17.6 (2560)
STD side 1 turn Approx. 17.6 (2560)

(3) Over load relief valve

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw
(2).

: 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)

1 turn Approx. 17.7 (2560)

13-10
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

(4) Over load relief valve (Swing) 0-:!& 0-:!

When the adjustment of pressure is required, 
loosen lock nut (1) and adjust the pressure with cap
(2).

: 30, 38 mm,
Tightening torque : 118 N•m (87 lbf•ft)
4 !
: 12 mm Fig. 13-10 Swing over load relief valve

No. of turns of adjust screw Pressure change MPa (psi)

1 turn Approx. 10 (1450)

(5) Travel over load relief valve

This valve was adjusted by valve maker. Do not
replace any inner parts except for O-ring.

Fig. 13-11 Travel over load relief valve

13-11
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED
(1) Purposes
Measure the track link revolution and confirm the
performances between the hydraulic pump and the
travel motor of the travel drive system.
(2) Conditions
Hydraulic oil temperature ;
45~55°C (113~131°F)
Crawler on the right and left sides are tensioned
evenly.
(3) Preparation
Attach the reflection panel shoe plate. Fig. 13-12 One side lifted position
Swing the swing frame through 90°as shown in Fig.
13-12 and make the crawler on one side take off the
ground, using the attachment. REFLECTION
PANEL
(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st-speed and 2nd-speed
Measuring points ; Right and left
Method, example
Measure the revolutions visually.

Fig. 13-13 Adhering position of reflection panel

Track link revolution Unit : sec / 3 rev

Measurement item Standard Reference value Service
value for remedy limit
H mode 1st speed 31.1~34.3 39.8~43.9 49.1~
STD
H mode 2nd speed 18.4~20.4 23.6~26.1 29.1~
H mode 1st speed 33.2~36.4 42.5~46.6 57.2~
LC
H mode 2nd speed 19.7~21.7 25.2~27.8 31.1~

13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20m (66ft) BOOM FOOT PIN
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the
travel drive system.
(2) Condition
Hydraulic oil temperature ; ARM TOP PIN
45~55°C (113~131°F)
RH and LH crawler are tensioned evenly.
Firm, level ground Fig. 13-14 Travel position
Engine revolution; Hi idle

13-12
 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")

13.5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a stopped
condition of the machine in a no-load travel position
and on a 15 degree slope.
(2) Condition BOOM FOOT PIN
A slope with (Approx. 15 deg) gradient and a
stopped condition in a no-load travel position
ARM TOP PIN
(3) Preparation
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 15 degree. 15 degree slope
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark Fig. 13-16 Parking brake operating position
(matching mark) on the shoe plate.
(4) Measurement
Five minutes after the engine stops, measure the
movement distance of the matching mark.

C
GUIDE FRAME
Fig. 13-17 Method of measurement

Parking brake Unit : mm/5min

Measuring Reference value
position Standard value for remedy Service limit
C 0 1 (0.04 in) 2 (0.08 in)

13-13
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose FORWARD 90 o 10
To measure the drain rate of the travel motor and to (3.54") (0.394")

confirm the performances of the travel motor. o 22 PIPE 40

(0.866") (1.57")
(2) Conditions
Hydraulic oil temperature ; RIB "A" STOPPER
150
(5.91")
45~55°C(113~131°F) "B"
Engine revolution; Hi idle
(3) Preparation o 90
(3.54")
ROTARY DIRECTION
1) Place a stopper under the RH and LH travel
sprockets. Fig. 13-18 Location of stopper applied to travel
2) Stop the engine and release pressure from the sprocket
hydraulic circuit.
3) Connect a hose with the drain port of the travel
motor and take drain in a container.
(4) Measurement ; at Travel Lock

Unless you observe the rotary force direction at

travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Fig. 13-18)

1) Start the engine and relieve pressure at the full

stroke of the travel lever. Fig. 13-19 Method of measuring the drain rate of
2) Measure the drain rate for 30 seconds of travel motor
relieving.
Travel deviation Unit : L/30sec
Measuring Reference value
position Standard value for remedy Service limit
Drain rate 7.0 (1.8 gal) 14.0 (3.7 gal) 21.0 (5.5 gal)

13-14
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump and the
swing motor of the swing drive system.
(2) Conditions
Hydraulic oil temperature ;
45~55°C (113~131°F)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
Put the bucket empty and extend the boom, arm
and bucket cylinder fully. Fig. 13-20 Swing speed measuring position (at the
And the machine becomes a position of minimum min. reach)
reach.
(4) Measurement
Swing the machine by bringing the swing lever to its
full stroke. Measure the time required to make three
turns after one turn of preliminary run.

13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose $ 

  ! 
"# 

Confirm the braking torque performances by the
   








swing relief valve.      


   
(2) Conditions
Hydraulic oil temperature ;

   
45 ± 55°C (113±131°F)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
1) Put the bucket empty, retract the arm cylinder
1.5m (4'11")
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is Fig. 13-21 Swing brake performance measuring
positioned at same height with boom foot pin. position
2) Put a matching mark on the outer circumference
of the swing bearing of the upper frame side and
of the track frame side. Place two poles (flags)
on the front and back of the extended line of the
matching mark.

13-15
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(4) Measurement MEASURING THE LENGTH OF THE ARC OVER

THE OUTER CIRCUMFERENCE OF OUTER RACE
1) When operating in regular swing speed, by
MATCHING MARKS ON
shifting lever to neutral position at pole position
OUTER RACE
the swing operation stops.
2) Calculate the swing drift angle by the following
equation, after the upper swing body stops,
using the amount of deflection (m) of the
matching marks on the swing race and the length
MATCHING MARKS
(m) of the circumference of the swing race : ON INNER RACE

       Fig. 13-22 Measuring position of swing brake

   
  
 
  performances
      
      
   
  Swing brake performance Unit : degree
Measuring Reference value
position Standard value for remedy Service limit
Swing 180 98 or less 108 118

13.6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside of the
swing motor.
(2) Conditions
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Put
the bucket empty, retract the arm cylinder fully and
extend the bucket cylinder fully. And move the
boom so that the arm top pin is positioned at same
height with boom foot pin.
Fig. 13-23 Swing parking brake performance
measuring position
(3) Preparation MEASUREING THE LENGTH OF THE ARC OVER
Put the angle meter on the shoe plate and make THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
sure that the angle is more than 15 degree. OUTER RACE
Put a matching mark on the outer race side and on
the inner race side.
(4) Measurement
When five minutes has passed after the engine
stops, measure the length of the movement of the
MATCHING MARKS
matching marks. ON INNER RACE

Fig. 13-24 Measuring position of swing parking

brake performances

Performance of swing parking brake Unit : mm/5min

Measuring Reference value
position Standard value for remedy Service limit
C 0 1 (0.04 in) 2 (0.08 in)

13-16
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
(2) Conditions
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
1) Stop the engine.
2) Release pressure from inside the hydraulic
circuit.
3) Disconnect the swing motor drain hose from its
end returning to the hydraulic oil tank and take
oil in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock Fig. 13-25
1) Start the engine and put the side faces of bucket
Travel deviation Unit : L/30sec
against the inside of the right or left shoe plates. Measuring Reference value
position Standard value for remedy Service limit
2) Relieve the swing motor at full stroke of the
swing motion. Drain rate 2.1 (0.55 gal) 5.2 (1.4 gal) 6.2 (1.6 gal)

3) Collect the amount of drained oil in a container

for 30 seconds.

13-17
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm and
bucket and confirm the performances between the
hydraulic pump and the cylinder of the attachment
drive system.
(2) Condition 30cm (1ft)
Hydraulic oil temperature ; 45~55°C(113~131°F) Fig. 13-26 Measuring position for bucket digging
Engine revolution; Hi idle and dump
Operating time excluding the cushion stroke


 
(3) Preparation  
   
  
 
Firm level ground with the bucket empty
(4) Measurement 1 ; Boom up and down
With the boom operating lever at full stroke,
measure the required operating time of the bucket
between the ground surface and its highest
position.
Fig. 13-27 Measuring position for boom up and
down motions

When lowering the boom, allow the bucket onto a

soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other
solid material.
30cm (1ft)
Measurement 2 ; Arm in and out, bucket digging
and dump Fig. 13-28 Measuring position for arm in and out
In a position in which the tooth of the bucket rises to motions
a level of about 30cm (1ft) above ground, measure
Cylinder Operating time Unit : sec
the full stroke operating time required with the arm
Measuring Reference value
and bucket operating levers at full stroke. position Standard value for remedy Service limit
2.7~3.3 3.5~4.2 4.5~
1.9~2.5 2.4~3.2 3.3~
2.7~3.3 3.5~4.2 4.5~
2.1~2.7 2.7~3.5 3.6~
3.4~4.0 4.4~5.1 5.6~
2.9~3.5 3.7~4.5 4.8~

13-18
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by checking the   
moving length of the cylinder rods.

(2) Condition 
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground    
After cylinders are replaced, bleed off air from the
cylinders, before checking for oil tightness. Fig. 13-29
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range Oil tightness of cylinder Unit : mm/5min
of the cushioning mechanism. Measuring
Standard value
Reference value
Service limit
position for remedy
(3) Preparation A 4 (0.16 in) 5 (0.2 in) 7 (0.28 in)
Put the bucket empty. Extend the arm cylinder rod B 6 (0.24 in) 7.5 (0.3 in) 10 (0.4 in)
50mm (2in) from the most retracted position. And C - - -
extend the bucket cylinders fully. Then hold the D 120 (4.7 in) 150 (5.9 in) 200 (7.9 in)
boom so that the arm top pin is positioned at same
height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is
turned off.

13-19
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.8 MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose
LOCATION OF BEARING
Measure the gap between the lower frame and the MOUNTING BOLTS
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.
SWING BEARING
(2) Condition A
Firm, level ground
The swing bearing mounting bolts are not
DIAL INDICATOR
loosened.
The swing bearing is lubricated well, not making LOWER FLAME
abnormal sound during turning.
Fig. 13-30 How to measure the axial play of swing
bearing
(3) Preparation
1) Install a dial indicator to the magnetic base and
fix it to the lower frame.
90 ~100
2) Direct the upper swing body and the lower frame
toward the travel direction, bring the probe of the
dial indicator in contact with the bottom surface
of the outer race on the swing body side and set 30cm (1ft)

the reading at zero. Fig. 13-31 Measuring position 1

(4) Measurement 1 (Measuring position 1 and 2)
1) Measure the displacement of the outer race in ARM TOP BOOM FOOT
PIN PIN
the axial direction in position 1 [The arm at
90°~110° and the crawler front is lifted by
attachment about 30cm (1ft)] and in position 2,
using a dial indicator.

Fig. 13-32 Measuring position 2

Axial play of swing bearing Unit : mm (in)

Measuring Reference value
position Standard value for remedy Service limit
0.8~1.8 2.3~3.3 3.6~
A (0.03~0.07) (0.09~0.13) (0.14)

(5) Measurement 2 (Measuring position 3)

1) With the arm cylinder most retracted and the ARM TOP BOOM FOOT
PIN PIN
bucket dump, lift the tip of the tooth of the bucket
about 10mm (0.4in) and swing the tip of the
bucket to the right and the left by the man power.
But in this case, the gap of the attachment is
included.

Fig. 13-33 Measuring position 3

Right and left movement of the tip of bucket Unit : mm (in)

Measuring Reference value
position Standard value for remedy Service limit
Bucket 30~50 (1.18~1.97) 100 (3.94) 120 (4.72)

13-20
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT

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

Fig. 13-34 INPUT / OUTPUT

13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT)

13.9.2.1 PURPOSE OF THE ADJUSTMENT

There are 3 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function
to ensure performance of machine.
(1) Adjustment of engine ("A" adjustment)
This adjustment is performed to set the relation between the acceleration command voltage output from
mechatro controller to engine controller and the engine speed.
(2) Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with
engine rated output.
(3) Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of unloading valve to improve the operability further.

13.9.2.2 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;

When the following parts are replaced or repaired, carry out the adjustment without fail.
(1) Mechatro controller
(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve

13-21
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
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9.2.4 ADJUSTING PROCEDURE

MULTI DISPLAY

BUZZER STOP SWITCH WORK MODE SELECT SWITCH

WASHER SWITCH

WIPER SWITCH
SELECTOR SWITCH

Fig. 13-35 Gauge cluster

(1) Adjustment of engine ("A" adjustment)
Procedure
1) Turn starter key switch ON keeping the work mode selector switch on the  
gauge cluster pressed, and hold it for 5~10 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 selecting adjustment is displayed. When adjustment data
ADJUST
READY
is not entered in mechatro controller, "READY" is indicated. If the adjustment FEED
operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Press selector switch on gauge cluster to display "START ENG".
START ENG
"Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ENGINE SPEED
2000rpm
command voltage) are indicated. PUMP PRESSURE
C-1 00.0M C-2 00.0M
STEP
140

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
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(2) Adjustment of pump ("B" adjustment)

Procedure
1) The adjustment automatically shifts from engine to pump, the speed shifts

  
from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the
 




unloading proportional valve and pump proportional valve actuate, accordingly   


   
the loading of pump is increased. 


 
 
The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value) are indicated.
2) After detection of the engine rated speed, the adjustment of pump is
FINISH PUMP
automatically completed. And "FINISH PUMP" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared PUMP PRESSURE
C-1 35.0M C-2 35.0M
and the adjustment is completed. The unloading adjustment required later is PROPO-VALVE
E-1 300mA E-2 300mA

not performed, and default value is written.)

(3) Adjustment of unloading valve ("C" adjustment)

Procedure
1) The adjustment shifts from pump to unloading, and the unloading valve
MEMORY UNLOAD
actuates, accordingly the pump pressure is detected. And "MEMORY ENGINE SPEED
2000rpm
UNLOAD" is displayed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PROPO- PROPO-VALVE
D-1 300mA D-2 300mA

VALVE" voltage (command value) are indicated.

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.    

The adjusting current value is indicated on the display of current of P1, P2

unloading proportional valves. The adjusting range is usually 520~635mA.

Stop the engine. (The adjusted data is automatically stored.)

(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
 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.

The P1 and P2 pump pressures usually increase to 33~38MPa

(4785~5510psi).
When the pressure does not increase;
a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
• Check that the pump proportional valve operates normally.
• Check that the pump regulator operates normally.
And so on.
3) In cases where unloading valve can not be performed; And "ERROR
ERROR UNLOAD
UNLOAD" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
The pump pressure does not increase up to the pressure in the range of the D-1 300mA D-2 300mA
specified adjustment. Or the increased pressure is held as it is.
Judging condition 2:
Pressure sensor of either P1 pump or P2 pump is failed.

Normally the pump pressures of P1 and p2 pumps gradually increase to

10~25MPa (1450~3625psi).
(It may be affected by operating oil temperature.)

When the pump pressure does not increase;

a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
(5) Other precautions:
1) In the event of a failure, there is case where the adjustment may not be
performed normally.
First serve the machine, and perform the adjustment work.
2) In the condition where large load is constantly applied to engine, the
adjustment could not be performed normally.

For machines equipped with lifting magnet, turn the generator OFF.

13-25
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".
START ENG
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ENGINE SPEED
2000rpm
command voltage) are indicated. PUMP PRESSURE
C-1 00.0M C-2 00.0M
STEP
140

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

(acceleration command current) are indicated.

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.    

The value of adjusting current is indicated on the display of current of P1 and

P2 unloading proportional valves. The adjusting range is usually 520~635mA.

Stop the engine. (The adjusted data is automatically stored.)

13-26
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER

(1) Engine emergency mode
When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating
emergency acceleration (E-27) provided on the seat rear side. (See Fig. 13-34)

Operating procedure:
1) Set the emergency acceleration to NORMAL position.
2) Start engine.
3) Turn the emergency acceleration to HI side and control the engine speed.
4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping.

Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed does not increase.
When the machine does not operate, set the emergency acceleration to NORMAL position.

(2) Pump emergency mode

In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is
indicated on multi display provided on the gauge cluster, the full power control of pump and positive control
through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to
emergency mode, making the operation with the power shift control of pump and the constant power control by
means of self-pressure possible. But be careful that, at emergency mode, the accuracy of inching becomes poor,
the frequency of engine down is increased, and the engine stalls in LOW speed condition.

The emergency mode should be used in only case of emergency. We recommend that the defective section is
repaired by troubleshooting as early as possible.

13-27
13. MAINTENANCE STANDARD AND TEST PROCEDURE

[MEMO]

13-28
 21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM.........................................................21-4

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ..................................................21-4
21.1.2 UNLOAD VALVE CONTROL..................................................................................21-6
21
21.1.3 POSITIVE CONTROL & P-Q CONTROL ...............................................................21-7
21.1.4 BOOM UP CONFLUX CONTROL ..........................................................................21-9
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL.............................................21-10
21.1.6 ARM-IN ANTI-CAVITATION CONTROL ................................................................21-12
21.1.7 ARM-OUT CONFLUX CONTROL ..........................................................................21-13
21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL ..............................................21-14
21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL ..............................................21-15
21.1.10 SWING PRIORITY CONTROL ...............................................................................21-17
21.1.11 TRAVEL STRAIGHT CONTROL ............................................................................21-18
21.1.12 PRESSURE RELEASE CONTROL ........................................................................21-20
21.1.13 N&B SWITCH CONTROL (OPTION) .....................................................................21-21
21.1.14 OPTION CONFLUX CONTROL (OPTION) ............................................................21-22
21.2 MECHATRO CONTROLLER...........................................................................................21-23
21.2.1 SUMMARY OF MULTI DISPLAY ...........................................................................21-23
21.2.2 SELF DIAGNOSIS DISPLAY..................................................................................21-28
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................................21-30
21.2.4 TROUBLE HISTORY DIAGNOSIS.........................................................................21-40
21.2.5 TROUBLE DIAGNOSIS MODE ..............................................................................21-41
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE ...........................................21-42
21.2.7 ADJUSTING PROCEDURE OF DISPLAY .............................................................21-43
21.2.8 MECHATRO CONTROL EQUIPMENT ..................................................................21-47

Book Code No. S5LC2111E02

21-1
21. MECHATRO CONTROL SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC2111E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2111E02
Revision February, 2007 ↑ K
(ASIA, OCE)

21-2
 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
21. MECHATRO CONTROL SYSTEM

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL

$
$
 $ 
 
 $
 

 $
$$

 $  

 



 $  
 

 $

   
$  $  

 $  

 $  
 $

 $$

'

 (


 $ $  

  ) *

& 


 

 

 

  $
 

 
   



$ 



 $ $
+ 

 
&
 &+


 

 
),,
 $ 


& 

&

 
$

$$  $





 $

 $





 
 


 

 

$ $
   



#
$ 


 

 

 
  $  

  


 
    !"  
 #
$   $  


% 


   $


 & 


 

$

$$   !" $
 !"



 
 
$
 
 $
$
$
  $

$  
$

 



 



21-4
 21. MECHATRO CONTROL SYSTEM

MAIN CONTROL VALVE

L1

SE-29

ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

(8) (2) (4) (3) (6) (8) SV-13

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

SWING MOTOR PARKING RELEASE

TRAVEL MOTOR 1,2 SPEED SELECT

BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE

SAFETY LOCK LEVER

ATTACHMENT BOOST

TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
ARM IN 2 SPEED

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
21. MECHATRO CONTROL SYSTEM

21.1.2 UNLOAD VALVE CONTROL

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

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

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
 21. MECHATRO CONTROL SYSTEM

21.1.3 POSITIVE CONTROL & P-Q CONTROL

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

(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE

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

PILOT SECONDARY PRESSURE

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
21. MECHATRO CONTROL SYSTEM

(1) Positive control

1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low
pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator, and
consequently the working speed according to the lever manipulated movement will be obtained.
(2) P-Q control
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller and
the mechatro controller processes pilot signal and operates the command according to the input voltage
(load pressure).
2) The lower value between command values calculated by positive control and operated value found by P-Q
control {operated value found in item 1)} is selected and is output to each pump proportional valve as
command value.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and
consequently working speed will be obtained according to lever movement.

POSITIVE CONTROL P-Q CONTROL

PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

SECONDARY PRESSURE

SECONDARY PRESSURE
PUMP PROPORTIONAL

PUMP PROPORTIONAL

PILOT PRESSURE PUMP DELIVERY PRESSURE

21-8
 21. MECHATRO CONTROL SYSTEM

21.1.4 BOOM UP CONFLUX CONTROL

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

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
BOOM UP PILOT SECONDARY PRESSURE SECONDARY PRESSURE

(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
21. MECHATRO CONTROL SYSTEM

21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL

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

ARM IN PILOT SECONDARY PRESSURE

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SECONDARY PRESSURE

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM IN PILOT SECONDARY PRESSURE

P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D

PILOT SECONDARY PRESSURE

pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE

P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE

21-10
 21. MECHATRO CONTROL SYSTEM

(1) Recirculation and conflux (Low loading)

1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool
and low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves,
P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor
and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal
according to the combined operation and outputs command, which is different from the arm-in independent
operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for
arm-in 2 spool.
3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it
switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls
recirculation rate and conflux rate.)
The other proportional valves output proportional secondary pressure according to command from mechatro
controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload
valve.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload
spools and arm 2 spool are switched according to the command output by mechatro controller, and
consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil
during arm operation.
(2) Recirculation cut
The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is
raised during arm operation the mechatro controller processes pilot signal processing according to the pressure
detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for
arm-in 2 spool.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command
output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently
recirculation passage is blocked.

21-11
21. MECHATRO CONTROL SYSTEM

21.1.6 ARM-IN ANTI-CAVITATION CONTROL

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

ARM IN PILOT SECONDARY PRESSURE

pi PILOT SIGNAL
PROCESS REVERSE PROPORTIONAL
VALVE CONTROL PROCESS
FOR ARM 2 SPOOL PSV-Bpi

ARM IN PILOT SECONDARY PRESSURE

pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE FOR ARM VALVE FOR ARM 2 SPOOL
2 SPOOL COMMAND PSV-A pi

ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

(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
 21. MECHATRO CONTROL SYSTEM

21.1.7 ARM-OUT CONFLUX CONTROL

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

ARM OUT PILOT SECONDARY PRESSURE

pi

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

ARM OUT PILOT SECONDARY PRESSURE

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM OUT PILOT SECONDARY PRESSURE

pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
ARM OUT PILOT SECONDARY PRESSURE
SECONDARY PRESSURE

(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
21. MECHATRO CONTROL SYSTEM

21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL

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

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVELSTRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

(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
 21. MECHATRO CONTROL SYSTEM

21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL

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

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
ACCEL VALVE PSV-B
POTENTIO
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

BUCKET DIGGING PILOT SECONDARY PRESSURE

PILOT SIGNAL
pi PROCESS
BUCKET ATT BOOST
ANTI-CAVITATION SOLENOID VALVE
PROCESS SV-2

ENGINE SPEED (COMMAND VALUE)

MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

21-15
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
 21. MECHATRO CONTROL SYSTEM

21.1.10 SWING PRIORITY CONTROL

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

MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE

(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
21. MECHATRO CONTROL SYSTEM

21.1.11 TRAVEL STRAIGHT CONTROL

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

TRAVEL STRAIGHT SIGNAL

pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE
PILOT SECONDARY PRESSURE CONTROLLER
SECONDARY PRESSURE

21-18
 21. MECHATRO CONTROL SYSTEM

(1) Judgment travel straight

1) During travel operation (right and left), pilot pressure switches each spool and is input to low pressure sensor
on carrying out attachment system operation.
2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in
the table from the low pressure sensor and turns travel straight signal on.
3) On turning travel straight signal on, the following commands are output to each proportional valve.
(2) Operation of each proportional valve
(Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in travel
straight condition.)
1) Travel straight proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system operating
(Boom, arm, bucket, swing, option) pilot pressure during operation.
2) P1 unload proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system operating
pilot pressure during operation.
3) P2 unload proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot pressure during
operation.
4) P1 pump proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system operating
pilot pressure during operation.
5) P2 pump proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot pressure during
operation.





     

 


 



21-19
21. MECHATRO CONTROL SYSTEM

21.1.12 PRESSURE RELEASE CONTROL

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
 21. MECHATRO CONTROL SYSTEM

21.1.13 N&B SWITCH CONTROL (OPTION)

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

B MODE SWITCH MECHATRO

CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID

(1) Nibbler circuit

1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main
control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display
is output to gauge cluster.
(2) Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display
is output to gauge cluster.

21-21
21. MECHATRO CONTROL SYSTEM

21.1.14 OPTION CONFLUX CONTROL (OPTION)

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

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE
OPTION PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE

(1) Select the Conflux with the aid of Conflux/Single switch.

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

21-22
 21. MECHATRO CONTROL SYSTEM

21.2 MECHATRO CONTROLLER

21.2.1 SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
(1) Controls

EMERGECY ACCEL DIAL

SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER

SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.

FUSE &
STARTER SWITCH RELAY BOX

ACCEL DIAL
DETAIL A

(2) Gauge cluster

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
21. MECHATRO CONTROL SYSTEM

(3) Screen selection by work mode select switch

Press the work mode selector switch ( ) in order, and "H" → "B" → "A" → "S" mode can be selected.
Select the effective work mode according to the work condition and working target from the table shown below.
For the selected work mode, refer to the table shown below.

• S mode: For standard excavating work

• H mode: For heavy duty excavating work
• B mode: For works with breaker
• A mode: For demolition works with crusher
(Nibbler)
10:25
S
• The initial setting (default) of work mode had been set
to "S" mode at factory.
As for the work mode after the engine starts, the
mode that was used the last time engine was stopped
is automatically set.
Check that the selected mode conforms to the work
before starting work.
• Check that the attachment in use conforms to the
work mode before starting work. If not conformed,
select proper mode with the work mode select switch.
• The operation under improper work mode may cause
damage to machine.

Work mode Display Contents

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".

For the work with breaker, select "B mode" without fail.
The work with breaker in any mode other than "B mode" may cause damage to the hydraulic equipment and
breaker.

21-24
 21. MECHATRO CONTROL SYSTEM

1) Pump flow rate adjustment (A mode /B mode)

No. Switches 1 2 3 4
1 Screen change switch
2 Buzzer stop switch
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 21-1

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 210L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.

Main screen Attachment mode (A mode)

10:25 Flow
rate 294 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m

Enter
H A A
(a) (b) (d)
Increase/Decrease

In Breaker mode (B mode)

Flow Flow Flow

rate 294 L/m rate 100 L/m rate 100 L/m

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 294 L/m rate 294 L/m

A B
(b) (c)

1. Turn starter key switch on and display main screen (a).

2. The display on the left lower corner of screen is changed in order of "S" → "H" → "B" → "A" each time the
"MODE" switch (3) is pressed under the condition where main screen (a) is displayed.
3. Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed.
4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and
the screen (d) is displayed. In this condition, press FEED (4)/ (5) and the flow rate value increases or
decreases.
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.

21-25
21. MECHATRO CONTROL SYSTEM

(4) MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the end of recommended replacement/change interval specified for
filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.

Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
ASIA 2,000 Hr
Hydraulic oil
OCEANIA 5,000 Hr

This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.

1. Remaining time display to the engine oil change

This display shows the remaining time to the coming engine oil change. 492Hr
ENGINE OIL
H

2. Remaining time display to the coming fuel filter replacement

This display shows the remaining time to the coming engine fuel filter 492Hr
replacement. FUEL FILTER
H

3. Remaining time display to the coming hydraulic oil filter replacement

This display shows the remaining time to the coming hydraulic oil filter 992Hr
replacement. HYD. FILTER
H

4. Remaining time display to the coming hydraulic oil change

This display shows the remaining time to the coming hydraulic oil 1992Hr
change. HYD. OIL
H

• 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
 21. MECHATRO CONTROL SYSTEM

(5) Gauge cluster display

After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The
display functions of multi display are explained below.
CLOCK DISPLAY

SELF DIAGNOSIS / WARNING

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.

. Warning These descriptions indicate error codes.

CAUTION LOW ENG OIL

W009 W005 PREHEAT W011
ATTACHMENT PRESS.

HIGH ENG
AUTO IDLE STOP WATER TEMP.
W006 CHARGE ERROR

POWER BOOST LOW ENG WATER

ON LEVEL
W004 LOW FUEL LEVEL

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.

21-27
21. MECHATRO CONTROL SYSTEM

21.2.2 SELF DIAGNOSIS DISPLAY

(1) Outline
This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine
operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector
No. and pin No., refer to the section "C-1 Mechatro controller" explained later. Electric circuit diagram or harness
is available to identify wire No. and wire color.
(2) I/O configuration


!
        

   


      
 

   

   

(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with
the aid of error code.
(%") ",'" #)"$  !" &,, !!"'.



 /) *' *' !' '-) 0("," "' ",)&*.
/) '-) 0(","  !" )#(".
 1 1   !" #$%&  '(#"' $ )*"& # +) "!!&! ,&'" ' !*-  !" '-*&.

      
/) 7 &*)!&"! /&+ (!" !" - (!" !" !&(&!)&* !&(&!)&* 0&"*&' 0(""' "*&! &)"*)&$")"! &$$ *,)&*
))"!# !"# *-*" 4 "# & )( )
'-) $"$&!# "*&! "*&! 55" &! 55" 55" &! ( $( 55" "),
*-*"
&&$ ( ( $( *&' ( $(  %&&) ,,""!)&*
))"!# !"# 8("! !6
'2 ) ') (!"5"*)&* !"#
&!3 "
&&$ '&+*  ( $(  *&'  ( $( 0+*- (!6*-
&&$ *-" 8("! !6 &!+!'
 '2 ) ') !&))&* !"#
4*&' !$ & )
&&$ "' !5" )!-) !5" 7 *-" "*&! !$ *-" 8("! !6 !"5"!"
 '2 ) ') (""' &! &5" !&))&* !"#

&&$ ( !$ *
&&$ !&' 1()&* *-" "*&! &! 8"! $&)&!
 '2 ) ') "",)&! &5" : 4
!$ *
,6")
,6") )!&6"
 '2 ) ') '--*- $)
!$ & )
,6") !$  (&&
 '2 ) ') ' $( &! !$ *
0+*-


!5" !-)  " "*&!

!5" ")
""! )& *"<) (-" =*-*">

0"",)&! (&)&*  9
'")",)&* ,&$$ *,)&*

0+*- "!
 !-) !"#
0+*- "!
 ") !"#
!5" !$
 !"#
'" &()&* 0 !"# 

 '" &()&* *-*" )&(
 !"#
0")# &,6
 "5"! !"#

'2 )$"*) 0")# !"#
 ') ",)&!
'2 )$"*)
 ') ",)&! 
& !$")"!
 ",)&!
& !$")"!
 ",)&! 
!&(&!)&*
 55" '2 ) ')
 )"!
 ,&$$ *,)&*
""! )& *"<) (-" =*-*">

/!-"! )* /!-"! )*

*&!$ !*-" *&!$ !*-"
!*)&! 1  9 "!!&!
 !" ; !& *'*-
 &!) ,!, )
8!&*- & )( ) 8!&*- & )( ) !*)&! !*)&! 15"! ! *
  19  !" 19  !"
,&**",)&* ,&**",)&* ,&**",)&* ,&**",)&* !*)&! 19 ,&**",)&* ,&**",)&* $"  &5"!
 !" ;
  ,&**",)&*
&+"! & !," &+"! & !," &+"! & !," &*),) (&*)  &+"! & !,"
  &!) ,!, ) &!) ,!, ) &!) ,!, ) $")"' *' '"!"' &!) ,!, )


21-28
 21. MECHATRO CONTROL SYSTEM

Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.

21-29
21. MECHATRO CONTROL SYSTEM

21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This
section explains the operating procedure and examples of each screen. The values in display changes according to
the conditions like engine speed, attachment position, etc.
(1) Service diagnosis display screen operating procedure

1) Turn starter switch ON keeping buzzer stop switch pressed.

2) After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.
• Mode No.1 : Screen No.1~No.30
• Mode No.2 : Screen No.1, Screen No.31~No.40
• Mode No.3 : Screen No.1, Screen No.41~No.50
3) The screen changes each time each switch is pressed from now on.
Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...)
Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1.
(No.1→No.2→No.3→No.1→...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to
No.3. (No.3→No.2→No.1→No.3→...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.

21-30
 21. MECHATRO CONTROL SYSTEM

(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low
speed and lever to neutral position.)
1) Service diagnosis mode No.1
No. Displays Contents No. Displays Contents
1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YN22E00001F1 P/No. indication K-1 AIS RELAY 2 OFF Indicated value
PROGRAM VERSION K-2 SAFETY RLY OFF Indicated value
1-VER 11.11 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 00.00 MERIT controller program version KEY SWITCH OFF Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER OFF Indicated value
SWITCH OFF Switch

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

21-31
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

21-32
 21. MECHATRO CONTROL SYSTEM

No. Displays Contents No. Displays Contents

23 27
NO.23 DIGITAL OUTPUT NO.27 MERIT SYSTEM
DO15 COMP. OFF Set value in computer
MEAS. OFF Measured value COMMUNICATION OFF Status of communication in MERIT controller
DO16 COMP. OFF Set value in computer 4
MEAS. OFF Measured value
DO17 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO18 COMP. OFF Set value in computer 0412051200
MEAS. OFF Measured value
DO19 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO20 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO21 COMP. OFF Set value in computer
MEAS. OFF Measured value
24 28
NO.24 DIGITAL OUTPUT NO.28 ENG CONT.
DO22 COMP. OFF Set value in computer TRANS.COUNT. 100 Counted number of transmission error
MEAS. OFF Measured value RECEIVE COUNT. 100 Counted number of reception error
DO23 COMP. OFF Set value in computer DIAG STATUS 9 Diagnosis status
MEAS. OFF Measured value NUMBER OF DIAG 100 Numbers of error
DO24 COMP. OFF Set value in computer BOOST PRESS. 100 Boost pressure
MEAS. OFF Measured value BOOST TEMP. -100 Boost temperature
DO25 COMP. OFF Set value in computer BAROMETRIC P. 100 Atmospheric pressure
MEAS. OFF Measured value FUEL TEMP. -100 Fuel temperature
DO26 COMP. OFF Set value in computer FUEL CONS. 200 Fuel consumption
MEAS. OFF Measured value INTAKE TEMP. -100 Intake air temperature
DO27 COMP. OFF Set value in computer ENG PRESS. 300 Engine oil pressure
MEAS. OFF Measured value GLOW OFF Glow output from ECU
DO28 COMP. OFF Set value in computer ENG STOP OFF Engine stop command from ECU
MEAS. OFF Measured value TORQUE 1000 Calculated torque of ECU
25
NO.25 WIPER SYSTEM
WIPER SW OFF Wiper switch
RISEUP SW OFF Wiper rise-up switch
REVERSE SW OFF Wiper reverse rotation switch
PREVENT ARC OFF Wiper motor ark prevention
CW MOTOR RLY OFF relay
CCW MOTOR RLY OFF Wiper normal rotation relay
WASHER SW OFF Wiper reverse rotation relay
MOTOR RELAY OFF Washer switch
Washer motor relay

2) Service diagnosis mode No.2

No. Displays Contents No. Displays Contents

1 33
NO.1 NO.33 BUCKET
MAIN CONT. P/N C-1 P1-PRES 13.9M Pump pressure sensor
YN22E00001F1 P/No. indication C-2 P2-PRES 13.9M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 600mA Command current
1-VER 11.11 Program version indication E-2 P2-PSV 600mA Command current
2-VER 00.00 MERIT controller program version D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current
SERVICE DIAG 2 Service diagnosis mode D-3 S-TRAVEL 600mA Command current
B-5 BUCKET DIG 1.9M Bucket digging pressure sensor
B-6 BUCKET DUMP 1.9M Bucket dump pressure sensor
G-3 ENG SPEED 2205 Engine actual speed
POWER SHIFT 100mA Power shift current

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

21-33
21. MECHATRO CONTROL SYSTEM

3) Service diagnosis mode No.3

No. Displays Contents No. Displays Contents

1 43
NO.1 NO.43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YN22E00001F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 11.11 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 00.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time

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

21-34
 21. MECHATRO CONTROL SYSTEM

(3) Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these data
to decide normal/abnormal status.
• The values in following display are reference values with standard attachment attached machine.
• The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
• The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
• The current value of pump proportional valve is reference value because it varies according to pump
pressure and adjusted torque value.
• The value in display during operation shows the value in steady state, rather than, at start of operation.
• Check on machine after sufficiently warming up machine.
• The value in display may differ according to software version. Contact our dealer/distributor.

Operation No.1 : No operation Operation No.2 : No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 0.2~2.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 2070~2130 G-3 ENG SPEED 1870~1930
POWER SHIFT 0 mA POWER SHIFT 0 mA

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

No.31 BOOM No.31 BOOM

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 13.0~18.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 13.0~18.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 630~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 630~725 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
B-1 BOOM RAISE 3.0 M B-1 BOOM RAISE 3.0 M
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-35
21. MECHATRO CONTROL SYSTEM

Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 5.0~9.0 M
C-2 P2-PRES 0.2~2.0 M
E-1 P1-PSV 600~620 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427~477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA

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 9.0~13.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 9.0~13.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 750~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 750~770 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-2 395 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 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-36
 21. MECHATRO CONTROL SYSTEM

Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out 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 15.0~22.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~22.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 570~680 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 570~680 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-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 3.0 M B-3 ARM OUT 3.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Operation No.10 : Operation No.11 :

Swing in full lever operation & relief Swing 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 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 10.0~15.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 615~770 mA E-2 P2-PSV 770 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 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-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 3.0 M B-7 SWING 3.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-37
21. MECHATRO CONTROL SYSTEM

Operation No.12 : Operation No.13 :

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 7.0~11.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 7.0~11.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 670~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 600~620 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 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.14 : Operation No.15 :

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~24.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~24.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 550~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 550~770 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 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-38
 21. MECHATRO CONTROL SYSTEM

Operation No.16 : Operation No.17 :

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 530~665 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 530~665 mA E-2 P2-PSV 770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 350 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA
* Conflux switch is ON. Relief set pressure is value of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

Operation No.18 : Operation No.19 :

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
H mode Hi idle H mode Hi idle
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 7.0~13.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 7.0~13.0 M
E-1 P1-PSV 770 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-39
21. MECHATRO CONTROL SYSTEM

21.2.4 TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one
of history. And the errors are able to be indicated on the multi display.
The warning content is stored partially in "Travel history screen".
The error code for self diagnosis is stored.

(1) How to display

1) Turn starter switch on.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR

Error detected in the past

3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)

• Press washer switch ( ), and the item moves upward.

• Press wiper switch ( ), and the item moves downward.

5) Turn starter switch off, and the display is disappeared.

(2) How to delete contents of trouble history

1) Display trouble history screen.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3) When "NO ERROR" is displayed, the deletion is completed.
4) Turn starter switch off.

All the stored items are erased. It is impossible to erase data partially.

21-40
 21. MECHATRO CONTROL SYSTEM

21.2.5 TROUBLE DIAGNOSIS MODE

The recent control system includes many electrical systems and it makes troubleshooting very difficult.
The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be
detected through the use of self diagnosis function (the failure can be specified through the use of error code) like
disconnection and abnormal output. This is useful to save the time for troubleshooting.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are automatically
actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition
or failed condition of the system.

For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".

21-41
21. MECHATRO CONTROL SYSTEM

21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE

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

Screen change Buzzer stop KPSS work mode

switch switch select switch

Interval of replacement of parts is mentioned below. Washer

switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
• Hydraulic oil : 2,000 Hr (ASIA) switch select switch
5,000 Hr (OCEANIA)

Procedure Operating Procedure Display on Multidisplay

After several seconds,

display is changed to 10:25
1 Turn starter key switch on.
clock autmatically.
H

Press " " switch press once display

change switch on the switch panel once. And 10:25 Press screen change 250 Hr
2 ENGINE OIL
the clock display changes to the display of switch once more.
remaining time for coming engine oil change. H H

Press " " switch press once select

switch once and the display for the engine 250 Hr Press select switch 250 Hr
3 ENGINE OIL ENGINE OIL
oil change reverses. once more.
H

When required to adjust the interval to the coming

Replacing interval is
4
change time by 10 hours, press " " switch 250 Hr changed with each 500 Hr
and the time to the coming engine oil change is ENGINE OIL ENGINE OIL
pressing of switch.
added. Press " " switch and the time to the
coming engine oil change is reduced.

When desired to return to the initial set time,

press " " buzzer stop switch once. 500 Hr To set the desired interval, 500 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL

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.

21-42
 21. MECHATRO CONTROL SYSTEM

21.2.7 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator

1) Auto idling stop

No. Switchs 1 2 3 4
1 Screen change switch
2 Buzzer stop switch
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 21-2

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

FEED FEED FEED

(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.

21-43
21. MECHATRO CONTROL SYSTEM

2) Clock Adjustment Switches

No. Switches 1 2 3 4
1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6

Main screen (a)

SWITCH STATUS
10:25 CLOCK/CONTRAST 13:15
H H
(a) (b)

(c) (d) (e)

SWITCH STATUS ADJUST CLOCK Y M D H M Enter
CLOCK/CONTRAST ADJ CONTRAST 06 04 01 13 15

Select Year/Month/Day/Hour/Minute Increase/Decrese

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).

21-44
 21. MECHATRO CONTROL SYSTEM

3) Contrast Adjustment Switches

No. Switches 1 2 3 4
1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6

Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST

H
(a) (b)

(c) (d) (a)

SWITCH STATUS ADJUST CLOCK
CLOCK/CONTRAST ADJ CONTRAST 10:25
H

(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).

21-45
21. MECHATRO CONTROL SYSTEM

(2) Function for service

Following items are provided for adjustment of service function.

Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of 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

21-46
 21. MECHATRO CONTROL SYSTEM

21.2.8 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view

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

CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21

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

21-47
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

21-48
 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
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
 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
21. MECHATRO CONTROL SYSTEM

(2) Gauge cluster (symbol C-2)

1) General view

MULTI
DISPLAY LCD

COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.

BUZZER STOP SWITCH WORK MODE SWIHCH

2) Connector CN-600 (Harness side)

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.

4) Summary of display and drive item

No. Item Remarks

1 Monitar display LCD dot 120×168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 —
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch
8 Back light LED

21-52
 21. MECHATRO CONTROL SYSTEM

(3) Relay & fuse box (symbol E-1)

1) General view

(Overhead view of box)

LABEL INSIDE

Note) These circles indicate the parts

which are used in standard specification

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

LOCATION OF CONNECTORS (Seen from backside)

LOCATION OF RELAY & FUSE

LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME

21-53
21. MECHATRO CONTROL SYSTEM

2) Circuit diagram

21-54
 21. MECHATRO CONTROL SYSTEM

21-55
21. MECHATRO CONTROL SYSTEM

21-56
 21. MECHATRO CONTROL SYSTEM

(4) High pressure sensor : YN52S00048P1

ECONOSEAL SERIES MARK (+)> SPECIFICATION :

3POLES CAP
MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa
POWER SOURCE VOLTAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESISTANCE : 100M OR MORE
HOUSING (BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
PLASTIC POTTING CONDENSER

COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM

O-RING P14 PIPE

JIS B2401 CLASS1B
THREAD
PF 3/8
Tightening torgue STRUCTURE
73.5N.m (54.2lbf.ft)

(5) Low pressure sensor : LC52S00019P1

A AMP MQS CONNECTOR 3 POLE (B TYPE)

OPPOSITE CONNECTOR (FEMALE)
HOUSING 2-967642-1
TERMINAL (GOLD PLATED) 965906-5

CONNECTOR TERMINAL POSITION

TERMINAL No.
1 COM
2 OUT PUT (+)
3 POWER (+)

VIEW A

19 21.9 HEX

O-RING P11
PF1/4 Tightening torgue
34.3N.m (25.3lbf.ft)

DETAIL OF SENSOR CONNECTOR SPECIFICATION :

PRESSURE RANGE : 0 3.0 MPa (0 448 psi)
RATED VOLTAGE : 5.0+0.5V DC
INSURANCE RESISTANCE : 100M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)

21-57
21. MECHATRO CONTROL SYSTEM

[MEMO]

21-58
 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

Book Code No. S5LC2211E02

22-1
22. HYDRAULIC SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC2211E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2211E02
Revision February, 2007 ↑ K
(ASIA, OCE)

22-2
 22. HYDRAULIC SYSTEM

22.1 SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety,
mass volume handling and low fuel consumption.
Table22-1

Perfor- Device
mance Function Features

Travel straight Travel straight at combined operation

Travel 2-speed change & Auto 1st (low) speed return 1-2 travel speed change and low speed / high torque at heavy duty
Travel

Auto parking brake Automatic braking when parking

Motor overrun protection Prevents overrunning of travel motor on the down hill slope.
Travel pilot operation Prevents hunting by the built in travel shockless mechanism
Reverse rotation protective function Easy positioning to protect it from swinging back when stops swinging.
Swing priority circuit Easy operation of stable swing speed, arm slanted leveling,
Swing

(simultaneous operation of arm in and swing motions) swing press digging

Easy operability and safety

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).
Multi control valve (Oceania) Changeable to 4 operating pattern with only 1 lever.

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

Return circuit To prevent hydraulic oil from contamination

Cooling hydraulic oil by oil cooler
Pressure draining circuit
Main control valve with optional valve
Switching of return line for N&B machine in the cab
(Option)
Electric flow controlled variable displacement pump
Mass handling capability
To prevent hydraulic oil from being deteriorated.
To release the main circuit pressure for piping repair work.
Optional piping and additional work are easy
Switching of return line for N&B machine is able to
change with a switch in the cab
Pump delivery rate control by a current command to the

solenoid proportional valve of the variable displacement pump

Pump

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

Arm conflux circuit Speed up of arm operation

Bucket conflux circuit For speed-up of bucket operation (digging & dump)
Optimum operation by work mode select (H,S,A,B) Efficient operation in all work modes
consumption

Auto accel Reduce fuel consumption and noise by lowering engine

computer
Low fuel

Micro

speed when control lever is in neutral position.

22-3
22. HYDRAULIC SYSTEM

22.2 HYDRAULIC CIRCUITS AND

COMPONENTS
STD. SCHEMATIC HYD. LINES LC01Z00072P1 (SE, ASIA) / LC01Z00070P1 (OCEANIA)
Item Component name Part No. Model No.
LC10V00014F1 K5V140DTP (SE. Asia : without PTO.)
1 Hyd. pump assy
LC10V00015F1 K5V140DTP (Oceania : with PTO.)
2 Control valve (main) LC30V00028F1 KMX15YD
3 Swing motor unit LC15V00022F1 M5X180-CHB
4 Travel motor unit LC15V00023F1 M4V290 / 170F-RG6.5F
5 Boom cylinder (RH & LH) LC01V00044F1 ø100×ø140×1550
LC01V00054F2 ø120×ø170×1788 (SE. ASIA)
6 Arm cylinder
LC01V00054F1 ø120×ø170×1788 (Oceania)
LC01V00055F2 ø100×ø150×1193 (SE. ASIA)
7 Bucket cylinder
LC01V00055F1 ø100×ø150×1193 (Oceania)
8 Swivel joint YN55V00053F1
9 Pilot valve (ATT) YN30V00111F1 PV48K2
10 Pilot valve (travel) YN30V00105F1 6TH6 NRZ
11 Inline filter YN50V00020F1 Y-457400
12 Suction strainer LC50V00004F1 BS281J0A007A
13 Solenoid valve assy YN35V00047F1 8KWE5A-30
14 Return filter LC52V01001F1 FZ1F180A001A
15 Air breather YN57V00004F1 AB0210GA008A
Multi control valve (lever less) YN30V00113F1 Australia : STD
16
Multi control valve (with lever) YN30V00117F1 New zealand : STD
17 Restrictor YN21V00005F1 07381-00000

The part numbers may be changed due to modification,

so use only the numbers for references.

22-4
 22. HYDRAULIC SYSTEM

22.2.1 STANDARD

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13

22-5
22. HYDRAULIC SYSTEM

22.2.2 N&B SPECIFICATION (OPTION)

N&B specification YN01Z00162P1

NO. PARTS PART No. MODEL No.
50 SELECTOR VALVE YN30V00104F1 VBY-174B
51 STOP VALVE 24100P3133F1
52 PILOT VALVE YN30V00080F1 16030-00000
53 RELIEF VALVE YN22V00021F1 KRX16EK22
P2 P1 T1 T2

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

MAIN PUMP CONFLUX FLOW OF NIBBLER CONFLUX "ON"

PCa SINGLE FLOW OF NIBBLER CONFLUX "OFF"
BREAKER CONFLUX "OFF"

3. WHEN USING NIBBLER, ACCORDING TO SPECIFICATION OF NIBBLER INSTALLED,

CHOOSE CONFLUENCE OR SINGLE FLOW BY CONFLUENCE FLOW CHANGEOVER SWITCH.
4. ADJUST OVERLOAD RELIEF VALVE OF OPTIONAL PORT TO CUSTOMIZE SPECIFICATION ORDINARY SET PRESSURE.

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
 22. HYDRAULIC SYSTEM

This page is blank for editing convenience.

22-7
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,
when the servo piston moves rightward, the
FOR HYDRAULIC CIRCUITS This section describes the following. (1) Type :
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
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG
651
652 M

1 29.0MPa
611 D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

643
a3
532 8
646 a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)

22-9
22. HYDRAULIC SYSTEM

22.5 TRAVEL CIRCUIT 22.5.2 2-SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
This section describes the following.
FUNCTION
(1) Travel forward pilot simultaneous operation circuit
(1) Purpose :
(2) 2 speed travel solenoid command circuit and auto
Change travel motor speed with switch.
1-speed return function
(2) Principle :
(3) Travel main circuit
If the switch is turned, an electric signal is issued. It
(4) Travel motor function excites the 2-speed travel solenoid which in turn
converts the primary pilot pressure and the self
22.5.1 TRAVEL FORWARD PILOT
pressure to a tilting angle of the variable
SIMULTANEOUS OPERATION CIRCUIT
displacement motor.
(1) Purpose :
(3) Operation :
Light operating force and shockless operation
If the rabbit marked switch on the gauge cluster is
(2) Mechatronics :
pressed, the solenoid (SV-3) of the proportional
1) If the travel lever with damping mechanism is valve block (13) is excited and changes the
operated for travel right, left and forward proportional valve. Then the solenoid command
motions, the secondary pilot proportional pressure is issued from port A3, enters the P port of
pressure comes out of the 3, 1 ports of P/V (10). the travel motor (4), opens the oil passage to the
The higher of the pressures is selected, comes 2nd speed select piston, and causes the motor to
out of the 6, 5 ports and acts upon the low run in the 2nd speed tilting mode by its self
pressure sensors (SE9) (SE-10). pressure. However, when the main circuit pressure
2) The pilot secondary pressure flows to PAr and rises above 28 MPa (4060 psi), the motor’s self
PAL ports of the control valve (2), moves the pressure pushes the 2nd speed select piston back
travel spool, and switches the main circuit. to the 1st speed.
3) The low pressure sensor output voltage is input
22.5.3 TRAVEL MAIN CIRCUIT
into mechatro controller. The mechatro
(1) Operation :
controller performs signal processing and
The delivery oil from Pump A1 and A2 ports by
outputs current corresponding to the increase
changing the travel spool with the operation of
of flow rate to P1 pump proportional valve
travel pilot flows in each VA port on the left side of
(PSV-P1) and P2 pump proportional valve
travel motor (4) through C,D ports of swivel joint (8)
(PSV-P2), and at the same time the command
from AL, AR ports of C/V, and rotates the travel
current is output to P1 unloading valve (PSV-D)
motor.
and P2 unloading valve (PSV-B).
4) The secondary pressures output by P1 pump 22.5.4 TRAVEL MOTOR FUNCTION
proportional valve (PSV-P1) and P2 pump (1) Function :
proportional valve (PSV-P2) exert on pump
1) Prevents the motor from over running on a
regulator, actuating the pump on the delivery
slope.
flow rate increase side.
2) Check valve that prevents cavitation of the
5) The secondary pressure delivered in P1
hydraulic motor.
unloading valve (PSV-D) and P2 unloading
3) Shockless relief valve and anti cavitation valve
valve (PSV-B) is fed to PBp1, Pcb, PBp2 and
when inertia force stops.
PCa ports provided in control valve (2).
The secondary pressure from proportional 4) High/Low 2 step speed change mechanism and
valve which has exerted on PBp1 and PBp2 auto 1st speed return at high load.
ports holds the by-pass cut spool on CLOSE 5) Travel parking brake.
side, like the operation in the lever neutral
position.
The secondary pressure from proportional
valve which has exerted on PCb and PCa ports
switches the unloading spool in CLOSE side.

22-10
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.

22-11
22. HYDRAULIC SYSTEM
22.6 BUCKET CIRCUIT
This section describes the following.
(1) Bucket digging pilot circuit
(2) Auto accel operation
(3) Flow control in the work mode
(4) Bucket digging travel straight main circuit
(5) Bucket spool stroke limiter
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING
(1) Mechatronics :
1) When the operation for bucket digging is
performed, the pilot proportional secondary
pressure is delivered through port 1 of the right
pilot V (9), flows to PAc port, and acts on the low
pressure sensor (SE-1), and at the same time
the bucket spool is switched.
2) The voltage output by low pressure sensor
inputs in mechatro controller. The mechatro
controller performs signal processing and
outputs current corresponding to the increase
of pump flow rate to pump proportional valves
(PSV-P1) and (PSV-P2) on the P1 and P2
pump sides, and at the same time the
command current is output to P1 unloading
valve (PSV-D), P2 unloading valve (PSV-B) and
travel straight proportional valve (PSV-C).
In the following pages, the relation of operation
of low pressure sensor to both the increase of
pump flow rate and unloading proportional
valve is the same. Therefore the explanation is
omitted.
3) The secondary pressure output by P1 pump
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exerts on pump
regulator, actuating the pump onto the delivery
flow increase side.
4) The secondary pressure delivered in P1
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is led to PBp1, PCb, PBp2 and
PCa ports provided in control valve (2).
The secondary pressure from proportional
valve which has exerted on PBp1 and PBp2
ports holds the by-pass cut spool on CLOSE
side, like the operation in the lever neutral
position.
The secondary pressure from proportional
valve which has exerted on PCb and PCa ports
switches the unloading spool in CLOSE side.
22-12
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
PTb port provided in control valve (2) and shifts bucket cylinder head side through AC port of C/
the travel straight valve one stage. V (2). On the other hand, the return oil from
cylinder rod (R) side is throttled by bucket spool
22.6.2 AUTO ACCELERATION OPERATION
and returns to tank circuit from BC port of C/V
(1) Principle : (2).
Auto acceleration actuates according to signals
References :
from low pressure sensor.
• In bucket dumping operation, the travel straight
(2) Operation :
valve also switches like digging operation,
<When lever is set to neutral position>
resulting in confluence with travel straight.
In the event where the sensor does not receive
• When the bucket operation and other operation
signal for 4 seconds or more even though the
are simultaneously performed, the travel straight
acceleration dial is set to MAX position, the engine
valve does not actuate, resulting in single flow of
speed should be raised to 1000rpm.
bucket circuit.
<When lever is operated>
When the pressure 0.6MPa (87psi) is input to low 22.6.5 BUCKET SPOOL STROKE LIMITER
pressure sensor in STD specification (travel,
(1) Purpose :
bucket, swing, arm), proportional voltage from low
To secure simultaneous operability of boom and
pressure sensor inputs in mechatro controller, and
arm on boosting up attachment pressure (Pump
then the engine speed returns to the dial set
flow rate decreases.) and to prevent cavitations at
position corresponding to the lever operation.
low engine speed
22.6.3 STAND-BY CURRENT CONSTANT (2) Operation :
CONTROL On boosting up attachment pressure, pilot primary
(1) Principle : pressure exerts on PCc port of C/V(2) through
When the engine speed is intermediate speed or attachment booster solenoid valve, operates stroke
lower, command current value to have the pump limiter of bucket spool, and throttle oil path of spool.
delivery rate constant is output. As a result, P1 pump pressure increases, making
the simultaneous operation of boom up and bucket
(2) Operation :
digging possible.
Even if the engine speed specified by acceleration
Even though the engine speed is low, similarly the
potentiometer is low speed, as the delivery rate
cavitations can be prevented by actuating the
corresponds to the intermediate speed, the
stroke limiter.
actuator moves earlier than the movement
equivalent to the control lever angle rate in light
load operation.
22.6.4 BUCKET DIGGING AND TRAVEL
STRAIGHT CONFLUENCE (CONFLUX)
MAIN CIRCUIT
(1) Operation :
1) The oil delivered through A1 port of P1 pump
goes into P1 port of C/V (2), opens load check
valve LCc through parallel circuit and enters in
bucket spool.
2) On the other hand, the oil delivered through P2
port of P2 pump goes into P2 port of C/V (2),
confluences with oil from P1 pump through
travel straight valve, and goes into bucket
spool. (Confluence of oil from 2 pumps)
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Travel straight conflux), Auto-accelation and Standby flow rate constant control

22-13
22. HYDRAULIC SYSTEM

22.7 BOOM CIRCUIT

This section describes the boom raise conflux
operation.
(1) Boom up pilot circuit
(2) Boom up 2 pumps conflux main circuit in C/V

22.7.1 BOOM RAISE PILOT CIRCUIT

(1) Operation :
1) If boom up operation is performed, the
secondary pilot proportional pressure from the
right pilot valve (10) gets out of port 3 and acts
upon the low pressure sensor (SE3). At the
same time, the pressure acts upon the PAb and
PB1 ports.
2) The secondary pressure which enters the PAb
port of C/V (2) shifts the boom spool. The
secondary pressure which enters the PB1 port
shifts the boom conflux spool.

22.7.2 BOOM UP 2 PUMPS CONFLUX MAIN

CIRCUIT IN C/V
(1) Purpose :
Boom up speed up
(2) Principle :
Confluxing oil from 2 pumps
(3) Operation :
1) The oil delivered through A1 port of P1 pump
flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since P1
unloading valve is closed, the boom spool is
moved and bypass circuit is closed, the oil
opens load check valve LCb through parallel
circuit and flows into boom spool.
2) Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led
into H side of boom cylinder through C/V (2) Ab
port.
3) Meanwhile, the oil delivered from the A2 port of
the P2 pump enters the P2 port of C/V (2) and
due to shut off the P2 unloading valve, the oil
then passes through the parallel circuit and via
the restrictor on the circumference of the boom
conflux spool, pushes the load check valve
CCb open from the boom conflux circuit, and
combines the oil delivered by the P1 pump
internally.
4) The return oil from boom cylinder R side flows
into tank circuit through boom spool from C/V
(2) Bb port.

22-14
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function.

22-15
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
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.

22-17
22. HYDRAULIC SYSTEM

22.8 SWING CIRCUIT 22.8.2 SWING AUTO PARKING BRAKE

This section describes the following operations. (1) Purpose :
Swing lock in neutral position and parking
(1) Swing left pilot circuit
(2) Principle :
(2) Swing auto parking brake
Release mechanical brake only when required to
(3) Swing main circuit
operate swing and arm in.
(4) Swing motor circuit
(3) Operation :
22.8.1 PILOT CIRCUIT FOR LEFT SWING 1) The swing parking system excites the swing
(1) Operation : parking SOL (SV-1) usually if the key switch is
turned on and works by the action of the
1) When the left swing operation is performed, the
mechanical brake.
pilot proportional secondary pressure is
delivered through port (5) of left pilot V (9), and 2) The mechanical brake is released if the swing
the secondary pressure acts on PBs port of C/ parking solenoid is de-excited only when the
V (2), and simultaneously flows out from Pss secondary operating pressure in the swing and
port of C/V and acts on low pressure sensor arm in actions acts upon any of the low
(SE-5). pressure sensors (SE-5, 7).

2) The voltage output by the low pressure sensor
is input in the mechatro controller, and is signal-
processed.
3) Then, the secondary pressure led into PBs port
of C/V (2) switches the swing spool.
3) The swing parking solenoid (SV-1) is excited
five seconds after the pressure of the swing low
pressure sensors (SE-5) is reduced to zero.
In the case of arm in operation, the swing
parking solenoid (SV-1) is excited the moment
the pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.

22.8.3 SWING MAIN CIRCUIT

(1) Operation :
The oil delivered from the A2 port of the P2 pump
enters the P2 port of C/V (2) and is branched off into
the bypass line and the parallel circuit. However,
since the bypass line is closed as the swing spool
is shifted, the oil pushes the load check valve LCs
open through the parallel circuit, enters the B port
of the swing motor via the Bs port of C/V (2), and
rotates the swing motor counterclockwise.

22.8.4 SWING MOTOR CIRCUIT

(1) Anti cavitation circuit at swing deceleration
(2) Shockless relief valve that prevents the swing
motor from being reversed.

22-18
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-6 SWING CIRCUIT : Swing operation (LH)

22-19
22. HYDRAULIC SYSTEM
22.9 ARM CIRCUIT
This section describes the following operations.
(1) Arm in, light-load operating pilot circuit
(2) Arm in, light-load variable normal recirculation main
circuit / internal conflux main circuit
22.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT
CIRCUIT
(1) Purpose :
Speed-up and Anticavitation when the arm is at
light loaded.
(2) Principle :
The oil returning from the arm cylinder rod (R) is
recirculated variably to the head (H) at arm 2 spool
in C/V.
(3) Operation :
1) When the arm in operation is performed, the
secondary pilot proportional pressure gets out
of port 7 of the left pilot valve (9) and acts upon
the low pressure sensor (SE-7).
At the same time, the pressure is branched off
in two flows, acts upon the Paa1 port and the
PLc2 port, changes over the arm spool and the
arm lock valve CRar. releases.
2) The output voltage by the low pressure sensor
is input into mechatro controller, and is pilot
signal-processed, and is output to P1, P2 pump
proportional valve (PSV-P1), (PSV-P2) and arm
2 inverse proportional valve (PSV-A).
3) The secondary pressure from pilot proportional
valve, which is reduced by arm 2 inverse
proportional valve (PSV-A) switches arm 2
spool.
From arm out
P/V
22.9.2 ARM-IN, LIGHT-LOAD VARIABLE
NORMAL RECIRCULATION, INTERNAL
CONFLUX MAIN CIRCUIT
(1) Operation :
1) The P2 pump delivery oil flows in travel left
section through P2 port of C/V (2) and is
branched off in by-pass circuit and parallel
circuit, but because arm 1 spool is switched, the
delivery oil which goes through parallel circuit
opens load check valve LCa and is flowed into
arm 1 spool.
2) On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and the flows in travel
straight section and travel right tandem path.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2,
goes through arm 2 spool, and confluences
22-20
with P2 pump delivery oil in the valve section,
and then is flowed into arm cylinder head (H)
side through Aa port of C/V (2).
3) The return oil from arm cylinder (R) side flows
in Ba port of C/V (2) and passes through the Ba
port because the arm lock valve CRar is open,
and is flowed into arm 2 spool through arm 1
spool.
4) Because arm 2 spool is switched to normal
recirculation position, causing restriction of
passage to tank, the return oil from arm cylinder
(R) side flows into arm cylinder (H) side.
• Because, at light load, the pressure in
cylinder rod (R) side is higher than that in
the head (H) side, it opens the check valve
housed-in arm 2 spool and is recirculated in
the head (H) side, resulting in the speed up
of arm-in operation at light load.
5) Cavitations prevention control in arm-in
operation
Command current is output to arm 2 solenoid
proportional valve by signal processing of E/G
speed and arm-in pilot pressure, accordingly
the arm 2 spool is switched to neutral
(cavitations prevention) position, resulting in
cavitations prevention.
Position of arm 2 spool
Neutral position
(Anticavitation position)
Normal recirculation position
Recirculation
From arm 2 inverse
proportional valve
Reference :
In light-load arm-in operation (normal recirculation,
conflux), when the attachment to which the circuit in
P1 pump side is applied is operated, the meter-in
path of arm 2 spool is closed, resulting in single flow
operation.
Spool position at arm in,
light load and combined operation
(This position is not shown in hydraulic diagram)
Neutral position Meter-in passage
(Close)
Normal recirculation opsition
Arm 2 spool
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function

22-21
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.

22.9.4 ARM IN, HEAVY LOAD OPERATING

RECIRCULATION CUT MAIN CIRCUIT
(1) Purpose :
Speed up for arm in operation
(2) Principle :
Cut the recirculation and reduce rod pressure.
(3) Operation :
1) P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in by-pass circuit and parallel
circuit. Consequently the arm spool is switched
and pushes and opens load check valve LCa
through parallel circuit, and flows in the arm
spool.
2) On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and flow in travel right
tandem passage through travel straight section.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2, and
confluences with P2 pump delivery oil in the
valve section, and is flowed into arm cylinder
head (H) side through Aa port of C/V(2).
3) The return oil from arm cylinder (R) side flows
in Ba port of C/V(2) and is flowed to arm lock
valve CRar, but because the arm lock valve
CRar is open, the return oil goes through arm
lock valve CRar and flows in arm 2 spool.

22-22
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function

22-23
22. HYDRAULIC SYSTEM

This section describes the following operations.
(5) Arm out pilot circuit
(6) Arm out 2 pumps conflux main circuit
(7) Natural fall protection with arm lock valve
22.9.5 ARM OUT PILOT CIRCUIT
(1) Operation :
1) When the arm out operation is performed, the
secondary pilot proportional pressure gets out
of port 8 of the left pilot valve (9), and acts upon
the low pressure sensor (SE-8). At the same
time, the oil is branched off in two flows and act
upon the PBa1 and Pba2 ports of C/V (2).
2) The operating proportional secondary pressure
flowed in Pba1 port of C/V (2) switches the arm
1 spool.
3) Then, the operating secondary pressure flowed
in PBa2 port of C/V (2) switches the arm 2 spool
valve.
22.9.7 NATURAL FALL PROTECTION WITH ARM
LOCK VALVE
(1) Purpose :
To prevent the arm from falling naturally by the
weight of the arm & bucket.
(2) Principle :
Complete seat of the return circuit against the arm
spool of the arm cylinder (R) side circuit.
(3) Operation :
1) When the secondary pressure for arm
operation disappears and the arm cylinder
stops, the pressure on the rod (R) side passes
through the selector of the lock valve from the
Ba port of C/V, acts the back pressure on the
lock valve CRar and seats the lock valve.
2) Since the oil flow into the arm spool from the
lock valve is shut off completely, natural fall of
the arm due to oil leaks through the arm spool
is prevented.

22.9.6 ARM OUT 2 PUMPS CONFLUX MAIN

CIRCUIT
(1) Purpose :
Arm out operation speed up.
(2) Principle :
The oil delivered by the P1 pump is confluxed with
that delivered by the P2 pump in C/V (2).
(3) Operation :
1) P1 pump delivery oil opens load check valve
(LCAT2) by switching arm 2 spool and
confluxes with P2 pump delivery oil just short of
the arm lock valve.
2) And, P2 pump delivery oil flows through arm 1
spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRar with
free flow and is flowed into arm cylinder rod (R)
side through Ba port of C/V(2).
3) On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and returns
into tank circuit through arm 1 spool and arm 2
spool.
The return line which does not pass through
boost check valve is used for this return circuit
to reduce the pressure loss.

22-24
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-9 ARM CIRCUIT : Arm out operation, Confluence function

22-25
22. HYDRAULIC SYSTEM
22.10 COMBINED CIRCUIT
This section describes only the difference in combined
operation.
(1) Boom up / travel, pilot circuit
(2) Boom up / travel, main circit
22.10.1 BOOM UP / TRAVEL, PILOT CIRCUIT
(1) Operation :
<Operation: Different point of pilot circuit from
independent operation >
1) The mechatro controller outputs command
current to travel straight solenoid proportional
valve after signal processing, and the solenoid
valve outputs secondary pressure and acts on
PTb port of C/V (2).
2) Then the pressure of PTb port switches the
travel straight valve one step.
22-26
22.10.2 BOOM UP / TRAVEL, MAIN CIRCUIT
(1) Purpose :
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle :
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation :
1) P1 pump delivery oil flows through P1 port of C/
V(2) and branches off in P1 parallel circuit and
travel straight spool.
P2 pump delivery oil flows through P2 port of C/
V(2) and branches off in P2 tandem circuit and
travel straight spool.
2) The delivery oil flowed into P1 parallel circuit of
P1 pump opens check valve CT1 and LCb and
flows in boom spool, which exerts on boom up
operation.
The delivery oil flowed into travel straight spool
of P1 pump opens check valve CT2 because
the travel straight spool is shifted, and flows in
boom conflux spool and exerts on boom up
operation with the internal oil conflux.
(In travel straight operation, P1 pump delivery
oil exerts on swing operation of attachment.)
3) The delivery oil flowed into P2 tandem circuit of
P2 pump flows in left travel spool to travel
leftward.
The delivery oil flowed into travel straight spool
of P2 pump flows in right travel spool because
the travel straight spool is shifted and exerts on
the right travel operation.
(In travel straight operation, P2 pump delivery
oil exerts on travel operation.)
4) However, a portion of the flow is led to the travel
straight spool notch restriction. The speed of
attachments like travel, boom, etc. is adjusted
by the circuit of restriction.
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 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 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(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
LC01Z00070P1 03
13
Fig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.

22-27
22. HYDRAULIC SYSTEM
In this section, the independent operation is omitted
and describes difference in combined operation.
(3) Swing / Arm in light load, pilot circuit
(4) Swing / Arm in, swing priority main circuit
22.10.3 SWING / ARM IN LIGHT LOAD, PILOT
CIRCUIT
(1) Operation :
1) On operating swing (left) and arm in motions
simultaneously, mechatro controller outputs
command current to travel straight solenoid
proportional valve (PSV-C) and arm 2 solenoid
inverse proportional valve according to signal
processing, and this proportional valve outputs
secondary pressure, which acts on PTb port
and PAa2 port of C/V(2).
2) PTb port pressure switches the travel straight
spool 2 steps, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.
22-28
22.10.4 SWING / ARM IN, SWING PRIORITY MAIN
CIRCUIT
(1) Purpose :
Stable swing speed.
(2) Principle :
Raise the oil pressure flowing to arm cylinder, and
give a priority of the delivery of P2 pump to swing
operation.
(3) Operation :
1) The swing main circuit operates with P2 pump
flow. But on P2 pump circuit side, the flow goes
to the swing circuit and arm circuit
simultaneously because the swing circuit and
arm circuit are parallel. Then since the return oil
from arm cylinder rod (R) side is restricted in
the arm 2 spool because the arm 2 spool is
switched to forced recirculation position, the
pressure of return oil is raised, causing the rise
of circuit pressure on the arm cylinder head (H)
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".
Position of arm 2 spool
Position of forced recirculation
Neutral position Meter-in passage
(Close)
From From arm 2
arm out inverse
P/V proportional valve
Normal recirculation opsition
Arm 2 spool