Training Text SK200-8
Training Text SK200-8
EXCAVATOR
SERVICE TRAINING
YN11-45001~
YQ11-06001~
LC10-07001~
YC10-03501~
1. OUTLINE
1.1 SK200-8.................................................................................................................... 1-3
1.2 SK330-8.................................................................................................................... 1-4
4. ENGINE
4.1 ENGINE SPECIFICATIONS (SK200-8) ................................................................... 4-3
4.2 ENGINE OUTSIDE VIEW (SK200-8) ....................................................................... 4-5
4.3 ENGINE MOUNTING (SK200-8).............................................................................. 4-5
4.4 FUEL INJECTION SYSTEM..................................................................................... 4-6
4.5 CONSTRUCTION & FUNCTION.............................................................................. 4-10
4.6 HOW TO READ TROUBLESHOOTING................................................................... 4-24
4.7 ENGINE SPECIFICATIONS (SK330-8) ................................................................... 4-32
4.8 ENGINE OUTSIDE VIEW (SK330-8) ....................................................................... 4-34
1
CONTENTS
5. MACHINE STRUCTURE
5.1 BOOM (SK200-8) ..................................................................................................... 5-3
5.2 ARM (SK200-8) ........................................................................................................ 5-7
5.3 BUCKET (SK200-8) ................................................................................................. 5-12
5.4 LOWER PARTS (SK200-8)...................................................................................... 5-15
5.5 REMOVING AND INSTALLING PROCEDURE OF ASSY
(RELEVANT UPPER FRAME) (SK200-8)................................................................ 5-23
5.6 WEIGHT OF COMPONENTS (SK200-8)................................................................. 5-35
5.7 BOOM (SK330-8) ..................................................................................................... 5-37
5.8 ARM (SK330-8) ........................................................................................................ 5-41
5.9 BUCKET (SK330-8) ................................................................................................. 5-46
5.10 LOWER PARTS (SK330-8)...................................................................................... 5-49
5.11 REMOVING AND INSTALLING PROCEDURE OF ASSY
(RELEVANT UPPER FRAME) (SK330-8)................................................................ 5-58
5.12 WEIGHT OF COMPONENTS (SK330-8)................................................................. 5-66
7. DATA 1.
7.1 WORKING RANGES (SK200-8) .............................................................................. 7-3
7.2 WORKING RANGES (SK330-8) .............................................................................. 7-5
2
CONTENTS
3
CONTENTS
4
1. OUTLINE
1-1
1. OUTLINE
1-2
1. OUTLINE
1.1 SK200-8
Comparison between old and new model's
Item Description Concept
(Old New)
Center section at engine bottom Fabricated plates 1 piece plate Increase strength to standardize the
frame conventional model and the
Upper others severe job application.
machinery Strengthened side deck D frame Sectional area of D-shaped frame 1.5 times larger size Less damage when slewing and
impact against object.
Under Slant shaped track frame. Slant shape Slant shape (continued) Mud stuck prevention
carriage
Strengthen boom top and boom foot boss. Steel plates fabricating type Cast steel made Improving durability of attachment
Moving boom cylinder head side port to the back. At front side At back side Preventing hydraulic piping damage
Strengthen Foot boss of arm. Steel plates fabricating type Forged material Improving durability of attachment
Attachment Strengthen arm equalizing current one with Nibbler and breaker
New 2 stage bushing Conventional bushing (1 pc) Flange type and Hard material
Continue urethane packing for hydraulic cylinders Long life without oil leakage
Large Capacity of fuel tank 340 litters 370 liters (SK200-8) Longer refueling interval
Large size port drain cock 9 mm in diameter Easier cleaning work
Fuel tank
New flange plate at bottom of tank No flange plate
Air New location of air conditioner unit Inside rear cover Underneath of operators seat Easier cleaning work for air filters
conditioner
New HINO engine (With common rail and EGR system) Mitsubishi 6 cylinders Hino 4 cylinders To comply Tier 3 emission
Engine horsepower UP 110 kW / 2,000 rpm 114 kW / 2,000 rpm Maximize performance
New arrangement of oil cooler, radiator and inter cooler Inline arrangement Side by side arrangement Easier cleaning work
Removable oil cooler, radiator and inter cooler Radiator All 3 units can be removable Easier cleaning work
New remote type engine oil filter and fuel filter Engine room pump room Easier replacement work
Power plant New fuel filter Conventional type Standardized for common rail
New fuel stop valve Easier replacement work for fuel
New Large capacity of air cleaner Double time life till clogged Longer maintenance time interval
New design air intaking chamber Preventing rain water
New engine oil drain cock Standardized drain cock Easier engine oil exchange work
New location of battery Too l box at right front In front of radiator Enlarge space of toolbox
Improve installation of Controllers Horizontal Vertical direction Preventing wet from condensation
Electric Improve reliability of mechatro controller Two sided print One side print Durability improvement
system Dustproof sealing of mechatro controller No gasket With Gasket
New Relay and fuse box Individual lay outing of relay and fuse Integrated into one box Easier maintenance work
New valve plate and pump casing Less noise while running
Main pump Increased pump capacity 105 cc 110 cc / rev Enlarge performance and long life
New long life oil seal NBR made Fluoro rubber made Improve of durability
Slewing
New structure of reduction unit Gear oil lubrication at lower bearing Change to grease
motor
New elec-volume style emergency mode for engine acceleration Mechanical cable type Electrical volume switch type Prevention of machine down
Emergency New auto-set style emergency mode for main pump Auto-set by controller
mode New emergency mode for control valve New system for unloading valve and cut valve
1-3
1. OUTLINE
1.2 SK330-8
Comparison with conventional model
Item Description Aim
(new models of conventional model)
Center section at engine bottom Fabricated plates 1 piece plate Increase strength to standardize the
frame conventional model and the
Upper others severe job application.
machinery Strengthened side deck D frame Sectional area of D-shaped frame 1.5 times larger size Less damage when slewing and
impact against object.
Under New slant shaped track frame. Slant shape Mud stuck prevention
carriage
Standardized heavy duty boom STD and optional HD boom Standardize HD boom only Improving durability of attachment
Strengthen boom top and boom foot boss. Steel plates fabricating type Cast steel made Improving durability of attachment
Moving boom cylinder head side port to the back. At front side At back side Preventing hydraulic piping damage
Standardized heavy duty arm Standardize HD arm only Improving durability of attachment
Attachment Strengthen Foot boss of arm. Steel plates fabricating type Forged material Improving durability of attachment
New 2 stage bushing Conventional bushing (1 pc) Flange type and Hard material
bushing
Continue urethane packing for hydraulic cylinders Long life without oil leakage
Large Capacity of fuel tank 560 litters 580 liters (SK330-8) Longer refueling interval
Large size port drain cock 5 9 mm in diameter Easier cleaning work
Fuel tank 200 mm dia opening with flange plate
Continue flange plate at bottom of tank
Air New location of air conditioner unit Inside rear cover Underneath of operators seat Easier cleaning work for air filters
conditioner
New HINO engine (With common rail and EGR system) Mitsubishi 6 cylinders Hino 6 cylinders To comply Tier 3 emission
Engine horsepower UP 184 kW / 2,200 rpm 197 kW / 2,100 rpm Maximize performance
New arrangement of oil cooler, radiator and inter cooler Inline arrangement Side by side arrangement Easier cleaning work
Removable oil cooler, radiator and inter cooler Radiator All 3 units can be removable Easier cleaning work
New remote type engine oil filter and fuel filter Engine room pump room Easier replacement work
New fuel filter Conventional type Standardized for common rail
Power plant system
New fuel stop valve Easier replacement work for fuel
filter
New Large capacity of air cleaner 1.7 time life till clogged Longer maintenance time interval
New design air intaking chamber Preventing rain water
New engine oil drain cock Standardized drain cock Easier engine oil exchange work
New location of battery Too l box at right front In front of radiator Enlarge space of toolbox
Improve installation of Controllers Horizontal Vertical direction Preventing wet from condensation
Electric Improve reliability of mechatro controller Two sided print One side print Durability improvement
system Dustproof sealing of mechatro controller No gasket With Gasket
New Relay and fuse box Individual lay outing of relay and fuse Integrated into one box Easier maintenance work
New valve plate and pump casing Less noise while running
Main pump Increased pump capacity 105 cc 110 cc / rev Enlarge performance and long life
New long life oil seal NBR made Fluoro rubber made Improve of durability
Slewing
New structure of reduction unit Gear oil lubrication at lower bearing Change to grease
motor
New elec-volume style emergency mode for engine acceleration Mechanical cable type Electrical volume switch type Prevention of machine down
Emergency New auto-set style emergency mode for main pump Auto-set by controller
mode New emergency mode for control valve New system by unloading valve and cut valve
1-4
2. CONSTRUCTION & FUNCTION
2-1
2. CONSTRUCTION & FUNCTION
2-2
2. CONSTRUCTION & FUNCTION
ARM CYLINDER
ARM
BOOM
BOOM CYLINDER
BUCKET
CYLINDER
CAB
SLEWING BEARING
IDLER LINK
SLEWING MOTOR
SWIVEL
JOINT FUEL TANK
HYDRAULIC TANK
BUCKET LINK
CONTROL VALVE
GUARD
MUFFLER
HYDRAULIC
PUMP
BUCKET
MONITOR PANEL
FRONT IDLER
ENGINE
IDLER ADJUST
COUNTER WEIGHT
UPPER ROLLER
2-3
2. CONSTRUCTION & FUNCTION
2.1.2 SK330-8
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
AIR CLEANER
COUNTER WEIGHT
LOWER ROLLER
RADIATOR AND OIL COOLER
BATTERY
TRAVEL MOTOR
2-4
2. CONSTRUCTION & FUNCTION
2.2.1.2 ENGINE
2.2.1.4 WEIGHT
Unit : kg (lbs)
Fully equipped weight 20,200 (44,500) 20,600 (45,400)
Upper structure 9,500 (21,000) ←
Lower machinery
6,730 (14,840) 7,130 (15,720)
(600mm grouser shoe)
Attachment
5.65m (18 ft-6in) Boom+2.94m (9ft-8in) Arm 3,420 (7,540) ←
+0.80m3 (1.05cu•yd) Bucket
2-5
2. CONSTRUCTION & FUNCTION
2.2.2 SK330-8
2.2.2.2 ENGINE
2.2.2.4 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
2-6
2. CONSTRUCTION & FUNCTION
3 4 5 6
7
20
21
8
9
2
11
10
12 22
13
15 DETAIL A
14
16
17
23
18
19
A 24
2-7
2. CONSTRUCTION & FUNCTION
22:00
• When caution sign was displayed on the multi-dis- S
play, stop the work immediately and check and ser-
vice the section in point.
For checking and servicing, refer to the section for 1
the checking and servicing.
• The display on the multi-display does not entirely as-
sure the condition of machine. 2
• For the maintenance and inspection of machine, the 3
visual checking should be carried out further without
completely depending on the display on the multi- 10
display. 6
4 9 8 5 7
2-8
2. CONSTRUCTION & FUNCTION
13
11
12
10
9 1
14
2
3
4 Detail A
2-9
2. CONSTRUCTION & FUNCTION
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2-10
2. CONSTRUCTION & FUNCTION
SE-29
P1 UNLOAD
ATTACHMENT BOOST
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
PL1
SOL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3
L4
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
L5
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
2-11
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective
low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by
mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the
pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
2-12
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
2-13
2. CONSTRUCTION & FUNCTION
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
2-14
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also
with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and
consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
2-15
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
2-16
2. CONSTRUCTION & FUNCTION
2-17
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low
pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot
signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2
unload proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve
for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by mechatro con-
troller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke ac-
cording 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.
2-18
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is
input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valves.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the com-
mand output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and conse-
quently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
2-19
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and
P2 unload proportional valves and travel straight proportional valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of the control valve.
(4) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
2-20
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
2-21
2. CONSTRUCTION & FUNCTION
(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.
2-22
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
VALVE
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure
sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot sec-
ondary 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 com-
mand by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched en-
abling 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.
2-23
2. CONSTRUCTION & FUNCTION
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTIONAL
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C
2-24
2. CONSTRUCTION & FUNCTION
2-25
2. CONSTRUCTION & FUNCTION
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) Press "Enter SW" on gauge cluster and select switch change mode. Press enter SW of switch displayed
on pressure release control screen. After the character is reversed, select control ON with switch and press
"Enter SW", and the mechatro controller decides it as pressure release mode.
(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 pres-
sure 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.
2-26
2. CONSTRUCTION & FUNCTION
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
2-27
2. CONSTRUCTION & FUNCTION
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
2-28
2. CONSTRUCTION & FUNCTION
Perfor- Device
mance Function Features
Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever
Attachment
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Holding valve for boom (Option) Prevention of boom falling when boom head side piping breaks
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
Positive flow rate control Flow control by positive pilot control pressure
Hydraulics backup control Backup control by hydraulic when the electric flow controlled
variable displacement pump fails.
Boom up conflux circuit Speed up of boom up operation
Attachment
Micro
2-29
2. CONSTRUCTION & FUNCTION
2-30
2. CONSTRUCTION & FUNCTION
2.6.1.1 SUMMARY
(1) Outside view and Hydraulic port
5
EYE BOLT (M10)
a3 PSV2
Dr
A3 2X4-M12
Depth 22
A1 A2
B3
a4 VIEW
PSV1
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2
4 PSV1 4
PSV2 PSV2
Dr3 a5
A1 A2 5
1 A2
Dr3
Hydraulic ports
Q'TY Code Ports name Size
No. Parts
SE.Asia Oceania A1,2 Delivery port SAE 6000psi 1"
1 Main pump assy 1 B1 Suction port SAE 2500psi 2 1/2"
2 Regulator assy 2 Dr Drain port PF3/4-20
3 Gear pump assy(for pilot) 1 PSV1,2 Servo assist port PF1/4-13
4 Solenoid proportional reducing valve 2 PH1,2 Pressure sensor port PF3/8-17
5 PTO unit 1 a1~a4 Gauge port PF1/4-15
a5 Gauge port PF1/4-14
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15
2-43
2. CONSTRUCTION & FUNCTION
Regulator Regulator
a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3
Main pump
Item Gear pump
SE. Asia Oceania
Pump assy YN10V00036F1 YN10V00040F1 -
Parts No.
Single Pump YN10V00043F1 YN10V00014F3
Pump model K3V112DTP1K9R-YT0K-HV ZX10LGRZ2-07G
Max.displacement capacity cm3 110 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2000
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure 37.8 (5480)
Max. flow L/min (gal/min) 220 (58) X 2 at 7.8MPa (1130 psi) 21 (5.5)
Max. input horse power kW (PS) 114 (155) 3.4 (4.6)
Max. input torque N.m (lbf.ft) 544 (401) 14.7 (10.8)
Part No. YN10V01009F1
Model KR3G-YTOK-HV
Regulator Electric flow control, positive flow control,
Control function
total power control at emergency mode and power shift control
2-44
2. CONSTRUCTION & FUNCTION
125
711 468
118 825 710 728
117
126
326 262
115
128
826
414
435
886
885
2-45
2. CONSTRUCTION & FUNCTION
2.6.2.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
PORT 1, 3 PORT 2, 4
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDLAULIC SYMBOL
2-46
2. CONSTRUCTION & FUNCTION
2.6.3.1 OUTLINE
(1) Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
(2) Specifications
P T
Item Specifications
Part No. YN30V00105F1
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
2-47
2. CONSTRUCTION & FUNCTION
2.6.4.1 SPECIFICATIONS
PBL
P2 CT2
CP2
CT1
P1
Pcb PAL
CT1 T1
PTb T2
P1 unload CT2
PCb PAL
Travel PL PCb PAL Travel left PBL
AL BL
straight P2 unload
CMR1 CMR2 Ar CP2
USE FOR YN30V00101
Br PAr PCa
Travel PB1 Boom
F1
(P3) (P2)
PBa2 PAo
PBp1 PBp2
PAa2
Arm 2 Option
PBo
PAc PAa1
Bucket Arm 1
(P4) PAa
(P3) PAb
Boom Swing
PBr PCa
Travel right P2 unload
(T3)
PTb
Travel PBL Travel left
straight
PAa2 PBo
A
VIEW A
2-48
2. CONSTRUCTION & FUNCTION
2.6.4.1.2 PORTS
2-49
2. CONSTRUCTION & FUNCTION
2.6.4.1.3 SPECIFICATIONS
Item Specifications
Model KMX15YD/B44001
Maximum flow rate [L/min (gal/min)] 220 (58)×2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 70×2L/min (18.5×2gal/min)]
When power boost pressure 37.8 (5480) [at 60×2L/min (15.9×2gal/min)]
Overload relief valve set pressure
39.7 (5760) [at 30L/min (8gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5480) [at 30L/min (8gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
2-50
2. CONSTRUCTION & FUNCTION
! '(
%& $*
!
)&
!
2-51
2. CONSTRUCTION & FUNCTION
2.6.4.1.5 OPERATION
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through
tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system,
because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the hy-
draulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though the
center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut
valve (606) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to
the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic
oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut
valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic
pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which
passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into
low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
! " !" #
" $
"%
2-52
2. CONSTRUCTION & FUNCTION
2-53
2. CONSTRUCTION & FUNCTION
2.6.5.1 SPECIFICATION
(1) General view
THREAD FOR
Port Tightening torque
M L
Symbol Port name EYE BOLT 2-M10
size N.m (lbf.ft) PB DEPTH 18
A,B Main port PF3/4 167 (123) RELIEF VALVE
B
(B PORT SIDE)
DB Drain port PF3/8 74 (55)
M Make-up port PF3/4 167 (123)
PA,PB Pressure measuring port PF1/4 36 (27) (SH)
RELIEF VALVE
A (A PORT SIDE)
DB
PA
PG IP
PG FILLING PORT
PT3/4
DB
PA PB
Grease
fitting
A B
Hydraulic diagram
2-54
2. CONSTRUCTION & FUNCTION
(2) Specifications
Displacement cm (in )
3 3 129.2 (7.88)
Working pressure MPa (psi) 32.4 (4700)
Max. flow L/min (gal/min) 220 (58)
Braking torque N•m (lbf•ft) 655 (483)
Release pressure MPa (psi) 2.5~5.0 (362~725)
Relief set pressure MPa (psi) 29 (4205)
Weight kg (lbs) 49 (108)
Anti- Type 2KAR6P72/240-712
reaction valve
Weight kg (lbs) 2.5 (5.5)
block
Hydraulic motor assy weight kg (lbs) 51.5 (114)
Part No. YN32W00019F1
Speed reduction type Planetary 2-stage
Reduction unit
2-55
2. CONSTRUCTION & FUNCTION
2.6.5.2 CONSTRUCTION
(1) Swing motor
993
702 712
ANTI
CAVITATION
PLUNGER
351 Arrangement of brake spring
355
051 RELIEF VALVE
469
051-1
488 ANTI-REACTION
VALVE BLOCK 401
052 151
303 162 171 161
985
163 985 444 984 131 451
712 A A
472 390 391
VIEW I
702
707
706
100
980
743
742
400-1
111
400-2 052
121
400
123 994 SECTION A-A
122
114 301
124 443 491 101
2-56
2. CONSTRUCTION & FUNCTION
2-57
2. CONSTRUCTION & FUNCTION
Be careful about
installation direction
of retaining ring. Drive this spring pin
into 1mm lower than
the surface of spider.
2-58
2. CONSTRUCTION & FUNCTION
2.6.6.1 SPECIFICATIONS
2.6.6.1.2 SPECIFICATIONS
Model
GM38VB
Item
Rated output torque N.m (lbf.ft) 20100 / 34200 (14800 / 25200)
Working revolution min-1 48.2 / 29.6
Reduction ratio 1 / 55.617
Max. displacement cm3/rev. (cu.in/rev) 78.8 / 130.8 (4.81 / 7.98)
Hydraulic Max. revolution min-1 2680 / 1648
motor Max. pressure MPa (psi) 34.3 (4970)
2 speed chamber pilot pressure MPa (psi) 2.94~5.88 (426~853)
2-59
2. CONSTRUCTION & FUNCTION
2.6.6.2 CONSTRUCTION
SECTION B-B
C C
SECTION C-C
SECTION A-A
2-60
2. CONSTRUCTION & FUNCTION
2-61
2. CONSTRUCTION & FUNCTION
VIEW Y
VIEW Z
2.6.7.2 SPECIFICATIONS
Item Specifications
Assy parts No. YN55V00053F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
F Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length : L 368 mm (14.5")
Weight 25 kg (245 lbs)
2-62
2. CONSTRUCTION & FUNCTION
2.6.8.1 SPECIFICATIONS
(1) General view
B A
n gth gth
n
d le d le
de te
xten rac
ly e et
Fu
l l ly r
Fu
SE. Asia YN01V00175F2 ø135 / ø95 1,558 3,637/ 2,079 With cushion on
Arm 249 (549)
Oceania YN01V00175F1 (5.32" / 3.74") (5-1) (11-11 / 6-10) both sides H-40,R-60
2-63
2. CONSTRUCTION & FUNCTION
Oil cooler
Level warning switch
Radiator
Inter cooler
Shroud
IN case of previous machine, radiator , oil cooler and intercooler were installed in order separately. Incase of this
machine all components become built-in and have been integrated as one unit.
2-64
2. CONSTRUCTION & FUNCTION
2.6.10.2 REMOVAL
(1) Attach tag on which hose name is entered to the re-
2
mote control hoses between multi control valve and 8 P/V 5
pilot V, and write numbers P1 to P8 on it. P/V P/V 1
P/V
: 19 mm, 22 mm 4 P2 P5
P/V
(2) Attach tag on which hose name is entered to the re- P8 0 P1
mote control hoses between multi control valve and 7 6
main control valve, and write numbers C1 to C8 on P/V P4 P6 P/V
it.
P7
: 19 mm, 22 mm 3
P/V P3
(3) Remove 4 sems bolts (B9) M8×20, and remove
multi control valve (0) with bracket (B3) from ma-
chine. Fig. 2-14 Connection between multi control valve
and main C/V
2.6.10.3 INSTALLATION
(1) Installing is done in the reverse order of removing PBb
PBc B16
(2) Relations between pilot valve and multi control C/V C/V PBs
valve hose C4
C2
C/V
C5 C1
P/V Hose ISO Multi Mark-
Port Control pattern port ing C6
Size Color
1 3/8 Red Bucket digging P1 1 0 PBa1
2 3/8 Blue C / V C / V CPAc
/V
Right side
Bucket dump P2 2
PAs
3 3/8 Green Boom up P3 3
C8
4 3/8 Gray Boom down P4 4
P 1/4 Black Pilot primary - - C3
T 3/8 Black C/V
Drain - - PAb
5 3/8 Gray Swing left P5 5 C7
C/V
6 3/8 Red Swing right P6 6 PAa1
Left side
(3) Tightening torque Fig. 2-15 Removing hoses between P/V and multi C/
V
2-65
2. CONSTRUCTION & FUNCTION
2-66
2. CONSTRUCTION & FUNCTION
2.7.1.1 SUMMARY
(1) Outside view and Hydraulic port
5
EYE BOLT (M10)
a3 PSV2
Dr
A3 2X4-M12
Depth 22
A1 A2
B3
a4 VIEW
PSV1
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2
4 PSV1 4
PSV2 PSV2
Dr3 a5
A1 A2 5
1 A2
Dr3
Hydraulic ports
Q'TY Code Ports name Size
No. Parts
SE.Asia Oceania A1,2 Delivery port SAE 6000psi 1"
1 Main pump assy 1 B1 Suction port SAE 2500psi 2 1/2"
2 Regulator assy 2 Dr Drain port PF3/4-20
3 Gear pump assy(for pilot) 1 PSV1,2 Servo assist port PF1/4-13
4 Solenoid proportional reducing valve 2 PH1,2 Pressure sensor port PF3/8-17
5 PTO unit 1 a1~a4 Gauge port PF1/4-15
a5 Gauge port PF1/4-14
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15
2-67
2. CONSTRUCTION & FUNCTION
Regulator Regulator
a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3
Main pump
Item Gear pump
SE. Asia Oceania
Pump assy LC10V00014F1 LC10V00015F1 -
Parts No.
Single Pump LC10V00020F1 YN10V00014F3
Pump model K5V140DTP1K9R-YT0K-HV ZX10LGRZ2-07G
Max.displacement capacity cm3 140 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2100
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure 37.8 (5480)
Max. flow L/min (gal/min) 294 (78) X 2 at 7.8MPa (1130 psi) 21 (5.5)
Max. input horse power kW (PS) 195 (265) 3.4 (4.6)
Max. input torque N.m (lbf.ft) 886 (653) 14.7 (10.8)
Part No. LC10V01005F1
Model KR3S-YTOK-HV
Regulator Electric flow control, positive flow control,
Control function
total power control at emergency mode and power shift control
2-68
2. CONSTRUCTION & FUNCTION
2.7.2.1 SPECIFICATIONS
PBL
P2 CT2
CP2
CT1
P1
Pcb PAL
CT1 T1
T2
PTb P1 unload CT2
PCb PAL
Travel PL PCb Travel left PBL
PAL AL BL P2 unload
straight CMR1 CMR2 Ar CP2
USE FOR YN30V00101
Br PAr PCa
PBr Travel PAr PB1 Boom
F1
PB1
Ab right conflux CCb Bs
PAb CP1 (HEAD) As
Bb PBs Swing
Boom PBb PBs PAs
(ROD) Aa
PBb Pss
LCb CRb PC LCs
PAc Bucket PCc PBa1 Pss
Ac Bc PBc Arm 1 PLc2 CRa (HEAD) PAa1
PBa1
(HEAD) (ROD) Ba
LCc LCa
PCAP2 LCAT2 MU PBa2 PAo (ROD)
PAa2 Arm 2 PBa2 PAo Option PBo
Ao Bo
LCo
PBp1 PBp2
(P3) (P2)
PBa2 PAo
PBp1 PBp2
PAa2
Arm 2 Option
PBo
PAc PAa1
Bucket Arm 1
(P4) PAa
(P3) PAb
Boom Swing
PBr PCa
Travel right P2 unload
(T3)
PTb
Travel PBL Travel left
straight
PAa2 PBo
A
VIEW A
2-69
2. CONSTRUCTION & FUNCTION
2.7.2.1.2 PORTS
2-70
2. CONSTRUCTION & FUNCTION
2.7.2.1.3 SPECIFICATIONS
Item Specifications
Model KMX15YD/B44031
Maximum flow rate [L/min (gal/min)] 294 (78) × 2
Maximum set pressure [MPa (psi)] 37.8 (5481) (Pump port)/ 39.7 (5757) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 135×2 L/min (at 36×2 gal/min)]
When power boost pressure 37.8 (5480) [at 125×2 L/min (at 33×2 gal/min)]
Overload relief valve set pressure
39.7 (5757) [at 30 L/min (at 8 gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5481) [at 30 L/min (at 8 gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
2-71
2. CONSTRUCTION & FUNCTION
CMR1
PL CMR2
PTb PBL
Travel straight
PCb PAL Travel left
P1 unload
AL
CT2 CP2 BL
CT1
(T3) Boom conflux
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr CCb
PBs
Dr
LCb LCs Pss
(HE AD) Ab
PAa1 Arm 1
PBb
LC c Aa (HEAD)
Bucket PAc
CRa
(ROD) B c PLc2
(HEAD) Ac
Ba (ROD)
PCc
PBc
LCAT2
LCAP2 LCo
Ao
Bo
PBo
PBa2
MU
PBp1 PB p2
(P3) (P4)
2-72
2. CONSTRUCTION & FUNCTION
2-73
2. CONSTRUCTION & FUNCTION
2.7.3.1 SPECIFICATION
(1) General view
Tightening
Symbol Port name Port size torque
N.m (lbf.ft)
A,B Main port SAE 3/4"
DB Drain port PF1/2 108 (80)
M Make-up port PF1 216 (159)
PA,PB Pressure measuring port 2-PF1/4 36 (27)
PR Parking brake release port PF1/4 36 (27)
Gear oil level gauge or
IP,L,AR Air breather port or PT3/4 98 (72)
Gear oil filling port
IP, L, AR
12- 22 Through
DB
B
PB
M
PR PA
A
THREAD FOR
EYE BOLT 2-M12
PR
DB
RELIEF VALVE
PB PA
M DB
A,B
M
PA PB PR
A B
Hydraulic diagram
2-74
2. CONSTRUCTION & FUNCTION
(2) Specifications
2-75
2. CONSTRUCTION & FUNCTION
2.7.3.2 CONSTRUCTION
(1) Swing motor
702 712
351
401
488 469
051-1 051
100
151
162 052 161 171
303 984
A A 163 985 391 390 444
131
451
472 400-1
400-2
712 400 052
706
986
742
743
994
111
491 101
121 123 122 124 114 301 443
2-76
2. CONSTRUCTION & FUNCTION
2-77
2. CONSTRUCTION & FUNCTION
34
22 11 27 25 24 3
4
SURFACE
5 OF LUBE OIL
10 3
23 6 20 35
7 8 3 VIEW
11 15
26 12
9 17 30 36, 37, 38, 39
14 31
3
28
29 18
33 32
13
21 19 16
2
1
DETAIL aa
aa
2-78
2. CONSTRUCTION & FUNCTION
2.7.4.1 SPECIFICATION
(1) Appearance
PILOT PORT
G(PF) 1/4 (P)
BEARING CENTER
VALVE PORT
2-G (PF) 1
(VA,VB)
DRAIN PORT
2-G (PF)1/2
18-M24 (D1,D2)
G (PF) 3/4
FILL PORT
LEVEL PORT OIL LEVEL
G (PF) 3/4
DRAIN PORT VIEW Y
Fig. 2-20 Travel motor
Rotation direction
Tightening
Oil inlet Oil outlet Rotation direction Port
Port size torque Function
port port (Viewed from valve port side) name
N•m (lbf•ft)
VA VB Right (Clockwise) P PF1/4 36 (26.6) Pilot (2 speed changeover) port
VB VA Left (counter clockwise) D1, D2 PF1/2 98.1 (72.4) Drain port
VA, VB PF1 255 (188) Motor drive port
MA, MB PF1/4 29.4 (21.7) Pressure measurement
2-79
2. CONSTRUCTION & FUNCTION
(2) Specifications
2-80
2. CONSTRUCTION & FUNCTION
2.7.4.2 CONSTRUCTION
2-81
2. CONSTRUCTION & FUNCTION
2-82
2. CONSTRUCTION & FUNCTION
2.7.5.1 SPECIFICATIONS
(1) General view
B A
n gth gth
n
d le d le
de te
xten rac
ly e et
Fu
l l ly r
Fu
Center distance of
Part No. of Cylinder bore / pins Dry weight
Use Stroke Cushion
cylinder assy Rod Dia. Full extend B / Full re- kg (lbs)
tract A
ø140 / ø100 1,550 3,651 / 2,101 With cushion on
Boom LC01V00044F1 269 (593)
(5.51" / 3.94") (5'1") (11'12" / 6'11") rod side
SE.Asia LC01V00054F2 ø170 / ø120 1,788 4,281/ 2493 With cushion on
Arm 504 (1,111)
Oceania LC01V00054F1 (6.69" / 4.72") (5'10") (14'1" / 8'2") both sides
SE.Asia LC01V00055F2 ø150 / ø100 1,193 3,005 / 1,812 With cushion on
Bucket 265 (584)
Oceania LC01V00055F1 (5.91" / 3.94") (3'11") (9'10" / 5'11") rod side
2-83
2. CONSTRUCTION & FUNCTION
2-84
2. CONSTRUCTION & FUNCTION
30
40
NOTE
1. Apply oil for refrigerant R134a to the
27 8 O-rings of all air-conditioner hose fittings.
8 2. Refrigerant volume : 900 50g
3. T : Tightening torque N.m(lbf.ft)
8 58
25 6
24
8
6
24
5
8
A
12
55
2
13
6
24 INITIAL BELT TENSION
54 When the belt is pushed by the 25
force of 28N, adjust the
4 deflection of L part to be 6mm.
39
8 22
51
JAM NUT FOR 18
TENSION PULLEY 20
T=46.1(33) 25
5
2 10
11 21
16
3
6 L
59
9
25 10
25 33
49 23
A 25
9 1
32 10
15
35 52 50
53
5
7 13
25
25
8 25
17 25
3 12
6
56 14
57
23
34 56
57
Fig. 2-24
2-111
2. CONSTRUCTION & FUNCTION
32 COMPRESSOR ASSY
L TUBE (10)
2-112
2. CONSTRUCTION & FUNCTION
&
#
! )
"
'
"
!
%
) ,
#
, *
+ $
+
*
Fig. 2-25
2-113
2. CONSTRUCTION & FUNCTION
35 6
7
51
4 15 25
9
10
11
6 12
52 25
3
32
25
57
6 58 50
52
E D
30
40
27
C
B
A
25
1
12 E
25
16
25
2
25
39 25
25
8
34
8
56
1 59
2 25
24 24
53
8
5 24
8 5 18
8
6
2
6 6
20
8 55 11
C A B
Fig. 2-26
1. Apply oil for refrigerant R134a to the O-rings of all air-conditioner hose fittings.
2. Refrigerant volume : 900±50 g (2±0.1 lbs)
2-114
2. CONSTRUCTION & FUNCTION
32 COMPRESSOR ASSY
S HOSE (5)
L TUBE (10)
2-115
2. CONSTRUCTION & FUNCTION
A
5
8
A
C
5
6
6
4 B
5
3
10 3
2 11
8
9
1
6 5
7
B C
Fig. 2-27
2-116
3. MECHATRO CONTROL SYSTEM
3-1
3. MECHATRO CONTROL SYSTEM
3-2
3. MECHATRO CONTROL SYSTEM
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
3-3
3. MECHATRO CONTROL SYSTEM
3.1.2.3 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.
3-4
3. MECHATRO CONTROL SYSTEM
MULTI DISPLAY
WASHER SWITCH
WIPER SWITCH
SELECTOR SWITCH
4) After starting engine, press selector switch on gauge cluster, and "MEMORY
ENG" is displayed, the engine speed is automatically increased, and the ad-
justment 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 ad-
justment and unloading adjustment required later are not performed, and de-
fault 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 un- STEP
400
loading adjustment required later are not performed, and default value is writ-
ten.)
3-5
3. MECHATRO CONTROL SYSTEM
2) When the unloading valve operates to the specified value, the adjustment of
LOAD" 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 un-
loading proportional valves. The adjusting range is usually 520~635mA.
(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 ap-
plied 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 in-
crease of pump pressure during adjustment of engine through adjustment
screen.
c. Checking acceleration command voltage: Measure the acceleration com-
mand voltage output from mechatro controller to engine controller. Check
that signal is regularly input to the engine controller by actual measure-
ment of voltage or with failure diagnosis tool of engine controller.
3-6
3. MECHATRO CONTROL SYSTEM
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 com- E-1 300mA E-2 300mA
pleted is 25MPa or less.
Judging condition 2:
The adjustment does not complete although the pump proportional valve cur-
rent reaches to the specified value.
For machines equipped with lifting magnet, turn the generator OFF.
3-7
3. MECHATRO CONTROL SYSTEM
(6) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are re-
placed, 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 indi-
cated. 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. 3-2)
Like the output adjustment, when adjustment data is not entered in mechatro
controller, "READY" is indicated. If the adjustment operation is once per-
formed, "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" (ac- PROPO-VALVE
D-1 300mA D-2 300mA
6) When the unloading proportional valve operates to the specified value, the ad-
UNLOAD" is indicated.
The speed is shifted to the speed corresponding to acceleration potentiometer.
3-8
3. MECHATRO CONTROL SYSTEM
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)
3-9
3. MECHATRO CONTROL SYSTEM
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25 For the work with breaker, select "B mode" without fail.
A mode
10:25 For the work with crusher (nibbler), select "A mode".
3-10
3. MECHATRO CONTROL SYSTEM
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 210L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.
10:25 Flow
rate 130 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 130 L/m rate 130 L/m
A B
(b) (c)
3-11
3. MECHATRO CONTROL SYSTEM
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
• 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 3.7 SET PROCEDURE OF MAINTENANCE SCHEDULE.
3-12
3. MECHATRO CONTROL SYSTEM
H
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 dis-
plays in order of recent occurrence.
4) Mechatro adjustment display ......... Displays procedure for adjustment of mechatro system like output ad-
justment 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
HIGH ENG
AUTO IDLE STOP WATER TEMP.
CHARGE ERROR
DATA
CPU COMMUNICATION CLOGGED AIR FLTR CHANGE ENG OIL
ERROR
SWING BRAKE
ENGINE STOP
DISENGAGED
3-13
3. MECHATRO CONTROL SYSTEM
!
12
Swing flasher
13 right relay
Swing flasher
14 left relay
Travel alarm
15 relay
P1 side option AIS relay 2
16
P2 side option Engine stop
17 relay
Safety lock
18 lever relay
19
Adjustment Safety relay
21 data sector 1
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust data
Cluster
31 communication
Refer to next page (Engine)
3-14
3. MECHATRO CONTROL SYSTEM
3-15
3. MECHATRO CONTROL SYSTEM
3-16
3. MECHATRO CONTROL SYSTEM
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 2205 No load setting rpm B-1 BOOM RAISE
MEAS1 2201 Actual rpm 1 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS2 2201 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 2.6M Sensor voltage / Pressure converted value
WATER TEMP 100 OFF Coolant temperaturre sensor B-3 ARM OUT
MODE HM Work mode 3.5V 2.6M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage B-4 ARM IN
POS. 100% Voltage % indication 3.5V 2.6M Sensor voltage / Pressure converted value
ECU OUTPUT 0.5V Accel output voltage to engine B-5 BUCKET DIG
controller 3.5V 2.6M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
3.5V 2.6M Sensor voltage / Pressure converted value
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL(R)
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL(L)
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
B-19 DOZER 2
3.5V 2.6M Sensor voltage / Pressure converted value
3-17
3. 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
3-18
3. MECHATRO CONTROL SYSTEM
31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
B-1 BOOM RAISE 1.9M Boom up pressure sensor D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL(R) 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVEL(L) 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot pressure at travel straight (P1 side)
Pi-P2 13.9M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
D-3 S-TRAVEL 600mA Command current D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARM OUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B-4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux/ Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current
3-19
3. MECHATRO CONTROL SYSTEM
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
15mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 2040 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 600mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 137 137 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 137 137 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 137 137 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 137 137 Angle adjustment
3-20
3. MECHATRO CONTROL SYSTEM
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
3-21
3. MECHATRO CONTROL SYSTEM
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 12.5~16.5 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 12.5~16.5 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 550~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 550~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 400 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA
3-22
3. MECHATRO CONTROL SYSTEM
3-23
3. MECHATRO CONTROL SYSTEM
3-24
3. MECHATRO CONTROL SYSTEM
3-25
3. MECHATRO CONTROL SYSTEM
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
3-26
3. MECHATRO CONTROL SYSTEM
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 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
3-27
3. MECHATRO CONTROL SYSTEM
3-28
3. MECHATRO CONTROL SYSTEM
3-29
3. MECHATRO CONTROL SYSTEM
3-30
3. MECHATRO CONTROL SYSTEM
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
All the stored items are erased. It is impossible to erase data partially.
3-31
3. MECHATRO CONTROL SYSTEM
For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE" of Shop
Manual.
3-32
3. MECHATRO CONTROL SYSTEM
time is stored. S
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 250 hours as a warning, but the buzzer does not
sound.
3-33
3. MECHATRO CONTROL SYSTEM
time is stored. S
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.
3-34
3. MECHATRO CONTROL SYSTEM
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
AUTO IDLING STOP
(d)
AUTO WARM-UP AUTO IDLE STOP AUTO IDLE STOP
OFF OFF ON
(c)
(e)
AUTO IDLE STOP AUTO IDLE STOP
OFF ON
OFF ON OFF ON
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST"
select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
3. In operation of FEED (4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
4. In operation of FEED (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
(e) is displayed.
5. Switch from "OFF" to "ON" in operation of FEED (4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
3-35
3. MECHATRO CONTROL SYSTEM
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).
3-36
3. MECHATRO CONTROL SYSTEM
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555)
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH
STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is dis-
played.
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 com-
pleted, and then the screen returns to main screen (a).
3-37
3. MECHATRO CONTROL SYSTEM
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option attach- Does left rotation pedal use?
ment (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 re-
Low temperature mode release
lease
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
3-38
3. MECHATRO CONTROL SYSTEM
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
24 RXD3 Reception RS232C communication
25 DL EARTH / OPEN(5V
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Rotary light (yellow) Output EARTH/OPEN
33 DO 24 Rotary light (green) Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
3-39
3. 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
3-40
3. 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
3-41
3. 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
3-42
3. 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
3-43
3. MECHATRO CONTROL SYSTEM
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
No. Item name Wire color No. Item name Wire color
Gauge cluster → Mechatro
GND source (+24V Battery di- Yellow /
1 controller (RS232C communi- White 5
rect connection) Black
cation)
Mechatro controller → Gauge
2 cluster (RS232C communica- Red 6 GND Black
tion)
Source (+24V starter switch
3 Reserved — 7 White
ON)
GND (RS232C communica-
4 Reserved — 8 Black
tion)
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 con-
troller through the communication port.
3-44
3. MECHATRO CONTROL SYSTEM
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
3-45
3. MECHATRO CONTROL SYSTEM
2) Circuit diagram
3-46
3. MECHATRO CONTROL SYSTEM
3-47
3. MECHATRO CONTROL SYSTEM
3-48
3. MECHATRO CONTROL SYSTEM
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
Vcc GND
SPECIFICATION :
PRESSURE RANGE : 0 3.0 MPa
RATED VOLTAGE : 5.0+0.5V DC
OUTPUT CHARACTERISTIC INSURANCE RESISTANCE : 50M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)
3-49
3. MECHATRO CONTROL SYSTEM
The emergency mode should be used in only case of emergency. We recommend that the defective section is re-
paired by troubleshooting as early as possible.
Procedure
1) In case of failure of mechatro controller, the following indication appears on the display of gauge cluster.
DATA
CPU COMMUNICATION
ERROR
It is dangerous to abruptly increase the engine speed immediately after the engine is started. To avoid this dan-
ger, follow the procedure mentioned above.
If not followed, the engine speed might be increased rapidly.
When the machine is in normal condition, hold this emergency accel dial to "NORMAL" position.
3-50
3. MECHATRO CONTROL SYSTEM
* In case of previous model SK200-6, the switch was performed manually but this machine employs the auto-
matic switch.
SE22
a1 P
MAIN PUMP PSV1 A1
PSV-P1
642 Spool for emergency mode
B1
Pilot pump
3-51
3. MECHATRO CONTROL SYSTEM
* In previous machine, each spool controlling actuators had bleed function, meter-in function and meter-out func-
tion, and additionally bypass cut valve had bleed function. In this machine, unload valve is located on the upper-
most stream of control valve for the purpose of improvement of operability and energy saving, and bleed-control
is performed by electric control. (At normal condition)
3-52
3. MECHATRO CONTROL SYSTEM
CMR1
PL
PTb CMR2
TRAVEL
P1UNLOAD PRIORITY TRAVEL LEFT
PCb
BR CP1
AR
PBr CCb
Dr
BOOM LCb LCs SWING
PBb
37.7MPa
BUCKET LCc
PCc
PBc
37.7MPa
CRar
(ROD)Bc
(HEAD)Ac
39.7MPa
39.7MPa
PAc
LCAT2
ARM 2
PBa2 LCAP2 OPTION
LCo
PAa2
MU
PBp1
P1 BYPASS P2 BYPASS
CUT CUT
3-53
3. MECHATRO CONTROL SYSTEM
[MEMO]
3-54
4. ENGINE
4-1
4. ENGINE
4-2
4. ENGINE
4-3
4. ENGINE
SHAFT TORQUE
SHAFT OUTPUT
4-4
4. ENGINE
OIL FILTER
ELEMENT
ALTERNATOR
FUEL FILTER
ELEMENT
STARTER
14
14 Pin
11
17 10
2
* 25 11
12
3 26
C
B
16
27 10 23
25
14
11
* 12
14 20
27 11
36 20
10 5 26 12
3
20 A
25 A
10 23
12 20 22
28 30 16
A D
2
17 D
2
1
* 5
4-5
4. ENGINE
System Comparison
(Instant high pressure)
Conventional injection
Injection
system Timer
pump
Governor
Nozzle
Electric
control
Common rail injection
system
Pressure sensor Electric
solenoid
Supply Common rail valve
pump
Injector
(Constant high pressure)
Adjustment of injection pressure (Decided by rotating speed and injection rate) Supply pump (PCV)
Common rail
(Pressure container
for each injector
for common use)
ECU
Injection pump
4-6
4. ENGINE
Plunger Control
chamber
Inlet valve Feed pump
Outlet valve
Regulate valve Large
diameter
Suction control orifice
valve (SCV)
Fuel overflow Piston
Nozzle
Nozzle chamber
Injector
Fuel inlet
Cam shaft
Fuel filter
Fuel tank
(with priming)
4-7
4. ENGINE
Tightening torque
22825 23.7 N•m {650 kgf•cm, 47 lbf•ft} 9068-08320 28.5 N•m {290 kgf•cm, 21 lbf•ft}
900124 108 N•m {1,100 kgf•cm, 80 lbf•ft} 9068-08400 28.5 N•m {290 kgf•cm, 21 lbf•ft}
900124A 25 N•m {250 kgf•cm, 18lbf•ft} 9068-08850 28.5 N•m {290 kgf•cm, 21 lbf•ft}
9068-08250 28.5 N•m {290 kgf•cm, 21 lbf•ft}
4-8
4. ENGINE
4-9
4. ENGINE
Exhaust port
Intake port
4-10
4. ENGINE
Cylinder block
Cooling jet
Cylinder liner
Piston pin
Piston ring
Conecting rod
Piston
Cooling jet
4-11
4. ENGINE
Nitrided layer
PVD film
Yielding point
Elastic range Plastic range
Axial force of bolt
Small dispersion
Fracture
Large dispersion
Elongation of bolt
4-12
4. ENGINE
Reservoir
Water temperature
EGR cooler
Thermostat case
Cylinder head
Air
compressor
Thermostat
Cylinder block
Radiator Turbo
Car EGR
charger
heater Valve
Reserve tank
Cylinder block
Drain cock
Coolant
pump Oil cooler
4-13
4. ENGINE
4-14
4. ENGINE
Roller pin
Cam Roller
Cam shaft
Cam idle
gear shaft
Sub idle
gear shaft
Turbo
charger
Strainer
Main
Oil pump Oil cooler Oil filter
oil hole
Connecting
Piston pin Crank shaft
rod
Supply pump
drive
Main
idle shaft
; Lubrication
; Return
4-15
4. ENGINE
(2) Construction
1) Oil cooler
• The oil cooler is in water cooling multi plate type and keeps the engine oil fed into each section of the engine
at a proper temperature, and is installed on water gallery on the right side face of cylinder block.
• The oil cooler is of construction in which the oil delivered by oil pump flows inside and coolant cooled by ra-
diator flows outside. Therefore when the engine oil temperature is high, cools the oil taking as oil cooler, and
conversely when the oil temperature is low, warms up the oil and keeps the oil at a proper temperature.
• The plate number of oil coolant element is optimized resulting in improvement of cooling coefficient and re-
duction of oil consumption.
Oil outlet
(From oil gallery)
Oil outlet
(to oil pan) Oil inlet
(from oil pump)
2) Oil filter
• Full flow oil filter (paper filter) and by-pass oil filter (paper filter) are used in one cartridge as one filter, and
attached as a one separate component.
• A part of oil flowing to full flow oil filter is filtered by by-pass oil filter and returns to oil pan.
4-16
4. ENGINE
Fuel inlet
Fuel outlet
Filter element
Bowl
Drain valve
Heater harness
Make sure to use low sulfur light oil (S50: sulfur content, 50 ppm or less, ASTM 2-D diesel fuel as stan-
dard). (But in cold region, use fuel suitable to the ambient condition.) The filling and mixing with fuel,
gasoline, light oil (kerosene) and alcoholic fuel other than specified fuel causes failure of fuel lubricating
section inside of supply pump and injector due to unsmooth sliding, and as a result exerts adverse ef-
fect on the engine and causes damage.
4-17
4. ENGINE
Coolant outlet
Section A-A
Coolant inlet
Exhaust gas inlet
4-18
4. ENGINE
(4) Operation
• The feedback control is performed according to EGR valve opening so that the suction oxygen concentration
which varies according to EGR reaches to target value which corresponds to the engine operating condition
(engine speed, supercharging pressure, temperature of every part, load, suction air volume) to improve ex-
haust gas purifying performance by the use of EGR system.
• The EGR rate is controlled according to the opening of EGR valve with lift sensor on the basis of suction air
orifice opening set in advance and variable nozzle turbo opening in order to expand the EGR area.
Exhaust gas
inlet Coolant
Exhaust gas
outlet Engine Exhaust manifold
4-19
4. ENGINE
Shift lever
Gear shift
Armature
Starter switch
H P B
M
Armature FC B S E
assembly
C
4-20
4. ENGINE
(2) Alternator
• The alternator is driven with about double rpm of engine rpm by the aid of belt drive, and made up of stator
coil, field coil, rotor Assy, rectifier, and rectifier end frame and so on.
• The rotor Assy is press fitted to shaft, and the drive end frame is supported by ball bearing and the rectifier
end frame side is supported by roller bearing. This rotor Assy varies magnetic field by rotating between field
coil and stator coil generates AC voltage and AC voltage is rectified to DC voltage by diode.
• The reliability and accuracy of adjusting voltage of the regulator is improved by built-in IC regulator in alterna-
tor. Also the regulator is reduced in weight by use of IC regulator.
Rotor assembly
Field coil
Fan
Regulator Pulley
Rear bearing
Rectifier
(Diode)
Front bearing
Bearing cover
Rectifier
(End frame)
Condenser
Diode
Fuse Load
L Lamp
(1.4~3 W)
R
Starter
P switch
Field
coil
N
Regulator
Stator
coil Battery 24 V
Alternator
4-21
4. ENGINE
4-22
4. ENGINE
Blower housing
Back plate
Turbine housing
Turbine wheel
Blower impeller
Center housing
2) Operation
• The engine exhaust gas flows from exhaust manifold to turbine case and rotates turbine wheel.
• The turbine wheel drives blower impeller which is integrally installed to other end of shaft.
• The blower impeller compresses intake air from the air cleaner and is discharged through outlet of blower
housing.
• The compressed high temperature air is cooled by intercooler and is fed into intake manifold as high-density
compressed air.
• When the exhaust gas volume is increased, the number of rotations of turbine wheel is increased, and then
because the number of rotation of blower impeller is also increased, more air is fed to intake manifold.
• Conversely when the exhaust gas volume is decreased, the air volume which is fed into intake manifold is
also decreased.
• Against over-boosting in high speed zone, the excess exhaust gas is not sent to turbocharger. In this case the
excess exhaust gas bypasses to exhaust pipe via waste-gate.
West-gate
Turbine casing
Exhaust manifold
Blower housing
Inter cooler
Intake
manifold
4-23
4. ENGINE
Confirm failure
Confirm failure onlamp
on check check lamp
Read DTC
(Diagnosis Trouble Code)
4-24
4. ENGINE
Actuator Relay
Fuse
Each Sensor Power
Main relay
Key switch signal Fuse
Starter signal
- + Battery
OUTPUT
Glow relay
Common rail T
Engine
P
EGR valve 1
(Linear solenoid)
4-25
4. ENGINE
Special tool :
Failure diagnosis connector
09121-1040 Hino-Bowie (Interface box)
09042-1220 Connecting cable
CD-ROM Hino-DX
Hino-Bowie
Connecting cable
Connect to the failure diagnosis
connector at the machine side.
4-26
4. ENGINE
or
Table of failure code (Refer to table of DTC code (failure code) in Shop Manual.)
4-27
4. ENGINE
Connect harness
to lower of engine ECU.
When measuring terminal of the engine ECU, connect the signal check harness to prevent damage to the connector.
Place the tester rod on the contact box of the signal check harness for measurement.
Terminal number in the text and the illustrations correspond as shown below in the "Computer pin arrangement".
A8
A
A
Signal check harness
(contact box)
4-28
4. ENGINE
ECU
Machine harness
Test lead
4-29
4. ENGINE
B6 B B7
OK
OK
Normal
4-30
4. ENGINE
4-31
4. ENGINE
4-32
4. ENGINE
SHAFT TORQUE
SHAFT OUTPUT
4-33
4. ENGINE
GASKET
THERMOSTAT KIT
OIL PLUG
V BELT
(COMPRESSOR)
STARTER
V BELT (3 PIECES)
4-34
4. ENGINE
! !
# #
! "
! "
' '
&
"
#
* +
#
$
%
!
)
$
&
%
!
&
$ + !! )
'
!# '
&
+
!
!
*
*
!$
4-35
4. ENGINE
[MEMO]
4-36
5. MACHINE STRUCTURE
5-1
5. MACHINE STRUCTURE
5-2
5. MACHINE STRUCTURE
Fig. 5-1 Boom dimensional drawing
Unit : mm (ft-in)
STD —
5.65 M (18ft-6in) BOOM
YN02B00403F1 —
No NAME DIMENSION
A Boom length 5,650 (18'6") —
B Boom foot width 670 (26.4") —
C Boom end inner width 347 (13.7") —
D Boom end outer width 482 (19") —
E Height of boom cylinder rod pin 1,008.5 (3'4") —
F Height of arm cylinder (head side) pin 1,203.5 (3'11") —
G Distance between pins of boss R2,589 (8'6") —
H Distance between pins of bracket R2,829.5 (9'3") —
I Arm cylinder (head side) inner width 126 (4.96") —
J Outer width of bracket on the arm cylinder (rod side) 468 (18.4") —
mounting
d1 Boom foot pin dia. ø 90 (3.54") —
d2 Boom cylinder (rod side) pin dia. ø 85 (3.35") —
d3 Pin dia. of boom end. ø 90 (3.54") —
d4 Arm cylinder (head side) pin dia. ø 85 (3.35") —
5-3
5. MACHINE STRUCTURE
A
C
5-4
5. MACHINE STRUCTURE
5-5
5. MACHINE STRUCTURE
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
Fig. 5-3 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 Repair- Service
No. Size No. Length
value able level limit
670
Boom
(26.4) 0.5 (0.02) 831
A-A Boom foot L1 PL1
676 or less (32.7)
Upper frame
(26.6) 2.0 2.5
105 (0.08) (0.10)
Boom cylinder
Boom cylinder (4.13) 0.6~1.0 241
B-B L2 PL2
(Head side) 111 (0.02~0.04) (9.49)
Upper frame Shim ad-
(4.37)
just
105
Boom cylinder L3 ment
Boom cylinder (4.13) 0.6~2.0 3.0 4.0 736
C-C PL3
(Rod side) 468 (0.02~0.08) (0.12) (0.16) (29.0)
Boom L3'
(18.4)
120
Arm cylinder
Arm cylinder (4.72) 0.6~1.0 2.0 2.5 260
D-D L4 PL4
(Head side) 126 (0.02~0.04) (0.08) (0.10) (10.2)
Boom
(4.96)
5-6
5. MACHINE STRUCTURE
VIEW J
SECTION X-X
5-7
5. MACHINE STRUCTURE
E F
D, D'
B
C
G
5-8
5. MACHINE STRUCTURE
5-9
5. MACHINE STRUCTURE
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X L3 PL5
X L6
X L5
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D
SECTION G-G
Fig. 5-6 Clearance of arm and cylinder installing sections in thrust direction
5-10
5. MACHINE STRUCTURE
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repair-
No. Size Service limit No. Length
value able level
325
Arm
(12.79) 1.0 (0.04) 2.0
A-A Arm point L1 PL1
326 or less (0.08)
Bucket
(12.83) 481
325 (18.9)
Link side
(12.79)
B-B Bucket link L2 — — PL2
327
Bucket
(12.87)
323 2.5
Idler link Arm 0.5 1.0
C-C L3 (12.72) (0.10) PL3
(Arm connection) (0.02) (0.04)
Link side -
Bucket link Rod side -
D-D (Idler link L4 323 427
Link side
connection) (12.72) (16.8)
0.6~1.0 2.0 Shim
105 PL4
Rod side (0.024~0.04) (0.08) adjust
Bucket link (4.13)
D’-D’ L4’ -ment
(Rod side) 111
Link side
(4.37)
105
Head side
Bucket cylinder (4.13) 235
E-E L5 PL5
(Head side) 111 (9.25)
Arm
(4.37) 0.6~2.0 3.0 4.0
120 (0.024~0.08) (0.12) (0.16)
Rod side
Arm cylinder (9.72) 260
F-F L6 PL6
(Rod side) 126 (10.2)
Arm
(4.96)
342
Arm
(13.46) 0.5 1.0 2.5 505
G-G Arm foot L7 PL7
347 (0.02) (0.04) (0.10) (19.9)
Boom
(13.66)
5-11
5. MACHINE STRUCTURE
Unit : mm (ft-in)
Type Hoe bucket
[SE. Asia STD]
[Oceania STD]
0.80 m3 0.51 m3 0.70 m3 0.93 m3
Capacity 0.80 m3
(1.05 cu•yd) (0.67 cu•yd) (0.92 cu•yd) (1.21 cu•yd)
(1.05 cu•yd)
Side pin type
Part No. YN61B00272F1 YN61B00258F1 YN61B00287F1 YN61B00286F1 YN61B00288F1
A R430 (16.9") ← ← ← ←
B R1,440 (4'9") ← ← ← ←
C 1,003 (3'3") ← 712 (28") 925 (36.4") 1,176 (3'10")
D 399 (15.7") ← ← ← ←
E 327 (12.9") ← ← ← ←
F 1,157 (4') ← 868 (34.2") 1,079 (3'6") 1,330 (4'4")
G 863 (34") ← 572 (22.5") 785 (30.9") 1,036 (3'5")
H 1,057 (3'6") ← 766 (30.2") 979 (38.5") 1,230 (4')
I 224 (8.82") ← 300 (11.8") 203 (7.99") 266 (10.5")
IO 224 (8.82") ← 300 (11.8") 203 (7.99") 266 (10.5")
d1 ø 95 (3.74") ← ← ← ←
d2 ø 80 (3.15") ← ← ← ←
5-12
5. MACHINE STRUCTURE
X B
J
A
BOSS
M
28 YB61B01002P1
(1.10) Apply rust prevention oil
19
(0.748)
3-G
B
F
N
D E
H
BOSS
SHIM 1 Insert this pin flush with surface YB61B01002P1
Five shims are installed
at shipping SECTION X-X
DETAIL B
Unit : mm (ft-in)
Lug plate thickness
Boss width.
Boss width.
Screw dia.
Capacity of
Hole dia.
A B D E F G H J M N
[Oceania STD]
Hoe 0.80 (1.05) YN61B00258F1 80 25 95 13 180 25 170 36 140
bucket (3.15") (0.984") (3.74") (0.512") (7.09") M16 (0.984") (6.69") (1.42") (5.51")
0.51 (0.67) YN61B00287F1
0.70 (0.92) YN61B00286F1
0.93 (1.21) YN61B00288F1
5-13
5. MACHINE STRUCTURE
H 5
(0.197")
oG
oC
oD
oA
oB
15 (0.591")
Unit : mm (ft-in)
Type Capacity of
Part No. of Part No.
of bucket øA øB øC øD E F øG H I
bucket of boss
bucket m3 (cu•yd)
[SE. Asia STD]
0.80 (1.05) YN61B00272F1
[Oceania STD]
Hoe 114.3 84 105.5 111.5 23 38 17 13 2.5
0.80 (1.05) YN61B00258F1 YB61B01002P1
bucket (4.50") (3.31") (4.15") (4.39") (0.91") (1.50") (0.669") (0.512") (0.098")
0.51 (0.67) YN61B00287F1
0.70(0.92) YN61B00286F1
0.93(1.21) YN61B00288F1
5-14
5. MACHINE STRUCTURE
5.4.1.1 CONSTRUCTION
FLAT SHOE
2
1-6
1-1
1-8
1-4
1-3 TRIANGLE SHOE
1-8 2 RUBBER PAD SHOE 3
1-7 2
1-1
4 3
1-7 1-5 3
1-2 1-2
Fig. 5-10 Track link assy and shoe plate
SK200-8 SK200LC-8
Shoe assy
5-15
5. MACHINE STRUCTURE
5.4.2.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
3
4
(2) Removing upper roller (1)
1) Remove nuts on support tightening section, and
2
also remove capscrew (2) M20×100.
1
: 30 mm
5.4.2.3 INSTALLING
Installing is done in the reverse order of removing.
(1) Inspection
Before reassembling, check it that it rotates smooth COUNTER-
manually and for leak. SINKING
end upward.
: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
2 1 3,4
5-16
5. MACHINE STRUCTURE
C
A
E
F
D D
B
Unit : mm (in)
REPAIR- SERVICE
No. ITEM STANDARD VALUE REMEDY
ABLE LEVEL LIMIT
A Dia. ø 140 (6.30) — —
B Width 150 (5.91) — —
Replace
C Tread dia. ø 120 (4.72) ø 107 (4.21) ø 105 (4.13)
D Tread width 33 (1.30) — —
Basic
Tolerance Fit Fit
dimension
Clearance between - 0.025
E
shaft and bushing (-0.00098) Clearance Clearance
ø 45 (1.772) Shaft
- 0.040 0.7 (0.028) 1.0 (0.039) Replace bushing
(-0.00157)
+ 0.030
Interference between Interference Clearance
F ø 50 (1.969) Hole (+0.00118)
roller and bushing 0 0.01 (0.0004)
0
Tightening torque of
G 115 N•m (85 lbf•ft)
socket bolt
Oil Engine oil API grade CD #30, 30 cc (1.83 cu•in) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly
5-17
5. MACHINE STRUCTURE
2 1 B2
Apply Loctite #262
T=397N.m (290 lbf.ft)
Fig. 5-13 Lower roller assy and track guide
5.4.3.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the low-
er frame by the front attachment and stop the en-
gine in that condition.
2) Place a safety block (wood) at the front and back
of the lower frame.
: 27mm,
Weight of track guide : Approx. 25 kg (55 lbs)
ROLLER
B2,B5
SK210LC-8 LC YN01F00036F1 STD
ITEM NAME Q'TY
B2 TRACK GUIDE : YN63D00003P1 2 2
B5 CAPSCREW : M18X40(P=1.5) 8 8
5-18
5. MACHINE STRUCTURE
+ +
*
-
)
0
Fig. 5-17 Lower roller (Track roller)
Unit : mm (in)
REPAIRABLE SERVICE LIM-
No. ITEM STANDARD VALUE REMEDY
LEVEL IT
A O.D. of flange ø 185 (7.28) — — Reinforcement weld,
B Tread dia. ø 150 (5.91) ø 134 (5.28) ø 128 (5.04) repair or replace
C Flange width 23.5 (0.925) 18 (0.709) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 65 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft
(2.55905) - 0.090 0.7 (0.276) 1.0 (0.394) Replace bushing
(-0.00354)
+ 0.030
Interference between ø 69 (+0.00118) Interference Clearance
E Hole
roller and bushing (2.71653) - 0.020 0 0.01 (0.0004)
(-0.00079)
F Oil Engine oil API grade CD #30, 160 cc (9.8 cu•in) Refill
Execute air leak test at 0.2 MPa (28 psi)
H Plug (8)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
5-19
5. MACHINE STRUCTURE
5.4.4.1 CONSTRUCTION
!
%
!
"
!
&
" $
#
"
!#
" "$
160(6.30)
C
F
D
E
B
A
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. of idler projection ø 535 (21.1) — —
B Tread dia. ø 497 (19.6) ø 490 (19.3) ø 487 (19.2) Replace
C Flange width 84 ± 0.5 (3.307±0.020) 78 (3.07) 76 (2.99)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 75 (-0.00118) Clearance Clearance
Shaft Replace
(2.95275) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
+ 0.035 Clearance
Interference between idler and ø 83 Interference
E Hole (+0.00138) 0.01
bushing (3.26771) 0
0 (0.0004)
F Oil Engine oil API grade CD #30, 200 cc (12.2 cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble
5-20
5. MACHINE STRUCTURE
5.4.5.1 CONSTRUCTION
" ! % # ' & $
X
E
C
A, B F
X D Y
BRACKET
DETAIL Y
SECTION XX
Fig. 5-21
5-21
5. MACHINE STRUCTURE
96.07 mm NUMBER OF
PITCH 21
(3.78 in) TEETH
SPECIFICATION
ø58.72 mm 644.602
ROLLER DIA. PITCH DIA.
(2.31 in) (25.333 in)
C
Fig. 5-22 Sprocket
Unit: mm (in)
REPAIRABLE SERVICE LIM-
No. NAME STANDARD VALUE REMEDY
LEVEL IT
Reinforcement weld, re-
A O.D. of sprocket ø 659 (25.9) ø 651 (25.6) ø 649 (25.6)
pair or replace.
B Width of sprocket teeth 66±2 (2.520±0.079) 60 (2.36) 58 (2.28) Replace.
Reinforcement weld, re-
C O.D. of sprocket bottom ø 586 (23.1) ø 578 (22.8) ø 576 (22.7)
pair or replace.
5-22
5. MACHINE STRUCTURE
5.5.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
A1-1
seat (A1) to ease handling.
2) Move the whole control stand to its foremost po- A1
sition.
3) Move the operator’s seat to its forward end. C1
4) Incline the reclining seat as forward as possible.
C2
(2) Remove operator’s seat. (Include upper rail.) B2
C1
1) With the above-mentioned condition, remove C2
two cap screws (B2) M8×20 from the upper rail.
Then move the control stand to its rearmost end
and remove two capscrews (B2) M8×20.
1
: 6 mm
2) Remove the operator’s seat. [about 20 kg (44 8
lbs).]
Carry out the following operations as required.
3) Remove seat belt (C1).
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (8).
5.5.1.2 INSTALLATION
Install it in reverse procedure of removing according to
the tightening torque table.
A4
A5
A2
# & $%
$% '#($ &' A6
!"# $& )(# %($
A1
5-23
5. MACHINE STRUCTURE
5.5.2.1 REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7)
Lift cover (A7) upwards and remove it. (Fixed with
2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6×16 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1). A22
(4) Remove the harness connector. A1
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71) (CN-72) and (CN-500)
at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 5-25 Disassembly and assembly of cover (A7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
(6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6×25 and 1 sems bolt (A39) M6×16. And right A3
A14
panels (A4) and (A4-2) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed
A22
with 3 clows and 2 clips)
B2
3) Unfix 3 harness clips (A4-8) of inside on right A40
A4-8
panel (A4-2). And free the harnesses connected A29
A4
to key switch.
A4-8 A39
4) With harnesses are connected condition, install A40
key switch cover (A3) to bracket (A1) of rear cab A4-8
temporally. (See Fig. 5-27)
5) Disconnect harness connectors of work light A29 A4-2
switch on right panel (A4), air conditioner panel
and cigarette lighter, and remove right panel (A4) A22
and (A4-2).
6) Loosen sems bolts (A22) M6×16 and (A23)
M6×40 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver
A5-2
A23
Fig. 5-26 Disassembly and assembly of right panels
(A4-2), (A3) and (A5-2)
5-24
5. MACHINE STRUCTURE
RELAY BOX
ASSY
5.5.2.2 INSTALLATION
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 79.4 (60
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)
5-25
5. MACHINE STRUCTURE
5.5.3.1 REMOVING
(1) Open left panel assy (21).
1) Open it with starter key.
2) Open left panel assy (21).
3) Fix it with stay.
: 17 mm
(3) Remove battery cable
1) Remove cable (A4) [between the earth and bat- 21
tery (–)].
Fig. 5-30
(Always remove (-) terminal first and install it at
last.) 7
Tightening torque
2) Cable (A3) [between battery (+) and (-)] 15.7 N.m (11.6 lbf.ft)
1
3) Cable (A2) [between battery (+) and battery re-
lay]
2
: 13 mm
5.5.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (3) against battery (B1), and tight-
en capscrew (4).
: 17 mm,
Tightening torque : 10.8 N•m (8.0 lbf•ft)
(2) Installing grounding cable
Install grounding cable (A4) last. Especially care
must be taken that the grounding face is free from
painting, rust, etc.
: 13 mm
5-26
5. MACHINE STRUCTURE
11
23
4
21
Fig. 5-32 Arrangement of guard assy
: 19 mm
Weight : 37 kg (82 lbs)
7
7
Fig. 5-33 Removing bonnet assy (11)
(2) Remove guard (5) 41b
1) Remove 4 sems bolts (41a) M12×25 on upper
41a
side.
5
2) Remove 3 sems bolts (41b) M12×25 on the side.
3) Remove guard (5)
41a
: 19 mm
Weight :10 kg (22 lbs) C
5-27
5. MACHINE STRUCTURE
: 19 mm D
3
Fig. 5-35 Removing guard (6)
(4) Remove stay (7)
1) Remove 2 sems bolts (41) M12×25.
2) Remove 2 sems bolts (43) M12×40. 7
: 19 mm
43
A
Fig. 5-36 Removing stay (7)
(5) Remove guard (2)
41
1) Remove 2 sems bolts (41) M12×25.
2) Remove connector for right side deck light. 2
3) Remove guard (2).
Deck light
: 19 mm
: 17 mm 4
Weight : 15 kg (33 lbs)
5-28
5. MACHINE STRUCTURE
: 17 mm
Weight : 10 kg (22 lbs)
: 17 mm
Weight : 15 kg (33 lbs)
41
15
: 19 mm 42
5-29
5. MACHINE STRUCTURE
: 19 mm
Weight : 8 kg (18 lbs) 4
10
12
5-30
5. MACHINE STRUCTURE
: 19 mm 6
: 19 mm
Weight : 15 kg (33 lbs) B
41
41
20
41
5-31
5. MACHINE STRUCTURE
: 19 mm
Weight : 30 kg
41
1-2
(20)Remove other brackets, as required.
5.5.4.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
5-32
5. MACHINE STRUCTURE
5.5.5.2 REMOVAL
(1) Remove 4 capscrews (A1) M16×40. (SK200-8)
B2
Remove 6 capscrews (A1) M16×45. (SK330-8)
: 24 mm
A4
(2) Hook the wire to the lifting eye on the fuel tank assy
(C1) and remove the fuel tank. C1
A6
Weight : 102 kg (225 lbs) … SK200-8
203 kg (448 lbs) … SK330-8
(3) Remove shim (A3).
A1
A8
5-33
5. MACHINE STRUCTURE
5.5.5.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A1) M16 × 40 (SK200-8)
M16 × 45 (SK330-8)
Tightening torque
No. Name Q'ty N.m (lbf.ft)
A1 Capscrew 4 191 (140)
A6 Machine screw 5 1.96 (1.4)
A8 Cock 1 34 (25)
5-34
5. MACHINE STRUCTURE
5-35
5. MACHINE STRUCTURE
Unit ; kg (lb)
Model
SK200 - 8 SK210LC - 8
Item
4. Lubricant and water (Assembly of following :) 550 (1,210) ←
4.1 Hydraulic oil 200 (440) ←
4.2 Engine oil 20 (44) ←
4.3 Fuel 310 (680) ←
4.4 Water 20 (44) ←
5-36
5. MACHINE STRUCTURE
d4
J
I
d3 K
d1
D C
H G B
E
F
K
A
J
d2
SECTION K-K
Unit : mm (ft-in)
STD
6.50 M (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")
5-37
5. MACHINE STRUCTURE
A
C
5-38
5. MACHINE STRUCTURE
5-39
5. MACHINE STRUCTURE
D
D C
A
L3 L3' X3
B A
PL3
X1 L1
SECTION C-C
X4
L4 PL4
PL2 PL2
PL1
X2 L2 L2 X2
SECTION B-B
Fig. 5-53 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 Repair- Service
No. Size No. Length
value able 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 ad-
(5.35)
just
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)
5-40
5. MACHINE STRUCTURE
VIEW J
SECTION X-X
5-41
5. MACHINE STRUCTURE
E F
D, D'
B
C
G
5-42
5. MACHINE STRUCTURE
5-43
5. MACHINE STRUCTURE
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. 5-56 Clearance of arm and cylinder installing sections in thrust direction
5-44
5. MACHINE STRUCTURE
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repair-
No. Size Service limit No. Length
value able 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) 570
380 (22.4)
Link side
(14.96)
B-B Bucket link L2 — — PL2
382
Bucket
(15.04)
390 2.5
Idler link Arm 0.5 1.0
C-C L3 (15.35) (0.10) PL3
(Arm connection) (0.02) (0.04)
Link side —
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) 286
E-E L5 PL5
(Head side) 136 (11.3)
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) 296
F-F L6 PL6
(Rod side) 146 (11.7)
Arm
(5.75)
400
Arm
(15.75) 0.5 1.0 2.5 577
G-G Arm foot L7 PL7
405.8 (0.02) (0.04) (0.10) (22.7)
Boom
(15.98)
5-45
5. MACHINE STRUCTURE
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") ← ← ←
5-46
5. MACHINE STRUCTURE
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. 5-58 Dimension of lug section
Unit : mm (ft-in)
Lug plate thickness
Plate thickness
Boss width.
Screw dia.
Capacity of
Hole dia.
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")
5-47
5. MACHINE STRUCTURE
)
gh
ou
thr
rill
(D
G
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
5-48
5. MACHINE STRUCTURE
5.10.1.1 CONSTRUCTION
1-3
1-8 1
1-1
1-7 7
1-4
1-2 3,4,5
1-6
1-5
1-9 1-10
1-11 6
Fig. 5-60 Track link assy & shoe plate
SK330-8 SK350LC-8
SHOE LC60D00010F3 SHOE LC60D00011F3
ASSY LC60D00010F1 ASSY LC60D00011F1
No. NAME Q'ty No. NAME Q'ty
1 •Link assy LC62D00004F1 1 1 2 •Link assy LC62D00004F2 1 1
1–1 ••Track link R 43 43 2–1 ••Track link R 46 46
1–2 ••Track link L 43 43 2–2 ••Track link L 46 46
1–3 ••Master link R 2 2 2–3 ••Master link R 2 2
1–4 ••Master link L 2 2 2–4 ••Master link L 2 2
1–5 ••Bushing 43 43 2–5 ••Bushing 46 46
1–6 ••Pin 43 43 2–6 ••Pin 46 46
1–7 ••Master bushing 2 2 2–7 ••Master bushing 2 2
1–8 ••Master pin 2 2 2–8 ••Master pin 2 2
1–9 ••Collar 4 4 2–9 ••Collar 4 4
1–10 ••Seal 86 86 2–10 ••Seal 92 92
1–11 ••Pin 2 2 2–11 ••Pin 2 2
3 •Shoe 600 mm 45 — 3 •Shoe 600 mm 48 —
5 •Shoe 800 mm — 45 5 •Shoe 800 mm — 48
6 •Bolt LC60D01001P1 180 180 6 •Bolt LC60D01001P1 192 192
7 •Nut 2420Z1414 180 180 7 •Nut 2420Z1414 192 192
5-49
5. MACHINE STRUCTURE
5.10.2.2 REMOVING
(1) Preparation for removal " ! !
Remove crawler (Above mentioned).
: 30 mm
5.10.2.3 INSTALLING
Installing is done in the reverse order of removing. Center of machine
(1) Inspection
Before reassembling, check it that it rotates smooth
manually and for leakage.
3,4
1
(2) Installing upper roller (1)
1) To install the upper roller, turn up nut (4) toward
the center of machine.
2,3
2) Insert it until collar comes in contact with support.
: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
5-50
5. MACHINE STRUCTURE
C
D D
F
J H
Unit : mm (in)
No. Item Standard value Service limit Remedy
A Dia. ø 185 (7.28) ø 175 (6.89)
Reinforcement
B Tread dia. ø 160 (6.30) ø 150 (5.91)
weld, repair or re-
C Width 95 (3.74) 85 (3.35)
place
D Flange width 19 (0.748) 15 (0.591)
Basic di-
Tolerance Standard Limit
mension
Clearance between shaft and -0.025
E
bushing ø 65 (-0.0010) Clearance Clearance
Shaft
F (+0.0012)
and bushing (2.7559) — 0
0
Tightening torque of socket
H 114.7 N•m (85 lbf•ft) Apply loctite #262
bolt
J Oil Engine oil API grade CD #30, 100 cc (6.1 cu•in) Refill or replace
Roller rotation Roller rotates smoothly by hand.
5-51
5. MACHINE STRUCTURE
" 1
! # 2 Apply loctite #262
T=731N.m (540 lbf.ft)
5.10.3.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the low-
er frame by the front attachment and stop the en-
gine in that condition.
2) Place a safety block (wooden) at the front and
back of the lower frame. SAFETY BLOCK
(SQUARE
TIMBERS)
(2) Removing track guide (See Fig. 5-16)
Remove capscrews (8) M24×52 and remove track Fig. 5-64 Preparation for removal
guide (5).
: 36 mm
Weight of track guide : Approx. 40 kg (88 lb)
9 2 5 9
8 SK330-8 8
(3) Remove lower roller
Remove capscrews (2) and remove lower roller (1).
: 32 mm
9 2 5 9
Weight of lower roller : Approx. 57 kg (126 lb) 8 SK350LC-8 8
5.10.3.3 INSTALLATION
(1) Installation of lower roller
Lower SK330-8 STD LC01F00019F1
Coat mounting capscrews (2) with Loctite #262 and
group SK350LC-8 LC LC01F00017F1
fasten all four capscrews temporarily. Then tighten
them to a specified torque. No. Name Q'ty
2 Track guide LC63D00004P1 2 2
: 32 mm 5 Capscrew ; M24 X 52 8 8
Tightening torque : 731 N•m (540 lbf•ft) 8 Capscrew ; M24 X 35 16 16
(2) Installation of track guide 9 Washer 16 16
Capscrews (8) with Loctite #262 and fasten all four
capscrews temporarily. Then tighten them to a
specified torque.
: 36 mm
Tightening torque : 932 N•m (690 lbf•ft)
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.
5-52
5. MACHINE STRUCTURE
C C
G
A
E
B
Unit : mm (in)
Repairable lev-
No. Item Standard value Service limit Remedy
el
A O.D. of flange ø 216 (8.50) — — Reinforce-
mentweld, repair
B Tread dia. ø 175 (6.89) ø 160 (6.30) ø 154 (6.06)
or replace
C Flange width 27 (1.06) — —
Basic di-
Tolerance Fit Fit
mension
Clearance between shaft
-0.060
D and bushing
ø 75 (-0.0024) Clearance Clearance Replace bushing.
Shaft
(Wrapped bushing)
(2.9528) -0.090 0.7 (0.276) 1.0 (0.394)
(-0.0035)
Interference between roll- ø 83 ±0.030 Interference Clearance
Hole
E
er and bushing (3.2677) (±0.0012) 0.01 (0.0004) 0
F Oil Engine oil API grade CD #30, 430 cc (26.14 cu•in) Refill
Execute air leak test at 0.2 MPa (28 psi) before tightening the
G Plug (8)
plug.
Roller rotation Rotates smoothly by hand. Reassembly
5-53
5. MACHINE STRUCTURE
5.10.4.1 CONSTRUCTION
'$%
4 VIEW I
$%& 1
()$%& * +
'#& ',-
204 (8.03")
C
F
E
D
A
B
Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
A Dia. Of idler projection ø 609 (24.0) — —
B Tread dia. ø 564 (22.2) ø 557 (21.9) ø 554 (21.8) Replace
C Flange width 102 (4.02) 96 (3.78) 94 (3.70)
5-54
5. MACHINE STRUCTURE
Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
Basic di-
Tolerance Fit Fit
mension
Clearance between shaft and – 0.072
D
ø 85 (-0.0028) Clearance Clearance
Shaft
bushing
(3.3465) –0.126 1.5 (0.059) 2.0 (0.079)
Replace bushing.
(-0.0050)
+ 0.035
Interference
Interference between idler and ø 89 (+0.0014) Clearance
Hole
E 0.01
bushing (3.504) 0 0
(0.0004)
(0)
F Oil Engine oil API grade CD#30, 350 cc (21.4 cu•in) Refill
Idler rotation Rotates smoothly by hand. Reassemble
5-55
5. MACHINE STRUCTURE
5.10.5.1 CONSTRUCTION
C F
A, B
D
5-56
5. MACHINE STRUCTURE
215.9 mm
Pitch Number of teeth 21
(8.5 in)
Specification
ø68 mm
Roller dia. Pitch dia. 732.47 (28.8 in)
(2.68 in)
C
A
Fig. 5-70 Sprocket
Unit : mm (in)
No. Name Standard value Repairable level Service limit Remedy
Reinforcement weld, re-
A O.d. Of sprocket ø 755 (29.7) ø 747 (29.4) ø 745 (29.3)
pair or replace.
B Width of sprocket teeth 85
0
(3.35 -0.157 ) 79 (3.11) 77 (3.03) Replace.
Reinforcement weld, re-
C O.D. of sprocket bottom ø 664.05 (26.1) ø 656 (25.8) ø 654 (25.7)
pair or replace.
5-57
5. MACHINE STRUCTURE
5.11.1.1 REMOVING
(1) Open left panel assy (21).
1) Open it with starter key.
2) Open left panel assy (21).
3) Fix it with stay.
: 17 mm
(3) Remove battery cable
1) Remove cable (C4) [between the earth and bat-
tery (–)]. 21
(Always remove (-) terminal first and install it at
Fig. 5-71
last.)
2) Cable (C2) [between battery (+) and (-)]
+"
3) Cable (C3) [between battery (+) and battery re-
lay] +
: 13 mm
5-58
5. MACHINE STRUCTURE
: 17 mm
2) Remove plate (A3).
3) Remove battery (B1).
A4
A3
B1
5.11.1.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (A3) against battery (B1), and
tighten capscrew (A4).
: 17 mm,
Tightening torque : 10.8 N•m (8.0 lbf•ft)
(2) Installing grounding cable
Install grounding cable (A4) last. Especially care
must be taken that the grounding face is free from
painting, rust, etc.
: 13 mm
5-59
5. MACHINE STRUCTURE
5 11
23
6
21
Fig. 5-74 Arrangement of guard assy
: 19 mm
Weight : 60 kg (132 lbs)
%
Fig. 5-75 Removing bonnet assy (11)
(2) Remove guard (7) %
1) Remove 3 sems bolts (38) M12×25 on upper !&
side. !'
: 19 mm
Weight : 11 kg (24 lbs)
5-60
5. MACHINE STRUCTURE
!" !'
: 19 mm
Weight :
guard (8) : 13 kg (29 lbs)
!'
guard assy (5) : 23 kg (51 lbs)
Fig. 5-77 Removing guard (5),(8)
(4) Remove stay (3)
1) Remove 2 sems bolts (38) M12×25.
2) Remove 2 sems bolts (40) M12×40. 3
3) Remove stay (3).
38
: 19 mm
Weight : 8.6 kg (19 lbs)
40
: 17 mm 4
Weight : 17 kg (37 lbs)
5-61
5. MACHINE STRUCTURE
: 17 mm
Weight : 17 kg (37 lbs)
!
Fig. 5-81 Removing panel assy (23)
(8) Remove panel assy (22)
22
1) Unlock and open panel assembly (22).
2) Remove 4 nuts (4) M10.
3) Remove panel assy (22).
: 17 mm
Weight : 17 kg (37 lbs)
$
!&
!&
5-62
5. MACHINE STRUCTURE
: 19 mm
Weight :
beam (11) : 6.8 kg (15 lbs)
pillar (10) : 17 kg (37 lbs)
panel (4) : 3 kg (6.6 lbs)
!'
!'
Fig. 5-84 Removing beam (11), pillar (10), panel (4)
(11)Remove beam (6), pillar (9), (12) 11
Remove battery relay box in advance and remove
pillar (12). (See Chapter 23) 39
39
39
39
: 19 mm
"' !'
Weight : 1.2 kg (2.6 lbs)
3) Loosen 2 sems bolts (38) M12×25. Fig. 5-86 Removing and installing of plate (49)
(Refer to Fig. 5-85)
4) Loosen 5 sems bolts (5) M12×30.
: 19 mm
5) Remove guard assy (13)
Weight : 17 kg (37 lbs)
5-63
5. MACHINE STRUCTURE
: 19 mm
Weight :
guard assy (2) : 12 kg (26 lbs)
guard assy (1) : 20 kg (44 lbs) 5
: 19 mm
3
2) Remove guard assy (4), guard (3)
Weight :
guard assy (4) : 8 kg (18 lbs)
guard (3) : 11 kg (24 lbs)
39
5-64
5. MACHINE STRUCTURE
: 19 mm
Weight : 30 kg
39
1-2
(17)Remove other brackets, as required.
5.11.2.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
5-65
5. MACHINE STRUCTURE
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 (2 pcs. for mounting bucket cylinder / 2 pcs. 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) ←
5-66
5. MACHINE STRUCTURE
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) ←
5-67
5. MACHINE STRUCTURE
[MEMO]
5-68
6. CHECK-UP & SERVICE
6-1
6. CHECK-UP & SERVICE
6-2
6. CHECK-UP & SERVICE
A. DAILY INSPECTION
Before starting the engine, walk around the machine to check for any loose nuts and bolts, any oil, fuel or coolant
leakage, and the condition of attachment and hydraulic system.
Check for any looseness in the electrical wiring and for any accumulated material (leaves, dirt , etc.). Repair and
clean as necessary.
The deposit of combustible, fuel leakage and oil leakage in heated area around the engine, muffler and bat-
tery may cause fire of machine. Check the area sufficiently, and if the abnormality is found, repair it or con-
tact our dealer/distributor.
6-3
6. CHECK-UP & SERVICE
(1) Open left rear cab door and check coolant level of 2
reserve tank (1).
(2) Open side door of radiator with starter key and 1
check that the coolant level is in the range of FULL
– LOW of reserve tank. If shorted, remove filler cap
(2) of reserve tank and supply to FULL level.
FULL
(3) After supply, tighten the cap securely.
(4) When the reserve tank is empty, after checking it for
oil leak check radiator coolant level for shortage,
and if shorted, first supply coolant to the engine and LOW
then to the reserve tank.
(5) Close the side door on the left side face of machine
and lock it with starter key.
6-4
6. CHECK-UP & SERVICE
G
Immediately after engine is stopped, there is a
possibility of getting burn with heated parts and
oil. Start working after the temperature is not
hot.
F
6-5
6. CHECK-UP & SERVICE
6-6
6. CHECK-UP & SERVICE
6-7
6. CHECK-UP & SERVICE
Checking
(1) The hydraulic tank is installed on the right side.
H
(2) Move the machine to firm level ground and set it in
G
the hydraulic oil level check position.
L
(3) Check the oil level through sight level gauge (G)
provided on the side of the hydraulic tank. Hydraulic
oil level should be between H and L.
Oil level varies depending on oil temperature.
Check the oil level referring to the followings.
• Before starting :
"L" level oil temp. 10~30 °C (50~86 °F)
• Normal operation :
1
"H" level oil temp. 50~80 °C (122~176 °F)
6-8
6. CHECK-UP & SERVICE
SK200-8
SK330-8
6-9
6. CHECK-UP & SERVICE
Climete Zone
Type of Capacities
Components -22 -4 14 32 50 68 104 F Specified Lubricant
86
Lubricant (When changed) -30 -20 -10 0 10 20 30
40 C
(KOBELCO BRAND)
ISO VG68
146 Liters KW68
(39 Gal) (KOBELCO BRAND)
Hydraulic 246 Liters ISO VG46 KW46 (20 L)
Hydraulic oil tank
oil (65 Gal) P/No. KAP3532R157D5
Hydraulic (KOBELCO BRAND)
system ISO VG32 KW32 (20 L)
P/No. KAP2421Z201D1
[Total volume]
(KOBELCO BRAND)
20.5 Liters
(5.4 Gal) JAS0DH-1
SAE 10W-30
Engine oil [H level] P/No. KAPYN01T01053D1
Engine oil pan JASO 18.0 Liters (20 L)
(4.8 Gal)
DH-1 [L level]
15 Liters SAE 15W-40 SAE 15W-40
(4.0 Gal)
Swing motor 3.0 Liter (KOBELCO BRAND)
reduction unit (0.8 Gal) A.P.I clssification for
Gear oil EXTREME GEAR OIL SAE #90
Travel motor 5.3 Liter X 2 "service GL-4"
reduction unit (1.4 Gal X 2) P/No. KAPG90020
Swing motor reduction
1.0 kg EP GREASE
unit (Housing)
Attachment pins 16 places EP GREASE
(KOBELCO BRAND)
Slewing ring gear 1 place EP GREASE
EP grease Extreme pressure
Track tension multipurpose
2 places EP GREASE
Adjustment grease No.2*2
Operating lever
As required EP GREASE
(Pilot valve)
8.6 kg
Swing gear
(19 lbs)
ASTM D-975 No.2
ASTM D-975
370 Liters Grade 2-D
Fuel tank Diesel fuel ASTM D-975 No.2
(98 Gal)
ASTM D-975
ASTM D-975 No.1
Grade 1-D
(KOBELCO BRAND)
6.5 L If commercial coolant
Engine is used, the mixing
Radiator Total
coolant 50% Mixture rate should conform
(Reserve tank) volume
with the specified.*1
(Antifreeze) 22 L P/No. KAPLLC95-20
(20 L)
• When the oil leak and damage are found in the lower roller, upper roller and front idler, contact our dealer/ distrib-
utor for repair.
• Use ASTM D-975 No.2 oil for fuel without fail.
This engine is equipped with electric control high pressure fuel injection system to obtain the features like excel-
lent fuel saving and emission in good condition. This system requires the parts in high precision and high lubri-
cating ability. Therefore if low viscosity fuel in low lubricating ability is used, the durability may be notably lowered.
6-10
6. CHECK-UP & SERVICE
Climete Zone
Type of Capacities
Components -22 -4 14 32 50 68 86 104 F Specified Lubricant
Lubricant (When changed) -30 -20 -10 0 10 20 30 40 C
146 Liters (KOBELCO BRAND)
ISO VG46 Long life hydraulic oil
(39 Gal) KW5046 (20 L)
Hydraulic 246 Liters P/No. KAP2421R157D9
Hydraulic oil tank
oil (65 Gal) (KOBELCO BRAND)
Hydraulic Long life hydraulic oil
ISO VG32 *3 KW5032S (20 L)
system P/No. KAP2421R157D7
[Total volume] (KOBELCO BRAND)
20.5 Liters JAS0DH-1
(5.4 Gal) SAE 10W-30
Engine oil [H level]
P/No. KAPYN01T01053D1
Engine oil pan JASO 18.0 Liters (20 L)
(4.8 Gal)
DH-1 [L level] SAE
15 Liters SAE 15W-40
15W-40 SAE 15W-40
(4.0 Gal)
Swing motor 3.0 Liter (KOBELCO BRAND)
reduction unit (0.8 Gal) A.P.I clssification for
Gear oil EXTREME GEAR OIL SAE #90
"service GL-4"
Travel motor 5.3 Liter X 2
reduction unit (1.4 Gal X 2) P/No. KAPG90020
Swing motor reduction
1.0 kg EP GREASE
unit (Housing)
Attachment pins 16 places EP GREASE
(KOBELCO BRAND)
Slewing ring gear 1 place EP GREASE
EP grease Extreme pressure
Track tension multipurpose
2 places EP GREASE
Adjustment grease No.2*2
Operating lever
As required EP GREASE
(Pilot valve)
8.6 kg
Swing gear
(19 lbs)
ASTM D-975 No.2
ASTM D-975
370 Liters Grade 2-D
Fuel tank Diesel fuel ASTM D-975 No.2
(98 Gal)
ASTM D-975
ASTM D-975 No.1
Grade 1-D
(KOBELCO BRAND)
If commercial coolant
Engine 6.5 L
is used, the mixing
Radiator Total rate should conform
coolant 50% Mixture
(Reserve tank) volume with the specified.*1
(Antifreeze) 22 L P/No. KAPLLC95-20
(20 L)
6-11
6. CHECK-UP & SERVICE
Climete Zone
Type of Capacities
Components -22 -4 14 32 50 68 104 F Specified Lubricant
86
Lubricant (When changed) -30 -20 -10 0 10 20 30
40 C
(KOBELCO BRAND)
ISO VG68
186 Liters KW68
(49 Gal) (KOBELCO BRAND)
Hydraulic 353 Liters ISO VG46 KW46 (20 L)
Hydraulic oil tank
oil (93 Gal) P/No. KAP3532R157D5
Hydraulic (KOBELCO BRAND)
system ISO VG32 KW32 (20 L)
P/No. KAP2421Z201D1
[Total volume]
(KOBELCO BRAND)
28.5 Liters
(7.5 Gal) JAS0DH-1
SAE 10W-30
Engine oil [H level] P/No. KAPYN01T01053D1
Engine oil pan JASO 26.0 Liters (20 L)
(6.9 Gal)
DH-1 [L level]
20 Liters SAE 15W-40 SAE 15W-40
(5.3 Gal)
Swing motor 7.4 Liter (KOBELCO BRAND)
reduction unit (2.0 Gal) A.P.I clssification for
Gear oil EXTREME GEAR OIL SAE #90
Travel motor 9.5 Liter X 2 "service GL-4"
reduction unit (2.5 Gal X 2) P/No. KAPG90020
Swing motor reduction
1.7 kg EP GREASE
unit (Housing)
Attachment pins 16 places EP GREASE
(KOBELCO BRAND)
Slewing ring gear 1 place EP GREASE
EP grease Extreme pressure
Track tension multipurpose
2 places EP GREASE
Adjustment grease No.2*2
Operating lever
As required EP GREASE
(Pilot valve)
28.7 kg
Swing gear
(63.2 lb)
ASTM D-975 No.2
ASTM D-975
580 Liters Grade 2-D
Fuel tank Diesel fuel ASTM D-975 No.2
(153 Gal)
ASTM D-975
ASTM D-975 No.1
Grade 1-D
(KOBELCO BRAND)
13.5 L If commercial coolant
Engine is used, the mixing
Radiator Total
coolant 50% Mixture rate should conform
(Reserve tank) volume
with the specified.*1
(Antifreeze) 30 L P/No. KAPLLC95-20
(20 L)
• When the oil leak and damage are found in the lower roller, upper roller and front idler, contact our dealer/distrib-
utor for repair.
• Use ASTM D-975 No.2 oil for fuel without fail.
This engine is equipped with electric control high pressure fuel injection system to obtain the features like excel-
lent fuel saving and emission in good condition. This system requires the parts in high precision and high lubri-
cating ability. Therefore if low viscosity fuel in low lubricating ability is used, the durability may be notably lowered.
6-12
6. CHECK-UP & SERVICE
Climete Zone
Type of Capacities
Components -22 -4 14 32 50 68 86 104 F Specified Lubricant
Lubricant (When changed) -30 -20 -10 0 10 20 30 40 C
186 Liters (KOBELCO BRAND)
ISO VG46 Long life hydraulic oil
(49 Gal) KW5046 (20 L)
Hydraulic 353 Liters P/No. KAP2421R157D9
Hydraulic oil tank
oil (93 Gal) (KOBELCO BRAND)
Hydraulic Long life hydraulic oil
ISO VG32 *3 KW5032S (20 L)
system P/No. KAP2421R157D7
[Total volume] (KOBELCO BRAND)
28.5 Liters JAS0DH-1
(7.5 Gal) SAE 10W-30
Engine oil [H level]
P/No. KAPYN01T01053D1
Engine oil pan JASO 26.0 Liters (20 L)
(6.9 Gal)
DH-1 [L level]
20 Liters SAE 15W-40 SAE 15W-40
(5.3 Gal)
Swing motor 7.4 Liter (KOBELCO BRAND)
reduction unit (2.0 Gal) A.P.I clssification for
Gear oil EXTREME GEAR OIL SAE #90
"service GL-4"
Travel motor 9.5 Liter X 2
reduction unit (2.5 Gal X 2) P/No. KAPG90020
Swing motor reduction
1.7 kg EP GREASE
unit (Housing)
Attachment pins 16 places EP GREASE
(KOBELCO BRAND)
Slewing ring gear 1 place EP GREASE
EP grease Extreme pressure
Track tension multipurpose
2 places EP GREASE
Adjustment grease No.2*2
Operating lever
As required EP GREASE
(Pilot valve)
28.7 kg
Swing gear
(63.2 lb)
ASTM D-975 No.2
ASTM D-975
580 Liters Grade 2-D
Fuel tank Diesel fuel ASTM D-975 No.2
(153 Gal)
ASTM D-975
ASTM D-975 No.1
Grade 1-D
(KOBELCO BRAND)
If commercial coolant
Engine 13.5 L
is used, the mixing
Radiator Total rate should conform
coolant 50% Mixture
(Reserve tank) volume with the specified.*1
(Antifreeze) 30 L P/No. KAPLLC95-20
(20 L)
6-13
6. CHECK-UP & SERVICE
Pilot line filter YN50V00020F1 Line filter 1 Every 2000 hours (Cleaning)
2412N289D11 Side cutter 1
2412N289D21 Side cutter 1
ZS13C24070 Bolt 8
Bucket (STD) When required
ZN13C24019 Nut 8
B12N0006E1 Tooth 5
B12N0006E2 Rubber lock pin 5
6-14
6. CHECK-UP & SERVICE
Pilot line filter YN50V00020F1 Line filter 1 Every 2000 hours (Cleaning)
2412N289D11 Side cutter 1
2412N289D21 Side cutter 1
ZS13C24070 Bolt 8
Bucket (STD) When required
ZN13C24019 Nut 8
B12N0006E1 Tooth 5
B12N0006E2 Rubber lock pin 5
6-15
6. CHECK-UP & SERVICE
Pilot line filter YN50V00020F1 Line filter 1 Every 2000 hours (Cleaning)
2412J351D1 Side cutter 1
2412J351D2 Side cutter 1
ZS13C24065 Bolt 10
Bucket (STD) When required
ZN13C24019 Nut 10
LC69B00001S1 Tooth 5
LC69B00001S2 Rubber lock pin 5
6-16
6. CHECK-UP & SERVICE
Pilot line filter YN50V00020F1 Line filter 1 Every 2000 hours (Cleaning)
2412J351D1 Side cutter 1
2412J351D2 Side cutter 1
ZS13C24065 Bolt 10
Bucket (STD) When required
ZN13C24019 Nut 10
LC69B00001S1 Tooth 5
LC69B00001S2 Rubber lock pin 5
6-17
6. CHECK-UP & SERVICE
A. Recommended Oil
Maker Mobil
Brand MOBIL EAL Envirosyn 46H
C. Flushing Procedure
(1) Drain mineral oil from the hydraulic tank completely.
(2) Drain mineral oil from the cylinder completely.
(3) Fill hydraulic oil tank with new BIO oil.
(4) After starting engine, move every cylinder 10 strokes respectively.
The abrupt operation may cause burning of seal because of trapped air in the cylinder.
Try to operate first 4 strokes slowly at engine low idling to charge hydraulic oil in the entire cylinder.
(5) Idle travel motor right and left for about 3 minutes.
(6) Repeat swing operation 10 rotations.
(7) Drain BIO oil from hydraulic tank completely.
(8) Drain BIO oil from each cylinder completely.
(9) Fill hydraulic tank with new BIO oil.
Similarly, repeat the procedure 4. to 9. two times.
(10)For hydraulic oil in final condition, analyze the hydraulic oil and be sure of amount of remaining mineral oil.
6-18
6. CHECK-UP & SERVICE
Check oil
O
level
Engine oil Engine oil
*1
Change O
(First)
*1
Change oil filter O Cartridge
(First)
Drain O
Fuel filter Cartridge
Change O
Fuel pre-filter Change O Element
Outer element
Check/ (When outer element is
O changed, inner element
clean
When warning is indicated on mul- must be replaced without
Air cleaner elements
tidisplay or every 250 HOURS. fail)
Engine
6-19
6. CHECK-UP & SERVICE
System
6-20
6. CHECK-UP & SERVICE
System
When Interval (Hours on Hourmeter) Lubricant, etc.
Maintenance to Perform
required (Replacing part)
8H 50H 120H 250H 500H 1,000H 2,000H
Check/fuel level O
Fuel system
(Breaker)
tank Suction
Clean O Strainer
strainer
*1 O
Return filter (Breaker at-
O Element
(First)
tachment)
6-21
6. CHECK-UP & SERVICE
System
Voltage check O
Inspect all wiring O
Check switches/light O
Check A/C Refrigerant O
Check A/C condenser
Air condi- O
and clean
tioner
Clean O
Filter
Change After 10 times cleaning is done
Accessories
6-22
6. CHECK-UP & SERVICE
When
System
Check oil
O
level
Engine oil Engine oil
*1
Change O
(First)
*1
Change oil filter O Cartridge
(First)
Drain O
Fuel filter Cartridge
Change O
Fuel pre-filter Change O Element
Outer element
Check/ (When outer element is
O changed, inner element
clean
When warning is indicated on must be replaced without
Air cleaner elements
multidisplay or every 250 fail)
HOURS.
Engine
6-23
6. CHECK-UP & SERVICE
When
System
6-24
6. CHECK-UP & SERVICE
System When
Interval (Hours on Hourmeter) Lubricant, etc.
Maintenance to Perform re-
(Replacing part)
quired 8H 50H 120H 250H 500H 1,000H 2,000H 5,000H
Check/fuel level O
Fuel system
tank Suction
Clean O Strainer
strainer
O
*1
Return filter (Breaker O Element
(First) attach-
ment)
6-25
6. CHECK-UP & SERVICE
When
Lower frame System
(50H)
Reversing backhoe bucket O
Bucket clearance O
Check bucket teeth and side cut-
O
ters
Check bolts/torque O
Battery electrolyte O
Battery Battery maintenance O
Electrical
Voltage check O
Inspect all wiring O
Check switches/light O
Check A/C Refriger-
O
ant
Check A/C condenser
Air condi- O
and clean
tioner
Clean O
Filter After 10 times cleaning is
Accessories
Change
done
Check wiper washer fluid level O
Check frame structure O
Check bolts/torque O
Check O
O
Seat belt
Change (3
years)
*3: All attachment has to be lubricated every 8 hours for the first 50 hours of operation.
Then the attachment should lubricated every 250 hours of operation.
Next it should lubricated every 500 hours of operation, but the lubrication around bucket has to be applied every
250 hours.
6-26
6. CHECK-UP & SERVICE
Table6-5
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition
Class
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23)
°C
— Atmospheric temp
50°C~-10°C
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — (122°F~14°F)
H mode Lo idle 1000 + 30 - 30 LOW throttle
Measure the engine
Engine speed
not required
Adjustment
speed at multi display on
B mode Hi idle 2000 + 30 - 30 Perform all mea-
the gauge cluster, or min-1
A mode Hi idle 2000 + 30 - 30 surement with the
measure with diesel
Decel 1050 + 30 - 30 air-conditioner
speed meter.
S mode Hi idle 1800 + 30 - 30 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure
P1 a1
Main relief
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-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 34.3 (4970) + 0.7 (+100) - 0.5 (-73) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 34.3 (4970) + 0.7 (+100) - 0.5 (-73) RH and LH
RV —
6-27
6. CHECK-UP & SERVICE
Standard
Inspection item Unit
value
Sprocket revolution 1st speed 30.5 ~ 27.5
min-1
(RH,LH) 2nd speed 50.4 ~ 45.6
Up 2.5 ~ 3.1
Boom
Down 2.2 ~ 2.8
Operating speed
55 ~ 75 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 160
ATT amount of drift Boom cylinder 14 mm / 10min (At no load)
Arm cylinder 11
Amount of horizontal play at the bucket tooth 30 ~ 50 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in ad-
vance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out
6-28
6. CHECK-UP & SERVICE
Table6-6
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)
not required
Adjustment
speed at multi display on
B mode Hi idle 2100 + 30 - 70 Perform all mea-
the gauge cluster, or min-1
A mode Hi idle 2100 + 30 - 70 surement with the
measure with diesel
Decel 1050 + 25 - 25 air-conditioner
speed meter.
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
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 —
6-29
6. CHECK-UP & SERVICE
Standard
Inspection item Unit
value
1st speed 34.3 ~ 31.1
Track ring 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
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 ad-
vance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out
6-30
7. DATA 1.
7-1
7. DATA 1.
7-2
7. DATA 1.
A
A'
G
C
H
D
E
K L
F
J
B
Unit : mm
Attachment 2.4 m (7’-10") Arm 2.94 m (9’-8") Arm 3.5 m (11’-6") Arm
Item + 0.93 m3 (1.22 cu•yd) Bucket + 0.80 m3 (1.05 cu•yd) Bucket + 0.70 m3 (0.92 cu•yd) Bucket
7-3
7. DATA 1.
A
A'
G
C
H
D'
D
K L
J
B
Unit : mm
Attachment 2.4 m (7’-10") Arm 2.94 m (9’-8") Arm 3.5 m (11’-6") Arm
Item + 0.93 m3 (1.22 cu•yd) Bucket + 0.80 m3 (1.05 cu•yd) Bucket + 0.70 m3 (0.92 cu•yd) Bucket
7-4
7. DATA 1.
A
A'
G
C
H
D
E
K L
F
J
B
Unit : mm
Attachment 2.25 m Arm + 2.30 m3 2.60 m Arm + 1.60 m3 3.30 m Arm + 1.40 m3 4.15 m Arm + 1.20 m3
Item (3.0 cu•yd) Bucket (2.09 cu•yd) Bucket (1.83 cu•yd) Bucket (1.57 cu•yd) Bucket
7-5
7. DATA 1.
A
A'
G
C
H
D'
D
K L
J
B
Unit : mm
Attachment 2.60 m Arm + 1.60 m 3 3.30 m Arm + 1.40 m 3 4.15 m Arm + 1.20 m3
Item (2.09 cu•yd) Bucket (1.83 cu•yd) Bucket (1.57 cu•yd) Bucket
A Maximum digging reach 10,750 11,400 12,110
Maximum digging reach at ground
A’ 10,550 11,210 11,930
level
* B Maximum digging depth 7,000 7,700 8,550
* C Maximum digging height 10,580 10,880 11,050
* D Maximum damping clearance 6,950 7,260 7,400
* D’ Maximum damping clearance (45°) 6,810 6,940 7,400
* E Minimum damping clearance 3,180 2,470 1,620
G Minimum swing radius 4,450 4,370 4,430
* H Max. height at min. slewing radius 8,750 8,640 8,650
* J 8 feet level digging depth 6,820 7,550 8,420
K Horizontal digging Stroke 3,150 4,240 5,550
L stroke at ground level Minimum 7,190 6,750 6,150
7-6
8. DATA (CIRCUIT DIAGRAM)
8-1
8. DATA (CIRCUIT DIAGRAM)
8-2