Training Text SK200-8

HYD.
EXCAVATOR
SERVICE TRAINING
YN11-45001~
YQ11-06001~
LC10-07001~
YC10-03501~
Technical Service Group,

Customer Support Department
Book Code No. S6OA00801ZE03

Printed in Japan 2006.08 (KE)
CONTENTS
1. OUTLINE
1.1 SK200-8.................................................................................................................... 1-3
1.2 SK330-8.................................................................................................................... 1-4
2. CONSTRUCTION & FUNCTION

2.1 NAME OF COMPONENTS ...................................................................................... 2-3
2.2 SPECIFICATIONS AND PERFORMANCE .............................................................. 2-5
2.3 OPERATOR CAB NOMENCLATURE (SK200-8, SK330-8) .................................... 2-7
2.4 SUMMARY OF MECHATRO CONTROL SYSTEM ................................................. 2-10
2.5 HYDRAULIC SYSTEM ............................................................................................. 2-29
2.6 HYDRAULIC COMPONENTS (SK200-8)................................................................. 2-43
2.7 HYDRAULIC COMPONENTS (SK330-8)................................................................. 2-67
2.8 ELECTRICAL EQUIPMENT AND HARNESS LAYOUT (SK200-8) ......................... 2-85
2.9 ELECTRICAL EQUIPMENT AND HARNESS LAYOUT (SK330-8) ......................... 2-101
2.10 AIR-CONDITIONER SYSTEM ................................................................................. 2-111
3. MECHATRO CONTROL SYSTEM

3.1 ADJUSTMENT OF MECHATRO CONTROLLER .................................................... 3-3
3.2 SUMMARY OF MULTI DISPLAY ............................................................................. 3-9
3.3 SELF DIAGNOSIS DISPLAY ................................................................................... 3-14
3.4 SERVICE DIAGNOSIS DISPLAY FUNCTION ......................................................... 3-16
3.5 TROUBLE HISTORY DIAGNOSIS........................................................................... 3-31
3.6 TROUBLE DIAGNOSIS MODE................................................................................ 3-32
3.7 SET PROCEDURE OF MAINTENANCE SCHEDULE............................................. 3-33
3.8 ADJUSTING PROCEDURE OF DISPLAY ............................................................... 3-35
3.9 MECHATRO CONTROL EQUIPMENT .................................................................... 3-39
3.10 EMERGENCY MODE............................................................................................... 3-50
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
4.9 ENGINE MOUNTING (SK330-8).............................................................................. 4-35
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
(RELEVANT UPPER FRAME) (SK330-8)................................................................ 5-58
5.12 WEIGHT OF COMPONENTS (SK330-8)................................................................. 5-66
6. CHECK-UP & SERVICE

6.1 CHECK-UP & MAINTENANCE ................................................................................ 6-3
6.2 LUBRICANT, FUEL & COOLANT SPECIFICATIONS (SK200-8)............................ 6-10
6.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS (SK330-8)............................ 6-12
6.4 MAINTENANCE PARTS (SK200-8)......................................................................... 6-14
6.5 MAINTENANCE PARTS (SK330-8)......................................................................... 6-16
6.6 USE OF BIO-DEGRADABLE OILS.......................................................................... 6-18
6.7 INSPECTION & MAINTENANCE CHART (For Asia)............................................... 6-19
6.8 INSPECTION & MAINTENANCE CHART (For Oceania) ........................................ 6-23
6.9 PERFORMANCE INSPECTION STANDARD TABLE (SK200-8) ............................ 6-27
6.10 PERFORMANCE INSPECTION STANDARD TABLE (SK330-8) ............................ 6-29
7. DATA 1.
7.1 WORKING RANGES (SK200-8) .............................................................................. 7-3
7.2 WORKING RANGES (SK330-8) .............................................................................. 7-5
8. DATA (CIRCUIT DIAGRAM)

8.1 HYDRAULIC CIRCUIT DIAGRAM (STANDARD) (SK200-8)................................... 8-3
8.2 HYDRAULIC CIRCUIT DIAGRAM (STANDARD) (SK330-8)................................... 8-4
8.3 HYDRAULIC CIRCUIT N&B SPECIFICATION (OPTION) (SK200-8, SK330-8) ..... 8-5
2
CONTENTS
8.4 ELECTRIC CIRCUIT DIAGRAM (SK200-8, SK330-8) ............................................. 8-6

8.5 ELECTRICAL EQUIPMENT LIST ............................................................................ 8-10
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
New style control valve Low fuel consumption

Large size hydraulic tubes at attachment
Hydraulic Hydraulic return line joints change.
tubes and Hydraulic tube joint to control valve change. ORS 4 volt flange
pipings New Nibbler and Breaker selector valve Manual shifting type Remote switching from cab Specification UP
New location of solenoid valve block. Air cleaner room Central section LHS
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
Counter New shape and design

weight
New design of engine bonnet and toolbox at right side front
Large storage space of toolbox at right side front
Guards Larger Fire wall covering area Safety requirement
Improve visibility of front guard for dismantle spec. Grid plates in parallel Grid plates in radial arrangement Widening front view
Appearance of cab has no change

New one-touch-lock for front top window Manual snapped lock Auto-lock and manual one-touch Easier lock and release work
Standardized Tapped blocks for optional 3-face-guard None Tapped block standards Less modification work in field
Cab
Removable floor mat Easier cleaning work
New roof window polycarbonate material Steel plate made To meet FOPS regulation as std.
New design instrument panel

Increasing swing up left console Raising angle Plus 10 degrees Easier access to cab
New design rear stand of cab (Remove Hot & cool box) Slant shape rear cover Flat shape for more room Improve conformability
New graphic design of side guard
Interior
Larger size cluster gauge Better visibility
New mounting way of arm rest Operators seat mounted Side console mounted Prevent interference to left lever
Lighter shifting force of control lever 10% reduction compare with previous model Less fatigue even long hours
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
New style control valve Low fuel consumption

Large size hydraulic tubes at attachment
Hydraulic Hydraulic return line joints change.
tubes and Hydraulic tube joint to control valve change. ORS 4 volt flange
pipings New Nibbler and Breaker selector valve Manual shifting type Remote switching from cab Specification UP
New location of solenoid valve block. Air cleaner room Central section LHS
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
Counter New shape and design

weight
New design of engine bonnet and toolbox at right side front
Large storage space of toolbox at right side front
Right rear side guard arrangement changed 2 piece guard Large 1 piece guard
Guards Right front side guard arrangement changed 1 guard next to fuel tank none in the place
Larger Fire wall covering area Safety requirement
Improve visibility of front guard for dismantle spec. Grid plates in parallel Grid plates in radial arrangement Widening front view
Appearance of cab has no change

New one-touch-lock for front top window Manual snapped lock Auto-lock and manual one-touch Easier lock and release work
Standardized Tapped blocks for optional 3-face-guard None Tapped block standards Less modification work in field
Removable floor mat Easier cleaning work
Cab New roof window polycarbonate material Steel plate made To meet FOPS regulation as std.
It corresponds to the pains down
method head guard.
New design instrument panel

Increasing swing up left console Raising angle Plus 10 degrees Easier access to cab
New design rear stand of cab (Remove Hot & cool box) Slant shape rear cover Flat shape for more room Improve conformability
New graphic design of side guard
Larger size cluster gauge Better visibility
Interior New mounting way of arm rest Operators seat mounted Side console mounted Prevent interference to left lever
control
Lighter shifting force of control lever 10% reduction compare with previous model Less fatigue even long hours
operation
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
2-1
2-2
2.1 NAME OF COMPONENTS

2.1.1 SK200-8
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
SHOE AND TRACK LINK
FRONT IDLER
ENGINE
IDLER ADJUST
COUNTER WEIGHT
UPPER ROLLER
AIR CLEANER TRACK GUIDE

RADIATOR AND OIL COOLER
ROTALY MULTI CONTROL VALVE
(OPTION)
LOWER ROLLER BATTERY

TRAVEL MOTOR
2-3
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
UPPER ROLLER ENGINE
AIR CLEANER
COUNTER WEIGHT
LOWER ROLLER
RADIATOR AND OIL COOLER
BATTERY
TRAVEL MOTOR
2-4
2.2 SPECIFICATIONS AND PERFORMANCE

2.2.1 SK200-8
2.2.1.1 SPEED AND CLIMBING CAPABILITY
Area & Model

SK200 - 8 SK210LC - 8
Item
Swing speed min-1 {rpm} 12.5 {12.5}
Travel speed (1-speed/2-
km/h (mile/h) 3.6 / 6.0 (2.2 / 3.7)
speed)
Gradeability % (degree) 70 (35)
2.2.1.2 ENGINE
Engine model HINO J05E-TA

Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine
Type
with inter cooler turbo-charger
4 -ø112 mm × 130 mm
Number of cylinders—Bore×Stroke
(4.41 in × 5.12 in)
Total displacement 5.123 L (312.61 cu•in)
Rated output / Engine speed 114 kW (155 PS) / 2,000 min-1
Maximum torque / Engine speed 572 N•m (422 lbf•ft)/ 1,600 min-1
Starter 24 V / 5.0kW
Alternator 24 V / 1.2kW
2.2.1.3 HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

Hydraulic motor (swing) Axial piston motor × 1
Variable displacement axial piston motor × 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve × 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type
2.2.1.4 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
2.2.2 SK330-8
2.2.2.1 SPEED AND CLIMBING CAPABILITY
Area & Model

SK330-8 SK350LC-8
Item
Swing speed min-1 {rpm} 10.0 {10.0}
Travel speed (1-speed/2-
km/h (mile/h) 3.3 / 5.6 (2.05 / 3.5)
speed)
Gradeability % (degree) 70 (35)
2.2.2.2 ENGINE
Engine model HINO J08E-TM

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

Hydraulic motor (swing) Axial piston motor × 1
Variable displacement axial piston motor × 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve × 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type
2.2.2.4 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
2.3 OPERATOR CAB NOMENCLATURE (SK200-8, SK330-8)

2.3.1 LOCATION OF CONTROL DEVICES
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
No. NAME No. NAME

1 Left Hand operator Control Lever (Horn Switch) 13 Throttle Potentiometer
2 Safety Lock Lever (For Hydraulics) 14 Working Light Switch (Boom, Deck)
3 Left Travel Pedal 15 Travel Alarm Select Switch (Option)
4 Left Travel Lever 16 Tuner (Oceania Spec.)
5 Right Travel Lever 17 Air Conditioner Control Panel
6 Right Travel Pedal 18 Cap (For Opt. Switch)
7 Hour Meter 19 Cigarette Lighter
8 Gauge Cluster 20 Potentiometer For Emergency Mode
9 Cup Holder 21 Swing Parking Brake Release Switch
10 Ash Tray 22 Fuse & Relay Box
11 Right Hand Operator Control Lever (Power Boost Switch) 23 Operator Seat
12 Starter Key Switch 24 Life Hammer
2-7
2.3.2 GAUGE CLUSTER

The gauge cluster is made up of gauges (fuel level, en-
gine coolant temperature), various switch panels and
multi-display. 11
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
GROUP No. NAME

1 Engine Coolant Temperature Meter
A
2 Fuel Level Meter
3 Screen Change Switch
4 Buzzer Stop Switch
5 KPSS Mode Select Switch
6 Washer Switch
B
7 Wiper Switch
8 Travel Speed Select Switch
9 Auto Accel Switch
10 Select Switch
C 11 L.C.D Display
2-8
2.3.3 LOCATION OF SWITCHES AND METERS
13
11
12
10
9 1
14
2
3
4 Detail A
No. NAME No. NAME

1 Starter Key Switch 8 Cigarette Lighter
2 Throttle Potentiometer 9 Horn Switch
3 Working Light Switch (Boom, Deck) 10 Power Boost Switch
4 Conflux/Single Flow Change Switch 11 Potentiometer for Emergency Mode
5 Tuner (Australia Spec.) 12 Swing Parking Brake Release Switch
6 Air Conditioner Control Panel 13 Hour Meter
7 Cap (For Opt. Switch) 14 Travel Alarm Switch (Option)
2-9
2.4 SUMMARY OF MECHATRO CONTROL SYSTEM

2.4.1 MECHATRO CONTROL SYSTEM IN GENERAL
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2-10
MAIN CONTROL VALVE

L1
SE-29
ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

(8) (2) (4) (3) (6) (8) SV-13
P1 UNLOAD
ATTACHMENT BOOST
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
PL1
SOL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3
L4
SWING MOTOR PARKING RELEASE
TRAVEL MOTOR 1,2 SPEED SELECT
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
SAFETY LOCK LEVER

ATTACHMENT BOOST
TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
ARM IN 2 SPEED
L5
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
2-11
2.4.2 UNLOAD VALVE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective
low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by
mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the
pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
2-12
2.4.3 POSITIVE CONTROL & P-Q CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
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
(1) Positive control

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

SECONDARY PRESSURE
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
PILOT PRESSURE PUMP DELIVERY PRESSURE
2-14
2.4.4 BOOM UP CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
BOOM UP PILOT SECONDARY PRESSURE SECONDARY PRESSURE
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
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
2.4.5 ARM IN RECIRCULATION & CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
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
P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE
2-16
(1) Recirculation and conflux (Low loading)

1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool
and low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller process-
es pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and
P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor
and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal ac-
cording to the combined operation and outputs command, which is different from the arm-in independent op-
eration, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for arm-
in 2 spool.
3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it
switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls re-
circulation rate and conflux rate.)
The other proportional valves output proportional secondary pressure according to command from mechatro
controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload
valve.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload
spools and arm 2 spool are switched according to the command output by mechatro controller, and conse-
quently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil during arm
operation.
(2) Recirculation cut
The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is
raised during arm operation the mechatro controller processes pilot signal processing according to the pressure
detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for
arm-in 2 spool.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command
output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recircu-
lation passage is blocked.
2-17
2.4.6 ARM-IN ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

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

pi
VALVE FOR ARM VALVE FOR ARM 2 SPOOL
2 SPOOL COMMAND PSV-A pi
ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low
pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot
signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2
unload proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve
for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by mechatro 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
2.4.7 ARM-OUT CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE

pi
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
SECONDARY PRESSURE
(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is
input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
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
2.4.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVELSTRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
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.
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
2.4.9 BUCKET DIGGING ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
ACCEL VALVE PSV-B
POTENTIO
pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

PILOT SIGNAL
pi PROCESS
BUCKET ATT BOOST
ANTI-CAVITATION SOLENOID VALVE
PROCESS SV-2
ENGINE SPEED (COMMAND VALUE)
MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
2-21
(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.
P2 unload proportional valves and travel straight proportional valve.
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
2.4.10 SWING PRIORITY CONTROL
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
VALVE
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure
sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot sec-
ondary pressure switches swing spool and is input to low pressure sensor.
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.
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
2.4.11 TRAVEL STRAIGHT CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTIONAL
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

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
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
2-24
(1) Judgment travel straight

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

In travel operation (P1)
In travel operation (P2)
2-25
2.4.12 PRESSURE RELEASE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
SE-23 SE-22
ENGINE
PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi
PILOT SIGNAL
P1 UNLOAD
VALVE PSV-D
MECHATRO
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
2.4.13 N&B SWITCH CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SE-29
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
B MODE SWITCH MECHATRO

CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
(1) Nibbler circuit

1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main
control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display
is output to gauge cluster.
(2) Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display
is output to gauge cluster.
2-27
2.4.14 OPTION CONFLUX CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
PILOT VALVE
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
P1 UNLOAD
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE
OPTION PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
(1) Select the Conflux with the aid of Conflux/Single switch.

(2) On starting option operation, option operating pilot pressure switches option spool and is input to low pressure
sensor.
P2 unload pressure proportional valves and travel straight proportional valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the command output
travel straight valve of the control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1
pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
2-28
2.5 HYDRAULIC SYSTEM

2.5.1 SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety,
mass volume handling and low fuel consumption.
Perfor- Device
mance Function Features
Travel straight Travel straight at combined operation

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

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

Easy operability and safety
Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever
Attachment
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
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
Return circuit To prevent hydraulic oil from contamination

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

Pump
Positive flow rate control Flow control by positive pilot control pressure
Hydraulics backup control Backup control by hydraulic when the electric flow controlled
variable displacement pump fails.
Boom up conflux circuit Speed up of boom up operation
Attachment
Arm conflux circuit Speed up of arm operation

Bucket conflux circuit For speed-up of bucket operation (digging & dump)
Optimum operation by work mode select (H,S,A,B) Efficient operation in all work modes
consumption
Auto accel Reduce fuel consumption and noise by lowering engine

computer
Low fuel
Micro
speed when control lever is in neutral position.
2-29
This page is blank for editing convenience.
2-30
2.6 HYDRAULIC COMPONENTS (SK200-8)

2.6.1 HYDRAULIC PUMP • REGULATOR
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
MIN. FLOW MIN. FLOW RATE

2 2 ADJUSTING SCREW
RATE
ADJUSTING a3
SCREW
PH1 PH2 PH2 PH1
a4
a1 3 a1
a2
a2 B3
B3
B1
Dr B1
A3
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
Fig. 2-6 Hydraulic pump • regulator
2-43
(2) Hydraulic circuit diagram
(FRONT) PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (REAR)

(KDRDE5K) (KR3G-YTOK-HV) (KR3G-YTOK-HV) (KDRDE5K)
Solenoid proportional Solenoid proportional

reducing valve (PSV-1) reducing valve (PSV-2)
Regulator Regulator
a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3
PTO gear case
Fig. 2-7 Hydraulic circuit diagram of pump

(3) Specifications
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
Others With solenoid proportional reducing valve (KDRDE5K-31/30C50)

Weight kg (lb) 141 (310) 143 (315)
2-44
(4) PTO gear case (For Oceania) (SK200-8, SK330-8)
125
711 468
118 825 710 728
117
126
326 262
115
128
826
414
435
886
885
No. Parts Q’ty No. Parts Q’ty

115 Idle shaft 1 435 Flange socket ; M10×20 4
117 2nd gear 1 468 VP plug ; PF3/4 1
118 3rd gear 1 710 O-ring ; 1B G80 1
125 Ball bearing 2 711 O-ring ; 1B G85 1
126 Roller bearing 1 728 O-ring ; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Sprig pin 1
414 Capscrew ; M10×20 4 886 Pin 2
2-45
2.6.2 PILOT VALVE (ATT) (SK200-8, SK330-8)
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)
The adjust nut

(opposing flats : 22) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by PF1/4
means of spanner or the like. T=29.4 (21.7)
Then tighten the mating lock
nut to 41 + 3 N.m (302.2 lbf.ft). T=Tightening torque
: N.m (lbf.ft)
VIEW A

Model PV48K2004
Operating torque Refer to the curve below
Max. primary pressure 6.9 MPa (1000 psi)
Primary pressure 5.0 MPa (725 psi)
Rated flow 20 L/min (5.3gal/min)
Weight Approx. 1.9 kg (4.2 lbs)
A
PORT 1, 3 PORT 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)

Secondary pressure [MPa (psi)]
Secondary pressure [MPa (psi)]

Operation torque [N.m (lbf.ft)]
Operation torque [N.m (lbf.ft)]

(464)3.2 (464)3.2
(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)
SINGLE OPERATING TORQUE SINGLE OPERATING TORQUE
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
(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

0.94(0.69) 0.94(0.69)
(87)0.6 (87)0.6
1.17 (0.86) 1.17 (0.86)
0.98 (0.72) 0.98 (0.72)
0 0 0 0
0 1.1 2 4 6 7 0 1.12 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDLAULIC SYMBOL
2-46
2.6.3 PILOT VALVE (TRAVEL) (SK200-8, SK330-8)
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
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
(3) Performance characteristics

Secondary pressure
[MPa (psi)] Secondary pressure
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
2-47
2.6.4 CONTROL VALVE (SK200-8)
2.6.4.1 SPECIFICATIONS
2.6.4.1.1 OUTSIDE VIEW

PTb
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
PBr PAr PB1

1
Ab right conflux CCb Bs
PAb CP1 (HEAD) As
PBs Swing
Bb Boom PBb PBs PAs
(ROD) PBb Aa
LCb CRb PC Pss LCs
PAc Bucket PCc PBa1 Pss
Ac Bc Arm 1 PLc2 CRa (HEAD) PAa1
PBc 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
Fig. 2-8 Outside view
2-48
2.6.4.1.2 PORTS
Port size Tightening torque Ports Description

PF3/4 150~180 N•m (111~133 lbf•ft) MU
(T3) Pluged
PF1/2 98~120 N•m (72~89 lbf•ft) (P3) Pluged
(P4) Pluged
PF3/8 69~78 N•m (51~58 lbf•ft) PAa1 Arm 1 (in) pilot port
PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PAL Travel left (forward) pilot port
PBL Travel left (reverse) pilot port
PAr Travel right (forward) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port
PF1/4 34~39 N•m (25~29 lbf•ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PBp1 Bypass cut valve (P1 side) pilot port
PL Attachment boost port
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
PCc Bucket (digging) stroke limiter pilot port
M12 83~110N•m (61~81 lbf•ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
T1 Tank port 1
T2 Tank port 2
M10 49~65 N•m (36~48 lbf•ft) Ar Right travel motor port (forward)
Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
2-49

Ao Optional pilot port
Bo Optional pilot port
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)]
37.8 (5480) [at 30L/min (8gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
2-50
2.6.4.1.4 HYDRAULIC CIRCUIT DIAGRAM

%& $*

%& &'

+

! '(
%& $*

! "# $

!

)&

!

Fig. 2-9 Hydraulic circuit diagram
2-51
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.

! " !" #

" $
"%
Fig. 2-10 In neutral position
2-52
2-53
2.6.5 SWING MOTOR UNIT (SK200-8)
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)
PG Parking brake release port PF1/4 36 (27)

L Gear oil level gauge PT1/2 65 (48) IP
IP Gear oil filling port PT3/4 98 (72) PG
RELIEF VALVE
A (A PORT SIDE)
DB
PA
PB PA ANTI-REACTION VALVE BLOCK

M DB
A,(B)
PG IP
PG FILLING PORT
PT3/4
DB
PA PB
Grease
fitting
A B
Hydraulic diagram
2-54
(2) Specifications
Swing motor unit part No. YN15V00036F1

Type M5X130CHB-10A-41C/295
Hydraulic motor
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
Reduction ratio 15.38

Lubicate oil Gear oil SAE90 (API class GL-4 grade)
Lubicate oil volume L (gal) 3 (0.8)
Grease Extreme pressure lithum base #2 grease
Grease volume kg (lbs) Approx. 1 (2.2)
Total weight kg (lbs) Approx. 197 (434)
2-55
2.6.5.2 CONSTRUCTION
(1) Swing motor
993
VALVE CASING SECTION
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
Tightening torque Tightening torque

N•m (lbf•ft) N•m (lbf•ft)
Anti-reaction valve ; M22-
177 (130) 051 Relief valve ; M33-P1.5 2 69 (51) 400 2
P1.5
051-1 O-ring ; 1B G30 2 400-1 O-ring ; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
Casing for anti-reaction
100 1 431 (318) 401 Socket bolt ; M20×45 4
valve
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 334 (246) 469 ROMH plug; M30-P1.5 2
122 Shoe 9 472 O-ring ; W1516,WG40 1
123 Set plate 1 488 O-ring ; 1B P28 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug ; PF1/4 2 706 O-ring ; W1516,WG38 1
161 O-ring ; 1B P11 2 707 O-ring ; W1516,WG41 1
162 O-ring ; 1B P12 2 712 Brake spring 18
163 O-ring ; 1B P6 2 742 Friction plate 3
29 (21) 171 Socket bolt ; M8×55 4 743 Separator plate 4
301 Casing 1 0.9 (0.66) 980 Plug ; PF1/4 1
303 Valve casing 1 1.7 (1.2) 984 Plug ; PF3/8 1
351 Plunger 2 4.4 (3.2) 985 Plug ; PF3/4 3
355 Spring 2 65 (48) 993 Plug ; PT1/2 1
390 Name plate 1 98 (72) 994 Plug ; PT3/4 1
391 Rivet 2
2-57
(2) Swing reduction unit

Be careful about installation
direction of retaining ring.
Apply Three Bond #1360 Caulk these 2 places
or equivalent. with punch.
OIL FILLING PORT PT3/4
LEVEL PORT PT1/2
Apply Loctite #515.
SURFACE OF Be careful about

LUBE OIL installation direction
of spring pin.
VIEW (II) (4 places)
Apply Loctite #515.
Be careful about
installation direction
of retaining ring. Drive this spring pin
into 1mm lower than
the surface of spider.
Apply Loctite #515.
Install the filling port Tightening torque

of this fitting toward 69.1+4.4 N.m
motor side. (51.0+3.2 lbf.ft)
Apply seal tape or
Loctite #577.
Fill up this space

with grease.

1 Pinion shaft 1 17 Needle bearing 4
2 #1 sungear 1 18 Washer 8
3 #1 pinion 3 19 Retaining ring 1
4 #2 sungear 1 20 Retaining ring 1
5 #2 pinion 4 21 Sleeve 1
6 Ring gear 1 22 Spring pin 4
7 Spider assy 1 181 (134) 23 Capscrew ; M14X135 11
8 Spider 1 24 Cap 2
9 Shaft 4 25 Tube L=112 1
10 Spherical bearing 1 26 Elbow 1
11 Spherical bearing 1 69.1 (51) 27 Plug 1
12 Oil seal 1 28 Retaining ring 3
13 Housing 1 30 Oil seal 1
15 Thrust Washer 6 31 Grease fitting 1
16 Needle bearing 3 32 Relief fitting 1
2-58
2.6.6 TRAVEL MOTOR (SK200-8)
2.6.6.1.1 GENERAL VIEW

[A] PF 1
O-ring port
[D] PF 1/2
O-ring port
[P] PF 1/4 [B] PF 1

O-ring port O-ring port
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)
Parking Breke torque N.m (lbf.ft) 470 (347)

brake Release pressure MPa (psi) 1.49 (216)
2-59
SECTION B-B
C C
SECTION C-C
SECTION A-A
2-60
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 Hub 1 Piston assy 1 Rear flange assy
3 Carrier [1] 1 161 •Piston 1 301 •Rear flange 1
4 Sun gear[1] 1 163 •Seal 1
5 Planetary gear[1] 3 162 Steel ball 1 •Spool assy 1
6 Carrier pin [1] 3 102 Shaft 1 323 ••Spool 1
7 Carrier [2] 1 326 ••Plug 2
8 Sun gear[2] 1 Swash plate kit 1 327 ••Valve 2
9 Planetary gear[2] 3 103 •Swash plate 1 328 ••Spring 2
10 Carier pin[2] 3 167 •Pivot 2 331 ••O-ring 2
11 Thrust washer[1] 6 107 Retainer plate 1 324 •Plug 2
12 Thrust washer[2] 6 108 Thrust ball 1 325 •Spring retainer 2
13 Thrust plate 1 109 Timing plate 1 329 •O-ring 2
14 Cover 1 112 Piston 1 330 •Spring 2
15 Cupling 1 113 Spring 8 363 •Spool 1
16 Parallel pin [1] 3 114 Spring 9 364 •Connector 1
17 Parallel pin [2] 3 115 Friction plate 3 365 •Pin 1
22 Lock washer 2 116 Separator plate 4 366 •Spring 1
23 Shim 1 119 Shim 1~2 367 •Spring retainer 1
24 Angular bearing 2 132 Oil seal 1 368 •G (PF) 1/4 plug 2
Needle-roller bearing
27 3 133 C-ring for hose 1 369 •O-ring 2
with cage
Needle-roller bearing
28 3 135 D-ring 1 370 •G (PF) 3/8 plug 1
with cage
29 Floating seal 1 139 D-ring 1 371 •O-ring 2
30 Plug 3 149 Tapered-roller bearing 1 372 •Orifice 2
31 O-ring 3 150 Tapered-roller bearing 1 373 •Orifice spring 2
35 Socket bolt 18 374 •G (PF) 1/8 plug 5
36 C-ring for hole 1 Relief valve assy 375 •O-ring 6
201 •Valve seat 2 376 •M6 orifice 3
101 Spindle 1 202 •Valve 1 377 •Check valve 3
137 Socket plug 1 203 •Sleeve 1 378 •Check valve spring 3
138 Expander 1 204 •Plug 1 379 •O-ring 1
205 •Spring retainer 1 380 •O-ring 1
Piston kit 1 206 •Piston 1 341 •Parallel pin 1
•Piston kit 9 207 •Spring 1 343 •Socket bolt 8
105 ••Piston 1 208 •Piston seal 1 345 •Socket plug 15
106 ••Shoe 1 209 •Piston seal 1
104 Cylinder block 1 210 •O-ring 1 399 Name plate 1
2-61
2.6.7 SWIVEL JOINT (SK200-8, SK330-8)
2.6.7.1 GENERAL VIEW
VIEW Y
VIEW Z
Fig. 2-11 General view of swivel joint
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
2.6.8 CYLINDER (SK200-8)
(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
Part No. and Manufacturing No.

Stamp position
Fig. 2-12 General view of cylinder

(2) Specifications
Unit : mm (ft-in)
Center distance of pins

Part No. of Cylinder bore / Dry weight
Use Stroke Full extend B / Full re- Cushion
cylinder assy Rod Dia. kg (lbs)
tract A
ø120 / ø85 1,355 3,199 / 1,844 With cushion on
Boom YN01V00151F1 166 (366)
(4.72" / 3.34") (4-5) (10-6 / 6-1) rod side R-50
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
SE. Asia YN01V00153F2ø120 / ø80 1,080 2,675 / 1,595 With cushion on

Bucket 149 (329)
Oceania YN01V00153F1 (4.72" / 3.15") (3-7) (8-9 / 5-3) rod side R-50
2-63
2.6.9 Radiator & Oil cooler (SK200-8, SK330-8)
2.6.9.1 General view
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
2.6.10 MULTI CONTROL VALVE (Only for Oceania) (SK200-8, SK330-8)
2.6.10.1 PREPARATION FOR REMOVAL

(1) Bleed pressure air in hydraulic oil tank.
(2) Remove under cover (3).
(3) Open the left panel assy (23) located at rear of cab.
Fig. 2-13 Removing multi control valve
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
7 3/8 Blue Arm in P7 7

8 3/8 Green Arm out P8 8
P 1/4 Black Pilot primary - -
T 3/8 Black Drain - - B3
B9
(3) Tightening torque Fig. 2-15 Removing hoses between P/V and multi C/
V

2-65
2-66
2.7 HYDRAULIC COMPONENTS (SK330-8)

2.7.1 HYDRAULIC PUMP • REGULATOR (SK330-8)
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
MIN. FLOW MIN. FLOW RATE

2 2 ADJUSTING SCREW
RATE
ADJUSTING a3
SCREW
PH1 PH2 PH2 PH1
a4
a1 3 a1
a2
a2 B3
B3
B1
Dr B1
A3
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
Fig. 2-16 Hydraulic pump • regulator
2-67
(2) Hydraulic circuit diagram
(FRONT) PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (REAR)

(KDRDE5K) (KR3G-YTOK-HV) (KR3G-YTOK-HV) (KDRDE5K)
Solenoid proportional Solenoid proportional

reducing valve (PSV-1) reducing valve (PSV-2)
Regulator Regulator
a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3
PTO gear case
Fig. 2-17 Hydraulic circuit diagram of pump

(3) Specifications
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
Others With solenoid proportional reducing valve (KDRDE5K-31/30C50)

Weight kg (lb) 141 (310) 143 (315)
2-68
2.7.2 CONTROL VALVE (SK330-8)
2.7.2.1.1 OUTSIDE VIEW

PTb
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
Fig. 2-18 Outside view
2-69
2.7.2.1.2 PORTS

PF3/4 150~180 N•m MU
(111~133 lbf•ft) (T3) Pluged
PF1/2 98~120 N•m (P3) Pluged
(72~89 lbf•ft) (P4) Pluged
PF3/8 69~78 N•m PAa1 Arm 1 (in) pilot port
(51~58 lbf•ft) PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PAL Travel left (forward) pilot port
PBL Travel left (reverse) pilot port
PAr Travel right (forward) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port
PF1/4 34~39 N•m Pss Swing pilot high pressure select port
(25~29 lbf•ft) PLc2 Lock valve select pilot port
PL Attachment boost port
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
PCc Bucket (digging) stroke limiter pilot port
M12 83~110N•m P1 Pump port (P1 side)
(61~81 lbf•ft) P2 Pump port (P2 side)
T1 Tank port 1
T2 Tank port 2
M10 49~65 N•m Ar Right travel motor port (forward)
(36~48 lbf•ft) Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
2-70

Ao Optional pilot port
Bo Optional pilot port
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)]
39.7 (5757) [at 30 L/min (at 8 gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
37.8 (5481) [at 30 L/min (at 8 gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
2-71
2.7.2.1.4 HYDRAULIC CIRCUIT DIAGRAM

P1 T1 T2 P2
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
Boom PAb PAs Swing

As
Bs
(RO D) Bb
PBa1
CRb LCa
(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
Arm 2 PAa2 PAo Option
Ao
Bo
PBo
PBa2
MU
PBp1 PB p2
(P3) (P4)
Fig. 2-19 Hydraulic circuit diagram
2-72
2-73
2.7.3 SWING MOTOR UNIT (SK330-8)
(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) Specifications
Swing motor unit part No. LC15V00025F1

Type M5X180CHB-10A-60B/295
Displacement cm (in )
3 3 180.1 (11.0)
Working pressure MPa (psi) 32.4 (4700)
Max. pressure MPa (psi) 39.2 (5680)
Hydraulic motor
Working flow L/min (gal/min) 294 (77.7)

Braking torque N•m (lbf•ft) 860~1121 (634~827)
Brake release pres-
MPa (psi) 2.4~5.0 (348~725)
sure
Relief set pressure MPa (psi) 29.0 (4205)
Weight kg (lbs) 72.5 (160)
Anti- Part No. YN22V00014F4
reaction valve Type 2KAR6P72/240-712
block Weight kg (lbs) 2.5 (5.5)
Hydraulic motor assy weight kg (lbs) 75 (165)
Part No. LC32W00007F1
Speed reduction type Planetary 2-stage
Reduction unit

Lubicate oil Gear oil SAE90 (API class GL-4 grade)
Lubicate oil volume 7.4 L (1.96 gal)
Grease Extreme pressure lithum base #2 grease
Grease volume kg (lbs) Approx. 1.7 (3.7)
Total weight kg (lbs) 446 (983)
2-75
(1) Swing motor
702 712
351
ARRENGEMENT OF BRAKE SPRING

355
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
702 707 SECTION A-A
706
986
742
743
994
111
491 101
121 123 122 124 114 301 443
2-76

177 (130) 051 Relief valve ; M33-P1.5 2 69 (51) 400 Anti-reaction valve ; M22-P1.5 2
051-1 O-ring ; 1B G30 2 400-1 O-ring ; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
Casing for anti-reaction
100 1 431 (318) 401 Socket bolt ; M20×45 4
valve
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 539 (398) 469 ROMH plug; M36-P1.5 2
122 Shoe 9 472 O-ring ; W1516,WG44 1
123 Set plate 1 488 O-ring ; 1B P34 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug ; PF1/4 2 706 O-ring ; W1516,WG42 1
161 O-ring ; 1B P11 2 707 O-ring ; W1516,WG45 1
162 O-ring ; 1B P12 2 712 Brake spring 14
163 O-ring ; 1B P6 2 742 Friction plate 3
29 (21) 171 Socket bolt ; M8×55 4 743 Separator plate 4
301 Casing 1 2.7 (2.0) 984 Plug ; PF1/2 1
303 Valve casing 1 5.6 (4.1) 985 Plug ; PF1 1
351 Plunger 2 0.9 (0.66) 986 Plug ; PF1/4 1
355 Spring 2 98 (72) 994 Plug ; PT3/4 1
390 Name plate 1
391 Rivet 2
2-77
(2) Swing reduction unit
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

1 Pinion 1 21 Ring 1
2 Shaft 1 22 Thrust washer 6
3 #1 Sungear 1 23 Thrust washer 8
4 #1 Planetary pinion 3 24 Snapring 1
5 #1 Spider assy 1 25 Snapring 3
6 #2 Sungear 1 26 Spring pin 4
7 #2 Planetary pinion 4 539±54 (398±40)*1 27 Capscrew ; M20×200 12
8 Ring gear 1 28 Grease fitting 1
9 #2 Spider assy 1 29 Relief fitting 1
10 Shaft 4 69.1±4.4 (51±3)*2 30 Tube 1
11 Needle bearing 11 69.1±4.4 (51±3)*2 31 Elbow 1
12 Roller bearing 1 69.1±4.4 (51±3)*2 32 Plug 1
13 Roller bearing 1 33 Cap 2
14 Oil seal 1 279±30 (206±22)*1 34 Capscrew 2
15 Housing 1 35 Wire ø1.6×250 1
16 Oil seal 1 36 Shim ; t=0.1 1
17 Sleeve 1 37 Shim ; t=0.2 1
18 Sleeve 1 38 Shim ; t=0.3 1
19 Plate 1 39 Shim ; t=0.5 1
20 Plate 1
*1 : Apply Three Bond #1360K.
*2 : Apply seal tape or Loctite #577.
*3 : Apply Loctite #515.
2-78
2.7.4 TRAVEL MOTOR (SK330-8)
(1) Appearance
PRESSURE MEASUREMENT PORT

2-G (PF)1/4
(MB,MA)
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) Specifications

TRAVEL MOTOR UNIT
Type M4V290 / 170F-RG6.5F
Part No. —
Type —
Reduction unit Number of reduction stages 2
Lube oil capacity L (gal) 9.5 (2.5)
Lube oil capacity specification Gear oil SAE90API GL4 or GL5
Weight kg (lbs) —
Type M4V290 / 170F
cc/rev
Max. displacement 290.7 (17.7)
(cu•in/rev)
cc/rev
Min. displacement 170.1 (10.4)
(cu•in/rev)
Relief valve set pressure MPa (psi) 35.0 (5075)
Travel motor
2 peed changeover pilot pres-
MPa (psi) 5.0 (725)
sure
Parking brake torque N•m (lbf•ft) 902 or more (665)
Parking brake release pressure MPa (psi) Less than 1.54 (223)
Working 0.2 (29)
Allowable drain pressure MPa (psi)
Surge 0.98 (142)
Weight kg (lb) —
Unit weight (with oil) kg (lb) 399 (880)
2-80
2.7.4.2.1 TRAVEL MOTOR
Fig. 2-21 Travel motor
No. NAME No. NAME No. NAME

1 Casing 21 Breake piston 41 Restrictor spring (brake valve)
2 NPT 1/16 plug 22 D-ring (small dia.) 42 G1/8 plug
3 Oil seal 23 D-ring (big dia.) 43 O-ring 1B P8
4 Retaining ring IRTW68 24 Rear cover 44 Check valve
5 Expander plug MB800-040 25 NPT 1/16 plug (MEC) 45 Check valve spring
6 Shifter piston 26 Spool assy (M4V RBV) 46 M6 restrictor (0.6)
7 Piston seal 27 Spring holder (M4V RBV) 47 O-ring 1B P12.5
8 Steel ball 25 28 Spring (M4V150RBV) 48 M8 restrictor (0.8)
9 Shaft 29 M42 plug (4V RBV) 49 O-ring 1B P15
10 Bearing HR32209J 30 O-ring 1B G40 50 O-ring 215.57×2.62
11 Pivot 31 Pilot valve spool dia. ø10 (M4V290) 51 Bearing HR32207C
12 Swash plate 32 Pin (MRC03) 52 Shim
13 Cylinder block 33 Spring holder (MRC03) 53 Parallel pin M68×12
14 Cylinder spring 34 Spring (MRC03) 54 Valve plate
15 Spring holder 35 G3/8 pilot valve plug 55 Brake spring
16 Ball joint 36 O-ring 1B P14 56 HEX. socket head bolt M18×50
17 Shoe retainer 37 Connector (MRC03) 57 Overload relief valve ORV-240L
18 Piston assy 38 G1/4 plug 58 Coupling
19 Separating plate 39 O-ring 1B P11 59 Retaining ring C-type 40
20 Friction plate 40 Restrictor (brake valve) 60 G1/2 plug
61 O-ring 1B P18
2-81
2.7.4.2.2 REDUCTION UNIT
Fig. 2-22 Reduction unit
No. NAME No. NAME No. NAME

1 Housing 11 Thrust washer 2 21 Spring pin 6×36
2 Bearing 245BA35S1GS 12 Needle bearing FBNP-608660 22 Sun gear 1
3 Ring gear 13 Carrier pin 2 23 Thrust plate
HEX. socket head bolt
4 14 Spring pin 10×50 24 Cover
M18×110
HEX. socket head bolt
5 Floating seal 368 15 Sun gear 2 25
M10×30
6 Shim 16 Carrier 1 26 Plug G3/4
7 Lock washer 17 Planetary gear 1 27 O-ring 1B P24
8 Support ring 18 Thrust washer 1
9 Carrier 2 19 Needle bearing FBNP-406040
10 Planetary gear 2 20 Carrier pin 1
2-82
2.7.5 CYLINDER (SK330-8)
(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
Part No. and Manufacturing No.

Stamp position
Fig. 2-23 General view of cylinder

(2) Specifications
Unit : mm (ft-in)
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
2-84
2.10 AIR-CONDITIONER SYSTEM

2.10.1 PIPING (SK200-8)
2.10.1.1 AIR CONDITIONER
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
Air conditioner YN20M00104F1

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
1 Hose : L = 3550 1 24 Clip 3
2 Hose : L = 2950 1 25 Clip 15
3 Bracket 2 27 Air conditioner assy 1
4 V-belt 1 30 Panel 1
3.92~4.9 (2.9~3.6) 5 Clip 4 32 Compressor assy 1
6 Sems bolt : M10×25 5 33 Pulley assy 1
7 Sems bolt : M6×20 2 34 Condenser 1
8 Sems bolt : M8×20 9 35 Air dryer assy 1
9 Capscrew : M8×100 4 39 Filter 1
10 Washer 6 40 Solar radiation sensor 1
23.5 (17.3) 11 Capscrew : M8×25 2 49 Clip 1
12 Tube for heater : L = 2400 1 50 Connector 1
13 Tube for heater : L = 1500 1 51 Bracket 1
14 Tube for D hose : L = 2350 1 52 Clip 1
15 Tube for S hose : L = 2050 1 53 Sems bolt : M10×20 1
16 Bracket 1 54 Grommet 1
17 Tube for L hose : L = 1800 1 55 Grommet 1
18 hose : L = 90 1 4.4 (3.2) 56 Capscrew : M6×50 4
20 Clip 2 57 Washer 4
21 Bracket 1 58 Tube for L hose 1
46.1 (34.0) 22 Sems bolt : M10×40 2 59 Clip 1
23.5 (17.3) 23 Sems bolt : M8×25 4
UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT
UNIT CONNECTION BOLT

S TUBE (9)
27 AIR CONDITIONER ASSY D HOSE (6)

S
32 COMPRESSOR ASSY
RECEIVER CONNECTION BOLT

S HOSE (5)
L TUBE (10)
L HOSE (8) L HOSE (7) 34 CONDENSER

Note : 35 RECEIVER DRYER
Numbers in ( ) shows the number in Fig. 2-25. RECEIVER DRYER MOUNTING BRACKET
2-112
2.10.1.2 AIR DRYER ASSY
&
#
! )
"
'
"
!
%
) ,
#
, *
+ $
+
*
Fig. 2-25
Air dryer assy YN96V00024F1

1 Receiver dryer 1 6 D hose 1
2 Bracket 1 7 L hose 1
3 Capscrew 2 8 L hose 1
4 Capscrew 2 9 S tube 1
5 S hose 1 10 L tube 1
2-113
2.10.2 PIPING (SK330-8)
2.10.2.1 AIR CONDITIONER
35 6
7
INITIAL BELT TENTION

When the belt is pushed by the
force of 27N, adjust the
50
deflection of L part to be 6mm.
3
10 13 6
17 54
33 14
25 21
1 22
5 23
49 25
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
Air conditioner LC20M00033F1

1 Hose : L = 4150 1 24 Clip 3
2 Hose : L = 3050 1 25 Clip 13
3 Bracket 2 27 Air conditioner assy 1
4 V-belt 1 30 Panel 1
3.92~4.9 (2.9~3.6) 5 Clip 4 32 Compressor assy 1
46.1 (34.0) 6 Sems bolt : M10×25 7 33 Pulley assy 1
4.9 (3.6) 7 Sems bolt : M6×20 2 34 Condenser 1
10.7 (7.9) 8 Sems bolt : M8×20 5 35 Air dryer assy 1
23.5 (17.3) 9 Capscrew : M8×100 4 39 Filter 1
10 Washer 6 40 Solar radiation sensor 1
11 Tube for S hose : L = 2450 1 49 Connector 1
12 Tube for heater : L = 3300 1 23.5 (17.3) 50 Sems bolt : M8×25 4
13 Tube for L hose : L = 1800 1 51 Clip 1
14 Tube for D hose : L = 2100 1 52 Clip 2
15 Tube for L hose : L=180 1 53 Bracket 1
16 Tube for heater : L = 1800 1 23.5 (17.3) 54 Capscrew : M8×20 2
17 Bracket 1 55 Grommet 1
18 Hose : L = 130 1 56 Grommet 1
3.92~4.9 (2.9~3.6) 20 Clip 2 4.4 (3.2) 57 Capscrew : M6×50 4
21 Bracket 1 58 Washer 4
46.1 (34.0) 22 Capscrew : M10×40 3 59 Tube for L hose : L=100 1
23 Washer 3 46.1 (34.0) 60 Sems bolt : M10×20 2
UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT

UNIT CONNECTION BOLT D TUBE (11)
D D HOSE (6)
27 AIR CONDITIONER ASSY S
S TUBE (9)
32 COMPRESSOR ASSY
RECEIVER CONNECTION BOLT
S HOSE (5)
L TUBE (10)
L HOSE (8) L HOSE (7) 34 CONDENSER

Note :
Numbers in ( ) shows the number in Fig. 2-27. 35 RECEIVER DRYER RECEIVER DRYER MOUNTING BRACKET
2-115
2.10.2.2 AIR DRYER ASSY
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
Air dryer assy LC96V00019F1

1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
3 Capscrew : M8×25 2 9 S tube 1
4 Capscrew : M6×25 2 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1
2-116
3-1
3-2
3.1 ADJUSTMENT OF MECHATRO CONTROLLER

3.1.1 ENGINE CONTROL INPUT / OUTPUT
E-27:
C-8: EMERGENCY
ACCEL
ENGINE CONTROLLER
INJECTOR
E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
Fig. 3-1 INPUT / OUTPUT
3.1.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT)
3.1.2.1 PURPOSE OF THE ADJUSTMENT

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

When the following parts are replaced or repaired, carry out the adjustment without fail.
(1) Mechatro controller
(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve
3-3
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
3.1.2.4 ADJUSTING PROCEDURE
MULTI DISPLAY
BUZZER STOP SWITCH WORK MODE SELECT SWITCH
WASHER SWITCH
WIPER SWITCH
SELECTOR SWITCH
Fig. 3-2 Gauge cluster

(1) Adjustment of engine ("A" adjustment)
Procedure
1) Turn starter key switch ON keeping the work mode selector switch on the
gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If
the engine is started, the following indication is not displayed. Therefore do not
start the engine.)

2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release
it and the screen for selecting adjustment is displayed. When adjustment data
ADJUST
READY
is not entered in mechatro controller, "READY" is indicated. If the adjustment FEED
operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Press selector switch on gauge cluster to display "START ENG".
START ENG
"Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ENGINE SPEED
2000rpm
command voltage) are indicated. PUMP PRESSURE
C-1 00.0M C-2 00.0M
STEP
140
4) After starting engine, press selector switch on gauge cluster, and "MEMORY

ENG" is displayed, the engine speed is automatically increased, and the 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
(2) Adjustment of pump ("B" adjustment)

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

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

unloading proportional valve and pump proportional valve actuate, accordingly

the loading of pump is increased.

The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump "PRO-
PO-VALVE" current (command value) are indicated.
2) After detection of the engine rated speed, the adjustment of pump is automat-
FINISH PUMP
ically completed. And "FINISH PUMP" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared PUMP PRESSURE
C-1 35.0M C-2 35.0M
and the adjustment is completed. The unloading adjustment required later is PROPO-VALVE
E-1 300mA E-2 300mA
not performed, and default value is written.)
(3) Adjustment of unloading valve ("C" adjustment)

Procedure
1) The adjustment shifts from pump to unloading, and the unloading valve actu-
MEMORY UNLOAD
ates, accordingly the pump pressure is detected. And "MEMORY UNLOAD" is ENGINE SPEED
2000rpm
displayed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PROPO- PROPO-VALVE
D-1 300mA D-2 300mA
VALVE" voltage (command value) are indicated.
2) When the unloading valve operates to the specified value, the adjustment of

unloading proportional valve is automatically terminated. And "FINISH UN-

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.
Stop the engine. (The adjusted data is automatically stored.)
(4) Corrective actions taken when the adjustment can not be performed;
ERROR ENG.
1) In cases where the adjustment of engine can not be performed; And ERROR ENGINE SPEED
2000rpm
PUMP PRESSURE
ENG" is displayed. C-1 2.0M C-2 2.0M
STEP
Judging condition: The read engine speed is 50rpm lower than the last value. 400
It is conceived that the error is caused by the speed read error, pump load 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
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.
The P1 and P2 pump pressures usually increase to 33~38MPa

(4785~5510psi).
When the pressure does not increase;
a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
• Check that the pump proportional valve operates normally.
• Check that the pump regulator operates normally.
And so on.
3) In cases where unloading valve can not be performed; And "ERROR UN-
ERROR UNLOAD
LOAD" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
The pump pressure does not increase up to the pressure in the range of the D-1 300mA D-2 300mA
specified adjustment. Or the increased pressure is held as it is.
Judging condition 2:
Pressure sensor of either P1 pump or P2 pump is failed.
Normally the pump pressures of P1 and p2 pumps gradually increase to

10~25MPa (1450~3625psi).
(It may be affected by operating oil temperature.)
When the pump pressure does not increase;

a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
(5) Other precautions:
1) In the event of a failure, there is case where the adjustment may not be per-
formed normally.
First serve the machine, and perform the adjustment work.
2) In the condition where large load is constantly applied to engine, the adjust-
ment could not be performed normally.
For machines equipped with lifting magnet, turn the generator OFF.
3-7
(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
celeration command current) are indicated.
6) When the unloading proportional valve operates to the specified value, the ad-

justment of unloading proportional valve automatically completes. "FINISH

UNLOAD" is indicated.

The speed is shifted to the speed corresponding to acceleration potentiometer.

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

P2 unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.)
3-8
3.2 SUMMARY OF MULTI DISPLAY

Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
(1) Controls
EMERGECY ACCEL DIAL

SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
(2) Gauge cluster
No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)
3-9
(3) Screen selection by work mode select switch

After starting engine, "S" mode is usually set.
The work modes "S","H","B" and "A" are selected in order every time ( ) is pressed.
Select efficient work mode according to the working condition and the purpose from the following table.
The selected mode is displayed on the left lower corner on multi display.
• S mode: For standard digging work

• H mode: For heavy duty digging work
• B mode: For works with breaker
• A mode: For works with crusher (nibbler) 10:25
H
Work mode Display Contents
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25 For the work with breaker, select "B mode" without fail.
A mode
10:25 For the work with crusher (nibbler), select "A mode".
3-10
1) Pump flow rate adjustment (A mode /B mode)

No. Switches 1 2 3 4
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 3-3
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 210L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.
Main screen Attachment mode (A mode)
10:25 Flow
rate 130 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
In Breaker mode (B mode)
Flow Flow Flow

rate 130 L/m rate 100 L/m rate 100 L/m
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 130 L/m rate 130 L/m
A B
(b) (c)
1. Turn starter key switch on and display main screen (a).

2. The display on the left lower corner of screen is changed in order of "S" → "H" → "B" → "A" each time the
"MODE" switch (3) is pressed under the condition where main screen (a) is displayed.
3. Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed.
4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and
the screen (d) is displayed. In this condition, press FEED (4)/ (5) and the flow rate value increases or
decreases.
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.
3-11
(4) MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the end of recommended replacement/change interval specified for
filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
ASIA 2,000 Hr
Hydraulic oil
OCEANIA 5,000 Hr
This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.
1. Remaining time display to the engine oil change

This display shows the remaining time to the coming engine oil change. 492Hr
ENGINE OIL
H
2. Remaining time display to the coming fuel filter replacement

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

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

This display shows the remaining time to the coming hydraulic oil 1992Hr
change. HYD. OIL
H
• The display automatically changes to the main screen, if switch is not operated for 30 seconds.
• For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the 3.7 SET PROCEDURE OF MAINTENANCE SCHEDULE.
3-12
(5) Gauge cluster display

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

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
CAUTION LOW ENG OIL

PREHEAT
ATTACHMENT PRESS.
HIGH ENG
AUTO IDLE STOP WATER TEMP.
CHARGE ERROR
POWER BOOST LOW ENG WATER

ON LEVEL
LOW FUEL LEVEL
WARM FINISH WARM-UP DRAIN WATER SEPA WARM AUTO WARMING UP
DATA
CPU COMMUNICATION CLOGGED AIR FLTR CHANGE ENG OIL
ERROR
SWING BRAKE
ENGINE STOP
DISENGAGED
3-13
3.3 SELF DIAGNOSIS DISPLAY

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

(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with
the aid of error code.
Alphabet: Decide system failure occurred.
10:25 B 01 3 Last 2nd and 3rd digits: Specifies failed section.
B013
Last 1 digit: Specifies failure type.
This failure symbol is displayed simultaneously with error code during failure diagnosis.
ERROR CODE
A B C D E F G H I K P R
Last 2,3 Controller Low pressure High pressure Proportional Proportional Solenoid Speed sensor Potentiometer Communication Battery relay Engine ECU Relay output
digits memory sensor sensor valve for valves valve for pumps valve etc
Engine Boom up P1 pump P1 unload P1 pump ATT boost Acceleration Battery relay Wiper ark
01 adjust data prevention relay
Torque Boom down P2 pump P2 unload P2 pump Swing parking Boom angle Wiper ark forward
02 adjust data rotation relay
Unload Arm out Boom head Travel straight Travel 1,2 Angle sensor Arm angle Wiper ark reverse
03 adjust data speed for shovel rotation relay
Boom up Arm in Boom rod Option Angle sensors for Washer motor
04 adjust data selector shovel & ECU
Arm in Bucket Bucket stroke
05 adjust data digging limit
Arm out Bucket Arm 2 spool
06 adjust data dump for arm in
Swing
07
08
Travel right Fuel sensor
09
Refer to next page (Engine)
Travel left
10
Selector position CAN
11 detection communication
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)
Larger than Larger than

0 normal range normal range
Transistor OFF CAN error
failure / Grounding
1 - short circuit
Wrong output Wrong output Transistor Transistor Over run
2 - ON failure ON failure
Disconnection Disconnection Disconnection Disconnection Transistor ON Disconnection Disconnection Time is over
failure /
3 - Disconnection
Power source Power source Power source Contact point is Power source
4 - short circuit short circuit short circuit melted and adhered short circuit
3-14
3-15
3.4 SERVICE DIAGNOSIS DISPLAY FUNCTION

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

2) After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as fol-
lows.
• Mode No.1 : Screen No.1~No.30
• Mode No.2 : Screen No.1, Screen No.31~No.40
• Mode No.3 : Screen No.1, Screen No.41~No.50
3) The screen changes each time each switch is pressed from now on.
Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...)
Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1.
(No.1→No.2→No.3→No.1→...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to
No.3. (No.3→No.2→No.1→No.3→...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.
3-16
(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low
speed and lever to neutral position.)
1) Service diagnosis mode No.1
No. Displays Contents No. Displays Contents
1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YN22E00001F1 P/No. indication K-1 AIS RELAY 2 OFF Indicated value
PROGRAM VERSION K-2 SAFETY RLY OFF Indicated value
1-VER 11.11 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 00.00 MERIT controller program version KEY SWITCH OFF Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER OFF Indicated value
SWITCH OFF Switch
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 2205 No load setting rpm B-1 BOOM RAISE
MEAS1 2201 Actual rpm 1 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS2 2201 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 2.6M Sensor voltage / Pressure converted value
WATER TEMP 100 OFF Coolant temperaturre sensor B-3 ARM OUT
MODE HM Work mode 3.5V 2.6M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage B-4 ARM IN
POS. 100% Voltage % indication 3.5V 2.6M Sensor voltage / Pressure converted value
ECU OUTPUT 0.5V Accel output voltage to engine B-5 BUCKET DIG
controller 3.5V 2.6M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
3.5V 2.6M Sensor voltage / Pressure converted value
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL(R)
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL(L)
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.
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
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
C-3 BOOM-HEAD B-13
C-4 BOOM-ROD B-14
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
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
controller
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
DI13 OFF ON/OFF indication
9 19 NO.19 DIGITAL INPUT
NO.9 PROPO-VALVE
E-1 P1 PUMP DI15 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
POWER SHIFT 100mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P2 DI24 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
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
3-18

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

1 33
NO.1 NO.33 BUCKET
MAIN CONT. P/N C-1 P1-PRES 13.9M Pump pressure sensor
YN22E00001F1 P/No. indication C-2 P2-PRES 13.9M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 600mA Command current
1-VER 11.11 Program version indication E-2 P2-PSV 600mA Command current
2-VER 00.00 MERIT controller program version D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current
SERVICE DIAG 2 Service diagnosis mode D-3 S-TRAVEL 600mA Command current
B-5 BUCKET DIG 1.9M Bucket digging pressure sensor
B-6 BUCKET DUMP 1.9M Bucket dump pressure sensor
G-3 ENG SPEED 2205 Engine actual speed
POWER SHIFT 100mA Power shift current
31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-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
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

1 43
NO.1 NO.43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YN22E00001F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 11.11 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 00.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
15mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 2040 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 600mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 137 137 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 137 137 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 137 137 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 137 137 Angle adjustment
3-20
(3) Service diagnosis data list (SK200-8)

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these data
to decide normal/abnormal status.
• The values in following display are reference values with standard attachment attached machine.
• The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
• The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
• The current value of pump proportional valve is reference value because it varies according to pump pres-
sure and adjusted torque value.
• The value in display during operation shows the value in steady state, rather than, at start of operation.
• Check on machine after sufficiently warming up machine.
• The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation Operation No.2 : No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1770~1830
POWER SHIFT 0 mA POWER SHIFT 0 mA
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.31 BOOM No.31 BOOM

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 560~750 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
3-21
Operation No.5 : Boom down in full lever operation & in op-

eration
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 600~617 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427~477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
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
3-22
Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~22.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~22.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 488~677 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 488~677 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 10.0~15.0 M
E-2 P2-PSV 528~750 mA E-2 P2-PSV 750 mA
3-23

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 4.0~8.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 650~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 540~563 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 6.0~15.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 577~750 mA
E-2 P2-PSV 415~435 mA E-2 P2-PSV 415~435 mA
3-24

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 459~584 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 459~584 mA E-2 P2-PSV 665~750 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
* Conflux switch is ON. Relief set pressure is value of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
3-25
(4) Service diagnosis data list (SK330-8)

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these data
to decide normal/abnormal status.
• The values in following display are reference values with standard attachment attached machine.
• The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
• The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
• The current value of pump proportional valve is reference value because it varies according to pump pres-
sure and adjusted torque value.
• The value in display during operation shows the value in steady state, rather than, at start of operation.
• Check on machine after sufficiently warming up machine.
• The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation Operation No.2 : No operation

H mode Hi idle S mode Hi idle
C-1 P1-PRES 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 0.2~2.0 M
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
No.31 BOOM No.31 BOOM

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 13.0~18.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 13.0~18.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 630~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 630~725 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
3-26
Operation No.5 : Boom down in full lever operation & in op-

eration
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 5.0~9.0 M
C-2 P2-PRES 0.2~2.0 M
E-1 P1-PSV 600~620 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427~477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
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
3-27

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~22.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~22.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 570~680 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 570~680 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
C-1 P1-PRES 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 10.0~15.0 M
E-2 P2-PSV 615~770 mA E-2 P2-PSV 770 mA
3-28

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 7.0~11.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 7.0~11.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 670~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 600~620 mA

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~24.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~24.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 550~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 550~770 mA
3-29

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 530~665 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 530~665 mA E-2 P2-PSV 770 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
* Conflux switch is ON. Relief set pressure is value of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 7.0~13.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 7.0~13.0 M
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
3-30
3.5 TROUBLE HISTORY DIAGNOSIS

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

1) Turn starter switch on.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR
Error detected in the past
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
• Press washer switch ( ), and the item moves upward.
• Press wiper switch ( ), and the item moves downward.

5) Turn starter switch off, and the display is disappeared.
(2) How to delete contents of trouble history

1) Display trouble history screen.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3) When "NO ERROR" is displayed, the deletion is completed.
4) Turn starter switch off.
All the stored items are erased. It is impossible to erase data partially.
3-31
3.6 TROUBLE DIAGNOSIS MODE

The recent control system includes many electrical systems and it makes troubleshooting very difficult.
The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be de-
tected through the use of self diagnosis function (the failure can be specified through the use of error code) like dis-
connection and abnormal output. This is useful to save the time for troubleshooting.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and en-
gine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are automatically
actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition
or failed condition of the system.
For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE" of Shop
Manual.
3-32
3.7 SET PROCEDURE OF MAINTENANCE SCHEDULE

3.7.1 For Asia
This machine is equipped with multi-display which makes confirmation of remaining time to the coming replacement/
change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil. When the remaining time reaches to Zero
(0), replace or change them and perform the initial setting in the following order.
Screen change Buzzer stop KPSS work mode

switch switch select switch
Interval of replacement of parts is mentioned below. Washer

switch
• Engine oil : 250 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
• Hydraulic oil : 2,000 Hr switch select switch
Procedure Operating Procedure Display on Multidisplay
After several seconds,

display is changed to 10:25
1 Turn starter key switch on.
clock autmatically.
S
Press " " switch press once display

change switch on the switch panel once. And 10:25 Press screen change 200 Hr
2 ENGINE OIL
the clock display changes to the display of switch once more.
remaining time for coming engine oil change. S S
Press " " switch press once select

switch once and the display for the engine 200 Hr Press select switch 200 Hr
3 ENGINE OIL ENGINE OIL
oil change reverses. once more.
S
When required to adjust the interval to the coming

Replacing interval is
4
change time by 10 hours, press " " switch 200 Hr changed with each 250 Hr
and the time to the coming engine oil change is ENGINE OIL ENGINE OIL
pressing of switch.
added. Press " " switch and the time to the
coming engine oil change is reduced.
When desired to return to the initial set time,

press " " buzzer stop switch once. 250 Hr To set the desired interval, 250 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL
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
3.7.2 For Oceania

This machine is equipped with multi-display which makes confirmation of remaining time to the coming replacement/
change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil. When the remaining time reaches to Zero
(0), replace or change them and perform the initial setting in the following order.
Screen change Buzzer stop KPSS work mode

switch switch select switch
Interval of replacement of parts is mentioned below. Washer

switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
• Hydraulic oil : 5,000 Hr switch select switch
Procedure Operating Procedure Display on Multidisplay
After several seconds,

display is changed to 10:25
1 Turn starter key switch on.
clock autmatically.
S
Press " " switch press once display

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

switch once and the display for the engine 250 Hr Press select switch 250 Hr
3 ENGINE OIL ENGINE OIL
oil change reverses. once more.
S
When required to adjust the interval to the coming

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

press " " buzzer stop switch once. 500 Hr To set the desired interval, 500 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL
time is stored. 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
3.8 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
1) Auto idling stop

No. Switchs 1 2 3 4
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 3-4
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
AUTO IDLING STOP
(d)
AUTO WARM-UP AUTO IDLE STOP AUTO IDLE STOP
OFF OFF ON
FEED FEED FEED
(c)
(e)
AUTO IDLE STOP AUTO IDLE STOP
OFF ON
OFF ON OFF ON
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST"
select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
3. In operation of FEED (4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
4. In operation of FEED (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
(e) is displayed.
5. Switch from "OFF" to "ON" in operation of FEED (4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
3-35
2) Clock Adjustment Switches

3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6
Main screen (a)

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

SWITCH STATUS ADJUST CLOCK Y M D H M Enter
CLOCK/CONTRAST ADJ CONTRAST 06 04 01 13 15
Select Year/Month/Day/Hour/Minute Increase/Decrese
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).
3-36
3) Contrast Adjustment Switches

3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(c) (d) (a)

SWITCH STATUS ADJUST CLOCK
CLOCK/CONTRAST ADJ CONTRAST 10:25
H
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555)
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH
STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is 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
(2) Function for service

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

(1) C-1 Mechatro controller
1) Outside view
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
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
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
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
22 D1 37 Spare Input GND / OPEN
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
16 Reserved
3-40
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
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
12 GA 0V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
24 GA 0V
25 GA 0V
28 DI 1 Cab slow up and down Input GND / OPEN
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
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
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
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
14 D13- -0~800mA
16 D14- -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
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
10 DI 20 ECU main relay 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
17 Reserved
3-42
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
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~
24 Reserved Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Accel signal 2 0~5V
28 H2- 0V
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
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
(2) Gauge cluster (symbol C-2)

1) General view
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
BUZZER STOP SWITCH WORK MODE SWIHCH
2) Connector CN-600 (Harness side)
No. Item name Wire color No. Item name Wire color
Gauge cluster → Mechatro
GND source (+24V Battery 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.
4) Summary of display and drive item
No. Item Remarks

1 Monitar display LCD dot 120×168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 —
4 Buzzer Piezo-electricity type
7 Work mode select switch
8 Back light LED
3-44
(3) Relay & fuse box (symbol E-1)

1) General view
(Overhead view of box)

LABEL INSIDE
Note) These circles indicate the parts

which are used in standard specification
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF RELAY & FUSE
LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME
3-45
2) Circuit diagram
3-46
3-47
3-48
(4) High pressure sensor : YN52S00048P1
ECONOSEAL SERIES MARK (+)> SPECIFICATION :

3POLES CAP
MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa
POWER SOURCE VOLTAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESISTANCE : 100M OR MORE
HOUSING (BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
PLASTIC POTTING CONDENSER
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
O-RING P14 PIPE

JIS B2401 CLASS1B
THREAD
PF 3/8
Tightening torgue STRUCTURE
73.5N.m (54.2lbf.ft)
(5) Low pressure sensor : YX52S00013P1

Tightening torgue
Vout
29.4 34.3N.m (21.7 25.3lbf.ft)
PF1/4
Vcc GND
ELECTRIC CONNECTING DIAGRAM
(Ex. Construction of internal controller)
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
3.10 EMERGENCY MODE

When the trouble of mechatro equipment occurs, as an emergency solution method this machine can be operated
by switching the mode of respective equipment from normal mode to emergency mode. This function has two sys-
tems of automatic switch and manual switch, and this machine equips this function as standard.
• Engine speed control : (Manual switch)
• Pump control : (Automatic switch)
• Unload control of control valve : (Automatic switch)
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.
(1) Emergency mode of engine speed control

This machine equips the engine controller (ECU) which is used to control engine. And also this machine equips
the mechatro controller (CPU) which is used to control engine controller and electric-hydraulic system. In case
of failure of mechatro controller (CPU), engine speed can be controlled by operating accel dial for emergency
which is provided on the seat rear side.
Procedure
1) In case of failure of mechatro controller, the following indication appears on the display of gauge cluster.
DATA
CPU COMMUNICATION
ERROR
2) Turn the emergency accel dial to "NORMAL" position.

3) Start engine.
4) Turn the emergency accel dial to "HI" side and adjust the engine speed to required rotation.
* Engine is able to operate.
5) To stop engine, at first return the emergency accel dial to "NORMAL" position.
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
(2) Pump emergency mode

When pump swash plate tilting control (pump displacement control) is unable to control by failure of mechatro
controller and/or electro magnetic solenoid proportional reducing valve, the inside circuit of pump is switched
automatically and the constant pump power control is performed by oil pressure control.
Take care that in case of emergency mode the operability becomes poor, the rate of engine speed-down increas-
es and the engine stalls in medium/low speed range.
* In case of previous model SK200-6, the switch was performed manually but this machine employs the auto-
matic switch.
Operation in normal condition

The emergency mode spool (642) is switched by secondary pressure of electro magnetic solenoid proportional
reducing valve (079) and the secondary pressure of electro magnetic solenoid proportional reducing valve is led
to pilot piston (643).
Operation in emergency mode

The electro magnetic solenoid proportional reducing valve (079) is not actuated and the emergency mode spool
(642) does not switch. (It is held at position as shown in figure.) Pilot primary pressure is led to compensation
piston (621) and to pilot piston (643), and pump becomes the status that the pump power can be controlled by
self pressure. The control of pump power is performed by pump self pressure which is led to stepped-section of
compensation piston (621).
079 Electro magnetic proportional reducing valve
SE22
a1 P
MAIN PUMP PSV1 A1
PSV-P1
642 Spool for emergency mode
621 Compensation piston
643 Pilot piston
532 Servo piston

a3
Dr
Large Small
M
B1
Pilot pump
3-51
(3) Emergency mode for control of control valve unload

In case that bleed-control at unload valve by electric control can not be performed due to failure of mechatro
controller and/or electric solenoid proportional reducing valve, this bleed-control can be performed by hydraulic
control. In this case, the mode switches to emergency mode automatically.
* 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)
Operation at normal condition

When engine is started, secondary pressures are output from P1 unload proportional valve (PSV-D) and P2 un-
load proportional valve (PSV-B) by command of mechatro controller. This secondary pressure acts on PCb port
and PCa port, then the pressure switches P1 unload valve and P2 unload valve to open side.Simultaneously,
the secondary pressure of each unload proportional valves acts on PBp1 and PBp2, then the pressure switches
P1 and P2 bypass cut valves to close side.
On starting any one of operations, the control pilot secondary pressure switches spools, and is input into respec-
tive low pressure sensors. The output voltage of low pressure sensor is input to mechatro controller, and the
mechatro controller processes pilot signal. And mechatro controller outputs the command according to the input
voltage to each unload pressure proportional valve.
Unload pressure proportional valves output pilot secondary pressure according to the command by mechatro
controller, and the secondary pressure switches the unload spools. With this operation, the bleed opening ac-
cording to lever manipulated movement is obtained.
Operation at emergency mode

Secondary pressure is not output from unload proportional valve, and unload valve and bypass cut valve are not
switched. Pump delivery oil is discharged to tank line through center bypass passage for actuator control spool
and bypass cut valve.
On starting any one of operations, the control pilot secondary pressure switches spools. And bleed-control is
performed at the bypass passage of the respective spool. Operation in this emergency mode, the operability and
fuel economy are lowered, and the long hours of work might cause over heat of engine.
3-52
MAIN CONTROL VALVE P2 P1 T1 T2

34.3MPa
37.8MPa
CMR1
PL
PTb CMR2
TRAVEL
P1UNLOAD PRIORITY TRAVEL LEFT
PCb
Unload valve CT2 CP2

(Bleed function) BOOM
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1
BR CP1
AR
PBr CCb
Dr
BOOM LCb LCs SWING
PBb
37.7MPa Center bypass

(ROD)Bb passage of spool
CRb
LCa
(HEAD)Ab
39.7MPa ARM 1
PAb
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
Bypass cut valve
(T3b) (T3a) (T4a)

(P3) (P4)
3-53
[MEMO]
3-54
4. ENGINE
4-1
4. ENGINE
4-2
4. ENGINE
4.1 ENGINE SPECIFICATIONS (SK200-8)

4.1.1 SPECIFICATIONS
Applicable machine SK200 - 8, SK210LC - 8

Engine model HINO J05E-TA
Water-cooled, 4-cycle 4-cylinder direct injection type
Type
diesel engine with intercooler turbo-changer
Number of cylinder × Bore × Stroke mm (in) 4 × 112 × 130 (4.41 × 5.12)
Total displacement cc (cu•in) 5,123 (313)
Compression ratio 18.0
Rated output kW (PS) at min -1
114 (115) at 2,000
N•m (lb•ft) at
Maximum torque 572 (422) at 1,600
min-1
High idling min-1 2,000 ± 30
Low idling min -1
1,000 ± 30
Injection starting pressure MPa (psi) 50 (7,250)
Start / Full open
Thermostat action 350 (170) / 363 (194)
K (°F)
Firing order 1–3–4–2
MPa (psi) at
Compression pressure 3.4 ~ 3.7 (493 ~ 537) at 280
min-1
Fuel injection timing 0°
Valve clearance Open Close
14 before top
°
30 after top dead
°
Intake valve 0.3 mm at cool
Valve clearance dead point point
54° before top 13° after top dead
Exhaust valve 0.45 mm at cool
dead point point
Starter capacity V × kW 24 × 5.0
Generator capacity (Alternator) V×A 24 × 50
ø650 (25.6") × suction type 7 fans, V-velt drive,
Cooling fan drive method
pulley ratio Crank / Fan = 0.89
Full level 18.0
Engine oil quantity L (gal) Low level 15.0
Total 21.5 (5.68)
Dry weight kg (lbs) 580 (1,280)
Fuel consumption ratio g/kW•h (g/ps•h) 217 (160)
Allowable inclination
Front / Rear and Right / Left : 35°
(Limited by E/G lubrication)
Dimension (L × W × H) mm (in) 1,063×725×995 (3 ft 5.86 in ×28.5 in ×39.2 in)
Rotating direction Counterclockwise seeing from flywheel side
4-3
4. ENGINE
4.1.2 ENGINE CHARACTERISTIC CURVE (HINO J05E-TA) (SK200-8)

Condition to be measured : The net value is indicated, measuring without cooling fan.
marks show the rated point.
SHAFT TORQUE
SHAFT OUTPUT
FUEL CONSUMPTION RATE
ENGINE SPEED (min-1)
Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
217g/kW.h
X 114kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
29.6
Fuel consumption in regular operation
(load factor 0.70~0.80)
20.7 L/h~23.7 L/h
4-4
4. ENGINE
4.2 ENGINE OUTSIDE VIEW (SK200-8)

THERMOSTAT
OIL FILTER
ELEMENT
ALTERNATOR
FUEL FILTER
ELEMENT
STARTER
Fig. 4-1 Outside view of engine
4.3 ENGINE MOUNTING (SK200-8)

27
27
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
Fig. 4-2 Engine mounting
4-5
4. ENGINE
4.4 FUEL INJECTION SYSTEM

4.4.1 COMPARISON OF INJECTION SYSTEM
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)
Type In-line type Common rail system
Adjustment of injection rate Pump (Governor) Injector (2WV)
Adjustment of injection timing Pump (Timer) Injector (2WV)
Boost Pump Supply pump
Distribution Pump Common rail
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
[Inline type pump] [Common rail type pump]
4-6
4. ENGINE
4.4.2 COMMON RAIL SYSTEM

• This system is made up of supply pump, common rail, injector and engine ECU which controls the above units,
sensor switches, relays, and lamps.
• The supply pump delivers fuel used to generate common rail internal fuel pressure. The fuel delivery rate is
controlled by supply pump fuel suction control valve (SCV) and the SCV is electronically controlled by engine
ECU.
• The common rail is used to distribute high pressure fuel produced by supply pump to injectors of each cylin-
der. This fuel pressure is detected by pressure sensor installed on common rail. And the engine ECU performs
the pressure feedback control so that the command pressure which is set in order to correspond to the engine
speed and engine load accords with the actual pressure.
• On injector, the fuel injection quantity and fuel injection timing are controlled by switching two-way solenoid
controlled valve ON/OFF. With the two-way solenoid controlled valve switched ON, since the fuel circuit is
switched so that high pressure oil flows out from the control chamber through orifice, the fuel is started inject-
ing because the needle valve is pushed up by nozzle valve opening force due to high pressure fuel in nozzle
chamber. With the two-way solenoid controlled valve switched OFF (Non-power distribution), since it returns
to fuel circuit that the high pressure fuel is applied to control chamber through orifice, the fuel stops injecting
because the needle valve moves down.
Therefore, the fuel injection timing is controlled by opening start time of two-way solenoid controlled valve and
the fuel injection quantity is controlled by the open period.
• Because the strength of pressure proof of each part is improved, higher fuel pressure injection is obtained.
Consequently, the micro-particulated fuel injection becomes possible. This realizes the good combustion con-
dition without unburned fuel, resulting in reduction of particulate materials (PM) emission.
Two-way solenoid valve
Engine ECU Two-way solenoid valve control pulse

Other
information Common rail pressure sensor
(Temperature, Common rail
pressure)
Accel sensor Leak

Small diameter orifice
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)
Engine Sub engine

speed speed
sensor sensor
4-7
4. ENGINE
4.4.3 FUEL SYSTEM PART LAYOUT (Without Air compressor)
11195 Nozzle clamp holder 22760 Common rail assembly

11491A Common rail bracket 23910 Injector
13691 Bearing holder case 9645A O-ring *
22730 Supply pump 9645A O-ring *
* Parts not to be reused.
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
23081 Leakage pipe 23766A Through feed pipe

23083 Through feed pipe 23783A Fuel pipe
23711 Injection pipe 9659B Gasket *
23712 Injection pipe 9659C Gasket *
23713 Injection pipe 9659CD Gasket *
23714 Injection pipe 9659E Gasket *
23766 Through feed pipe
* Parts not to be reused.
4-9
4. ENGINE
4.5 CONSTRUCTION & FUNCTION

4.5.1 ENGINE
(1) Combustion chamber
• The combustion chamber is direct injection type which has special shape combustion chamber and the noz-
zles are located on the center of pistons. The valve is of 4-valve construction, 2 valves for air intake and 2
valves for exhaust air, which provides efficient combustion, combined with improvement of intake air distribu-
tion and air suction efficiency with special shape intake port.
Valve Grow plug Grow plug
Combustion chamber Nozzle Combustion chamber Nozzle

Valve
(2) Cylinder head

• Cylinder head is integrally formed, is made of alloyed cast iron and is cross flow type of which 2 suction valves
are alternatively located respectively to improve the reliability to high speed and high load continuous running.
• The intake port is of special construction shown in the figure to generate optimum mixing swirl which provides
efficient combustion.
• The valve seat is sintered insert type for both air intake and exhaust.
• The nozzle sleeve is wet type and the head valve side and the nozzle sleeve are cooled by cooling jet to obtain
reliable durability.
• J05E type cylinder head is integrated with cam housing to make it small size and reduce the engine overall
height.
Exhaust port
Intake port
4-10
4. ENGINE
(3) Cylinder block and cylinder liner

• The cylinder block is made of special cast iron and of rigid high dry liner construction, and further the rigidity
around bore and between cylinders is reinforced.
• The water gallery is enlarged to improve the cooling capacity and quietness.
• Each cylinder is equipped with cooling jet to cool the piston.
• The cylinder liner is made of high tensile special cast iron and the smooth contact with piston ring and cylinder
block is improved by allowing proper clearance to engagement with cylinder block and treating the inside and
outside surfaces of cylinder liner.
Piston ring Piston
Cylinder block
Cooling jet
Cylinder liner
(4) Piston and piston pin

• The piston is made of heat resistant aluminum alloy. The effective combustion and low fuel consumption are
realized with special shape combustion chamber.
• The piston perimeter shape is in optimum profile taking thermal expansion and piston oscillation into consid-
eration.
• The piston is treated by skirt coating to reduce noise level.
• The piston is maintained to proper temperature by cooling with piston cooling jet and is provided with cooling
cavity to ensure sufficient reliability to high power. (The inadequate injection due to deformation of cooling jet
and wrong installation may cause insufficient cooling, resulting in failure of piston.)
• The piston is made of case hardening steel and withstands high load operation because full floating type is
employed.
Piston pin
Piston ring
Conecting rod
Piston
Cooling jet
4-11
4. ENGINE
(5) Piston ring

• The piston ring is made of steel of nitriding treatment to improve wear and abrasion resistance.
• The top ring is treated by PVD (*) coating to improve wear and abrasion resistance remarkably resulting in
reduction of oil consumption and blow-by gas.
• The ring sectional form maintains oil consumption to proper level and is designed with care to reduce the abra-
sion and prevent gas leak and scuffing.
(*) PVD is abbreviation of Physical Vapor Deposit.
Nitrided layer
PVD film
Nitrided layer Nitrided layer

Nitrided layer
Top ring Second ring Second ring
(6) Plastic range

The plastic range is the method that bolt is tightened at area the vibration of axial force to elongation of bolt is
small and has the following advantages.
• Stable and high axial force can be obtained ;
The axial force of bolt is stabilized because dispersion of axial force is smaller, compared with tightening to
elastic range.
• The bolt has a limitation for reusing ;
The bolt has a limitation for reusing because plastic elongation is produced each time when it is used.
Yielding point
Elastic range Plastic range
Axial force of bolt
Small dispersion
Fracture
Large dispersion
Elongation of bolt
Character of bolt in plastic range
4-12
4. ENGINE
4.5.2 COOLING SYSTEM

(1) Outline
• The engine is provided with water cooling type of which the coolant is forced to circulate by coolant pump.
• EGR valve and EGR cooler are added to coolant circulation system.
• The coolant cooled in the radiator core by cooling fan flows through hose from radiator lower part, passes
through thermostat and gets into coolant pump.
• The coolant delivered by coolant pump enters oil cooler and then enters cylinder block while exchanging heat
with engine oil.
• The coolant flown into cylinder block enters water jacket, cools each cylinder liner and goes up to cylinder
head side.
• After cooling the area between valves and port section in the cylinder head side, the coolant flows through
thermo case and thermo cover and returns to radiator.
• A part of coolant in the cylinder block returns to thermo cover after cooling exhaust gas through EGR cooler
by the operation of "cool EGR".
• The thermostat opens fully when the coolant temperature is higher than 90 °C. And the thermostat closes at
76.5 °C or less immediately after starting engine, and does not feed coolant to radiator but bypasses coolant
to coolant pump directly. It flows inside of engine and circulate to prevent overcooling of engine.
Reservoir
Water temperature
EGR cooler
Thermostat case
Cylinder head
Air
compressor
Thermostat
Cylinder block
Radiator Turbo
Car EGR
charger
heater Valve
Coolant Oil cooler

pump
Drain cock Drain cock
Reserve tank
Radiator Air bleeding

cap EGR
cooler
Air bleeding
Thermo cover
(outlet) Heater
Water
temperature
Thermostat
mostat
Radiator Cylinder head
Thermo cover
Thermostat
mostat
(intlet) Turbo
charger
Cylinder block
Drain cock
Coolant
pump Oil cooler
EGR Drain cock

Valve
4-13
4. ENGINE
(2) Coolant pump

• The coolant pump is installed on cylinder block front side and is driven with V-belt.
• The coolant pump is provided with coolant seals fitted on vane and case for leak prevention and also prevents
water leak by sliding seal of ceramic plate on the vane side and special carbon plate on the case side.
4.5.3 LUBRICATING SYSTEM

(1) Outline
• The oil in oil pan is pumped up through strainer by built-in oil pump on the cylinder block rear side, and after
heat exchanging with coolant through oil cooler, it is filtered by oil filter and is led to main oil hole in the cylinder
block.
• The oil led to main oil hole flows to crankshaft journal, camshaft and rocker arm shaft for lubrication.
• The oil used for lubrication of each journal (main bearing) of crankshaft flows to pin section through oil gallery
in crankshaft and lubricates the large end of connecting rod.
• On the other hand, a part of oil on each journal of crankshaft flows to sub oil hole and cools piston with piston
cooling jet provided on each cylinder.
• The lube oil in supply pump drive gear branches in the course of oil path of sub oil hole.
• The oil led to camshaft is fed to each journal through oil hole in the camshaft, and lubricate the journals.
• The oil led to rocker arm shaft is fed to each rocker arm bushing to lubricate them and then fed into roller and
roller pin through oil hole of each rocker arm for lubrication.
• Each idle gear is lubricated by oil led through main oil hole or sub oil hole.
• For oil pressure adjustment on each section, the highest standard pressure is held to 530 ± 40 kPa (77 ± 6
psi) with regulator valve and when the low temperature pressure is too high, the safety valve of oil pump ac-
tuates [Valve open pressure: 1,640 kPa (238 psi) to return oil into oil pan.
• When oil cooler and/or oil filter are clogged, the safety valve [Oil cooler valve open pressure: 392 ± 40 kPa
(57 ± 6 psi), oil filter valve open pressure: J05E type 196 ± 20 kPa (28 ± 3 psi): J08E type 147 ± 10 kPa (21
± 1 psi)] is installed in the mid-course to prevent shortage of oil.
• The pressure of oil pressure switch is supplied from secondary side of oil filter and check valve [Injection pres-
sure: 254 kPa (37 psi)] is installed on each piston cooling jet to cool it to proper temperature.
4-14
4. ENGINE
Roller pin
Cam Roller
Cross Adjust Rocker Rocker

Valve
head screw arm arm shaft
Oil pan
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
Sub idle gear shaft

(Supply pump drive
or air con compressor)
Piston cooling jet

Sub oil hole
(Check valve)
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 cooler element
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.
By-pass oil filter
Full-flow oil filter
4-16
4. ENGINE
4.5.4 FUEL SYSTEM

(1) Fuel filter
• The contamination of dirt in fuel may cause damage and early wear of supply pump and injector resulting in
deterioration of function. Therefore sufficient filtration is required.
• The fuel filter is a cartridge type, and special tool is used to replace the fuel filter and to prevent fuel leakage.
The filter is attached as a one separate component.
Priming pump Airbleeding

Air bleeding plug
plug
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
4.5.5 EGR SYSTEM

(1) Outline
• EGR is abbreviation of Exhaust Gas Recirculation, and leads exhaust gas in combustion chamber to slow the
combustion speed, and lowers the combustion temperature to reduce emission of NOx (nitrogen oxides).
• The "cool EGR" is of construction EGR cooler in water cooling tube type is integrated into EGR in externally-
installed pipe type, and cools exhaust gas in the course of returning from exhaust side to suction side by the
aid of coolant, and leads high density exhaust gas into suction side resulting in high efficiency of EGR.
• The "cool EGR" is made up of EGR cooler used to cool exhaust gas and EGR pipe used to regulate gas flow
rate.
(2) EGR cooler
• The EGR cooler is equipped with 63 tubes in which EGR gas passes through and which are installed in the
tank filled with coolant to cool EGR gas. The tubing additionally forms a spiral shape which strikes a good
balance between cooling efficiency and performance deterioration to conform to exhaust gas regulation si-
multaneously with achievement of low fuel consumption.
• The cooling pipe is equipped with sub line other than main line on the core body to secure proper flow rate in
the core and at the same time cooling efficiency is improved obtaining further reliability.
• The EGR cooler body is made of stainless steel which is excellent in heat resistance and corrosion resistance
to secure reliability. Especially tubing for gas passage is made of very low carbon stainless SUS 316L to se-
cure reliability for corrosion resistance.
Exhaust gas outlet
Coolant outlet
Section A-A
Coolant inlet
Exhaust gas inlet
(3) EGR valve

• This EGR valve is in electronic control double seat valve linear solenoid type to improve the regulating accu-
racy of EGR rate and to reduce particulate material and NOx emission simultaneously.
• The proper EGR control is achieved by feedback the gas to ECU according to EGR pipe opening because
the EGR valve lift sensor is installed.
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.
EGR valve lift sensor
Linear solenoid actuator Engine speed

Linear solenoid Accelerator sensor
actuator Intake pressure, Atmospheric pressure
EGR valve lift sensor
Coolant temperature
Intake air volume
Double EGR cooler

seat valve
Exhaust gas
inlet Coolant
Exhaust gas
outlet Engine Exhaust manifold
4-19
4. ENGINE
4.5.6 ELECTRICAL SYSTEM

(1) Starter
• The starter is 24 V - 5 kW electromagnetic pinion shaft type integral with main switch, and is made up of motor,
reduction, pinion clutch and start magnetic sections, and is used to in combination with the attached starter
relay.
• The motor is in high speed type of 4-pole control short time rating, and the armature is supported by each
bearing of gear housing and commutator end frame. Needle bearing is used as front bearing and metal bear-
ing is used as rear bearing. Four metal graphite brushes are pressed to commutator by brush spring.
• The reduction part is used to reduce armature rotation to about one fifth (1/5) through reducing gear, and
transmit rotation to pinion gear. This reduction gear employs planetary gear type.
• The pinion clutch is used to transmit motor revolution to engine and works to prevent the engine power to be
transmitted in reverse to engine (armature) during operation by the aid of roller clutch.
• The pinion gear is separated from clutch, is linked with inner sleeve by straight spline and is fixed by snap ring
and stopper collar.
• The start magnetic switch is used to open/close the main contact to engage/disengage pinion gear by means
of lever.
• Dust seal is attached to top end of start drive housing (pinion case) to prevent entering of clutch powder due
to abrasion into bearing.
• The drive spring is attached between pinion gear and inner sleeve to improve the engaging performance with
ring gear.
• The planetary single shaft motor is installed to make it in compact size.
Start magnet switch assembly

(Engine switgh)
Shift lever
Gear shift
Armature
Starter switch
H P B
M
Armature FC B S E
assembly
C
Starter Starter relay

Battery
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.
Stator coil Drive end frame
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
(3) Glow-plug (Starting aid components at low temperature)

1) Outline
• The starting aids is made up of glow-plug, coolant temperature sensor heater relay, indicator lamp and engine
ECU which controls the above units. And the starting of engine at low temperature is eased by coolant tem-
perature detecting type automatic preheating system.
2) Operation
• When coolant temperature is 0 °C or less, the engine ECU detects low temperature on turning starter switch
"ON" and sends a current to heater relay. And then heater relay 8 turns "ON" and current is delivered to glow-
plug and indicator lamp.
• When low temperature starting aids is actuated, the preheating is automatically held for 5 seconds and the
indicator lamp goes off. When the water temperature is over 0 °C, it is not preheated.
• Then, turn the starter switch to "ST" in neutral condition, and the after-glow actuates and maintains the glow-
plug to constant temperature for about 90 seconds, resulting in good engine starting. However, if the engine
starter switch is not turned to starting position "ST" within 3.5 seconds, the control timer is cancelled and the
after-glow does not actuates. And when machine is moved off within 90 seconds after starting engine, the af-
ter-glow is stopped actuating at the time.
Grow lamp assembly
Upper view of engine
4-22
4. ENGINE
4.5.7 EXHAUST SYSTEM

(1) Turbocharger
1) Outline
• The fuel consumption at medium and high speeds under the conditions of large capacity and after improve-
ment of efficiency by providing scroll shape which is suitable for high speed operation, which are brought by
introduction of high efficiency turbocharger, is improved.
• When engine is at low speed running, the fuel consumption is improved by common rail type injection system.
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
Exhaust gas Tubine wheel

Blower impeller
Compressed air
Air
4-23
4. ENGINE
4.6 HOW TO READ TROUBLESHOOTING

4.6.1 FAILURE DIAGNOSIS FOR ENGINE
Confirm failure
Confirm failure onlamp
on check check lamp
Check and repair

as necessary
Read DTC
(Diagnosis Trouble Code)
4-24
4. ENGINE
4.6.2 CONNECTION TO ECU CONTROLLER

(1) System block diagram
Actuator Relay
Fuse
Each Sensor Power
Main relay
Key switch signal Fuse
Starter signal
- + Battery
Accelerator signal 1,2

Diagnosis tool
Diagnosis switch
Neutral switch
I/F
PTO Switch
Accelerator sensor for operation
PC Diagnosis tool
Engine speed main sensor
Engine speed sub sensor
OUTPUT
Glow relay
EGR valve 1 drive signal

INPUT
Injector drive signal

Supply pump
Supply pump control valve drive signal

Supply pump drive signal S/P
Others
Fuel temperature sensor (Supply pump)
EGR lift sensor1

Boost pressure sensor
Common rail pressure sensor1
Water temperature sensor
Common rail pressure sensor2 Engine ECU
Common rail T
Engine
P
EGR valve 1
(Linear solenoid)
4-25
4. ENGINE
(2) Connection to ECU

1) Pre-inspection Maintenance Cover (A)
1. If error occurs on the system, the DTC code is

indicated on the gauge cluster of machine.
2. Reading of failure code
a. Connection of Hino-DX
1. Press down the upper tab of mainte-
nance cover (A: 1 place), which is locat-
ed on the cover at rear of operator seat,
and remove cover (A). And the engine
failure diagnosis connector appears.
2. Connect the cable (Special cable with
Hino-Bowie interface box) to above
Engine ECU
mentioned engine failure diagnosis
connector (16 Pin) as shown in right fig-
ure. And then connect the other end of
cable to the Hino-DX pre-installed per-
Engine failure
sonal computer. diagnosis
connector
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.
2) Deletion method of past failure

1. To delete past failures of the engine ECU, use
Hino-DX on the PC.
(Refer to "Hino field support system operation
manual".)
4-26
4. ENGINE
(3) Indication of failure diagnosis
or
If DTC (Diagnosis Trouble Code) to table of failure code.
Table of failure code (Refer to table of DTC code (failure code) in Shop Manual.)
(a) Failure diagnosis and

DTC code Estimated failure cause
(b) Alarm dispiay (alarm status)
a. Engine does not start. P0335 Engine speed main sensor circuit malfunction
Engine stopped. P0606 CPU malfunction (Hard detection)
Supply pump SCV malfunction (Power source line
b. DTC code indication. P0629
short)
a. Low output P0200 ECU charge circuit high input
b. DTC code indication. P0611 ECU charge circuit low input
a. Low output (LOW idle 800 rmp
P2120 Accelerator sensor 1 and 2 mulfunction
fixing)
b. DTC code indication.
a. Low output P0217 Engine overheat
Preheat circuit malfunction (Open / GND short cir-
a. Difficult to start engine. P0540
cuited)
b. DTC code indication. P0540 Preheat circuit malfunction ( + B short circuited)
a. Low output P0234 Turbochager over boost
4-27
4. ENGINE
(4) Connection of signal check harness

1) Signal check harness
Rear of operator seat Engine ECU
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".
ECU terminal name
ECU terminal number

[Example] For A8 terminal
A8
A
A
Signal check harness
(contact box)
4-28
4. ENGINE
2) Connection of signal check harness

1. Set the starter key to "LOCK" and disconnect the connector from the engine ECU.
2. Connect the signal check harness to the engine ECU and the machine harness.
Special tool : Signal check harness (09049-1080)
ECU
Machine harness
Signal check harness
Test lead
Signal check connector
4-29
4. ENGINE
4.6.3 CHECK AND REPAIR

(1) Measurement of resistance between terminals
1) Set the starter key to "LOCK" and connect the signal check harness.
2) Disconnect the ECU side connector of the signal check harness and measure the resistance between ter-
minal B6 and terminal B7.
Standard value : Approx. 125.5±17 (20°C (68 °F))
B6 B B7
NG (3) Go to measurement of resistance between sensor

terminals.
OK
(2) Check of diagnosis code

1) Connect the ECU side connector of the signal check harness. After deleting the past failure, start the engine
and confirm the no diagnostic code output.
Standard : No diagnostic code
NG Contact failure of ECU connector, short-circuit of harness
OK
Normal
(3) Measurement of resistance between terminals

1) Disconnect the connector of the main engine speed sensor and measure the resistance between No.1 and
No.2 terminals at the sensor.
Standard : Approx. 125.5±17 (20 °C (68 °F))
NG Failure of main engine speed sensor
This means mainly, replacement of

engine speed sensor is required.
In this case, check harness of related circuit

OK
and repair the failure.
Harness disconnection or connector failure
4-30
4. ENGINE
4.6.4 HOW TO USE FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Use "Failure diagnosis for each engine status" to investigate the cause. And repair or replace the
failed parts according to the instruction in "Action".
(Refer to table of DTC code (failure code) in Shop Manual.)
Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat (radiator) Clogging of radiator Cleaning of radiator
Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat (compression pres-
Non-synchronous injection timing Adjust injection timing
sure)
Faulty fuel injection pressure Adjust injection pressure
Faulty injector Replace injector
Engine overheat (lubrication unit) Deterioration of engine oil Replace engine oil
Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
4-31
4. ENGINE
4.7 ENGINE SPECIFICATIONS (SK330-8)

4.7.1 SPECIFICATIONS
Applicable machine SK330-8, SK350LC-8

Engine model HINO J08E-TM
Water-cooled, 4 cycle 6 cylinder direct injection type die-
Type
sel engine with intercooler turbo-charger
Number of cylinder×Bore×Stroke mm (in) 6 × 112 × 130 (4.41 × 5.12)
Total displacement cc (cu•in) 7,684 (469)
Compression ratio 18.0
Rated output kW (PS) at min -1
197 (268) at 2,100
N•m (lb•ft) at
Maximum torque 998 (736) at 1,600
min-1
High idling min-1 2,310 ± 30
Low idling min -1
1,000 ± 30
Injection starting pressure MPa (psi) 3.2 (464)
Start/Full open
Thermostat action 350 (170) / 363 (194)
K (°F)
Firing order 1-4-2-6-3-5
Compression pressure MPa (psi)at min -1 3.4~3.7 (493~537) at 280
Fuel injection timing 0° before top dead point
Valve clearance Open Close
14° before top 30° after bottom
Intake valve 0.3 mm at cool
Valve clearance dead point dead point
54° before bottom 13° after top dead
Exhaust valve 0.45 mm at cool
dead point point
Starter capacity V × kW 24 × 5.0
Generator capacity (Alternator) V×A 24 × 60
ø850 (33.5") × suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.80
Full level 26.0 (6.87)
Engine oil quantity L (gal) Low level 20.0 (5.28)
Total 28.5 (7.53)
Dry weight kg (lbs) 680 (1,500)
Fuel consumption ratio g/kW•h (g/ps•h) 225 (165)
Allowable inclination
Front / Rear and Right / Left : 35°
(Limited by E/G lubrication)
Dimension (L×W×H) {without fan} mm (in) 1,294 × 868 × 987 (4ft-2.95in × 34.2in × 38.9in)
Rotating direction Counterclockwise seeing from flywheel side
4-32
4. ENGINE
4.7.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-TM)

Condition to be measured: The net value is indicated, measuring it without cooling fan.
marks show the rated point
SHAFT TORQUE
SHAFT OUTPUT
FUEL CONSUMPTION RATE
ENGINE SPEED (min-1)
Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
225g/kW.h
X 209kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
56.3
Fuel consumption in regular operation
(load factor 0.70~0.80)
39.4 L/h~45.1 L/h
4-33
4. ENGINE
4.8 ENGINE OUTSIDE VIEW (SK330-8)
GASKET
THERMOSTAT KIT
OIL PLUG
OIL FILTER FUEL FILTER

ELEMENT ELEMENT
ALTERNATOR V BELT (2 PIECES)
V BELT
(COMPRESSOR)
STARTER
V BELT (3 PIECES)
Fig. 4-3 Outside view of engine
4-34
4. ENGINE
4.9 ENGINE MOUNTING (SK330-8)

! !
# #
! "
! "

' '
&
"
#
* +
#
$
%
!

)
$
&
%
!
&
$ + !! )
'
!# '
&
+
!
!
*
*
!$
Fig. 4-4 Engine mounting
4-35
4. ENGINE
[MEMO]
4-36
5-1
5-2
5.1 BOOM (SK200-8)

5.1.1 BOOM DIMENSIONAL DRAWING

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
5.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section
A
C
Fig. 5-2 Clearance of pin and bushing on boom section
ASIA Unit : mm (in)

Standard value Clearance
Sym- Bushing Repair-
Item Pin part No. Pin dia. Standard Service Remedy
bol Pin dia. i.d. able
tolerance value limit
tolerance level
+ 0.020 + 0.217 + 0.237
ø 90 (+0.0008) (+0.0085) (+0.0093)
A Boom foot YN02B01719P1
(3.5433) - 0.020 + 0.071 + 0.051
(-0.0008) (+0.0028) (+0.0020)
+ 0.243 + 0.283
0
Boom cylinder ø 85 - 0.040
(+0.010) (0.011)
B YN02B01720P1
(Head side) (3.3465) + 0.085 + 0.085 More
(-0.0016) Replace
(+0.0033) (+0.0033) than 2.5
bushing
+ 0.020 + 0.247 + 0.267 2.0 (0.1)
or pin
Boom cylinder (+0.0008) (+0.0097) (+0.0105) (0.08)
C YN02B01721P1
(Rod side) - 0.020 + 0.093 + 0.073
ø 85 (-0.0008) (+0.0037) (+0.0097)
(3.3465) + 0.030 + 0.252 + 0.282
Arm cylinder (+0.0012) (+0.0099) (+0.0111)
D YN02B01839P1
(Head side) - 0.030 - 0.099 + 0.069
(-0.0012) (-0.0039) (+0.0027)
5-4
OCEANIA Unit : mm (in)

tolerance level
+ 0.020 + 0.217 + 0.237
ø 90 (+0.0008) (+0.0085) (+0.0093)
A Boom foot YN02B01719P1
(3.5433) - 0.020 + 0.071 + 0.051
(-0.0008) (+0.0028) (+0.0020)
+ 0.243 + 0.283
0
(+0.010) (0.011)
B YN02B01720P1
(Head side) (3.3465) + 0.085 + 0.085 More
(-0.0016) Replace
(+0.0033) (+0.0033) than 2.5
bushing
+ 0.247 + 0.267 2.0 (0.1)
or pin
Boom cylinder (+0.0097) (+0.0105) (0.08)
C YN02B01721P1
(Rod side) + 0.020 + 0.093 + 0.073
ø 85 (+0.0008) (+0.0037) (+0.0097)
(3.3465) - 0.020 + 0.230 + 0.250
Arm cylinder (-0.0008) (+0.009) (+0.010)
D YN02B01722P1
(Head side) + 0.065 + 0.045
(+0.003) (+0.002)
5-5
(2) Clearance in thrust direction on the boom cylinder installation section
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
5.2 ARM (SK200-8)

5.2.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
SECTION Y-Y SECTION Z-Z
Fig. 5-4 ARM DIMENSIONAL DRAWING
YN12B00904F1 (ASIA) Unit : mm (ft-in)

2.94 m (9 ft-8in) ARM
YN12B00802F1 (OCE)
Code NAME DIMENSION Code NAME DIMENSION
C Arm length 2,940 (9'8") N Bracket inner width 126 (4.96")
Distance between pins of boss
D R874 (34.4") O Bracket inner width 111 (4.37")
and bracket
D1 I.D of boss ø110 (4.33") P Idler link dimension 630 (24.8")
D2 I.D of boss ø85 (3.35") Q Bucket link dimension 610 (24")
Height between pins of boss and
D4 I.D of boss ø105 (4.13") R 31 (1.22")
center
E R2,169 (7'1") d1 Pin dia. ø80 (3.15")
and bracket
F R420 (16.5") d2 Pin dia. ø70 (2.76")
and boss
G 665.5 (26.2") d3 Pin dia. ø85 (3.35")
bracket
H 312 (12.3") d4 Pin dia. ø90 (3.54")
bracket
K Arm top end boss width 325 (12.8") d5 Pin dia. ø80 (3.15")
L Arm link section boss width 323 (12.7")
M Boss width 342 (13.5")
5-7
5.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing
E F
D, D'
B
C
G
Fig. 5-5 Clearance of pin and bushing on arm section
ASIA Unit : mm (in)

Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.253 +0.333
(+0.0100) (+0.0131)
A Arm point
–0.020 +0.080 +0.100
ø80 (-0.0008) (+0.0031) (+0.0039)
YN12B02407P1
(3.1496) –0.080 +0.284 +0.364
Bucket link (-0.0031) (+0.0112) (+0.0143)
B
(Bucket side) +0.156 +0.176
(+0.0061) (+0.0069)
+0.253 +0.313
Idler link
ø70 (+0.0100) (+0.0123)
C (Connected part YN12B02408P1
(2.7559) +0.194 +0.194
of arm) (+0.0076) (+0.0076)
0 +0.232 +0.292
Bucket link (0) (+0.009) (+0.0115)
D
(Idler link side) –0.060 +0.161 +0.161
(+0.0063) (+0.0063) Replace
(-0.0024) 2.0 2.5
YN12B02412P1 bushing
+0.338 (0.08) (0.01)
Bucket cylinder ø80 (+0.0133) or pin
D'
(Rod side) (3.1496) +0.278 +0.141
(+0.0109) (+0.0056)
+0.141 +0.308
Bucket cylinder (+0.0056) (+0.0121)
E YN12B02413P1
(Head side) +0.030 +0.111
(+0.0012) (+0.0044)
–0.030 +0.252 +0.282
Arm cylinder ø85 (-0.0012) (+0.0099) (+0.0111)
F YN02B01839P1
(Rod side) (3.3465) +0.079 +0.049
(+0.0031) (+0.0019)
+0.020 +0.292 +0.312
Arm foot
ø90 (+0.0008) (+0.0115) (+0.0123)
G (Connected part YN12B02415P1
(3.5433) –0.020 +0.195 +0.175
of boom)
(-0.0008) (+0.0077) (+0.0069)
5-8

Pin dia.
+0.253 +0.313
(+0.0100) (+0.0123)
A Arm point
–0.020 +0.080 +0.100
ø80 (-0.0008) (+0.0031) (+0.0039)
YN12B02215P1
(3.1496) –0.060 +0.220 +0.280
Bucket link (-0.0024) (+0.009) (+0.0110)
B
(Bucket side) +0.076 +0.096
(+0.0030) (+0.0038)
+0.285 +0.325
Idler link
ø70 (+0.0112) (+0.0128)
C (Connected part YN12B02216P1
(2.7559) +0.128 +0.128
of arm) (+0.0050) (+0.0050)
0 +0.225 +0.265
Bucket link (0) (+0.009) (+0.0100)
D
(Idler link side) –0.040 +0.043 +0.043
Replace
(-0.0016) (+0.002) (+0.0020) 2.0 2.5
YN12B02217P1 bushing
+0.285 (0.08) (0.01)
or pin
Bucket cylinder ø80 (+0.0110)
D'
(Rod side) (3.1496) +0.245 +0.089
(+0.010) (+0.0040)
+0.089 +0.265
E YN12B02218P1
(Head side) +0.069
(+0.0030)
+0.020 +0.230 +0.250
Arm cylinder ø85 (+0.0008) (+0.009) (+0.0100)
F YN02B01722P1
(Rod side) (3.3465) –0.020 +0.065 +0.045
(-0.0008) (+0.003) (+0.0020)
+0.214 +0.234
Arm foot
ø90 (+0.008) (+0.0090)
G (Connected part LC12B02094P1
(3.5433) +0.067 +0.047
of boom)
(+0.003) (+0.0020)
5-9
(2) Clearance of arm and cylinder installing sections in thrust direction
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X L3 PL5
X L6
X L5
PL1 PL3 PL6

SECTION A-A SECTION C-C SECTION E-E SECTION F-F
PL7
X2 L2 X7 L7
X L4
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
Unit : mm (in)
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
5.3 BUCKET (SK200-8)

5.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
Fig. 5-7 Bucket dimensional drawing
No. NAME No. NAME

A Distance between pin and bracket G Inner width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug Io Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.
5.3.2 BUCKET DIMENSIONAL TABLE
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
5.3.3 LUG SECTION DIMENSIONAL DRAWING
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
Fig. 5-8 Dimension of lug section
Unit : mm (ft-in)
Lug plate thickness
Screw hole P.C.D

Boss outer dia.
Boss outer dia.

Spring pin dia.
Pin hole dia.
Boss width.
Boss width.
Screw dia.
Capacity of
Hole dia.
Type of Part No. of

bucket
bucket bucket
m3 (cu.yd)
A B D E F G H J M N
[SE. Asia STD]

0.80 (1.05) YN61B00272F1
[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
5.3.4 BOSS SECTION DIMENSIONAL DRAWING
H 5
(0.197")
oG
oC
oD
oA
oB
15 (0.591")
Fig. 5-9 Dimension of boss section
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
5.4 LOWER PARTS (SK200-8)

5.4.1 CRAWLER (SK200-8)
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
YN60D00054F2 Shoe assy

YN60D00055F2
YN60D00054F5 YN60D00055F4
YN60D00054F6 YN60D00055F5
No. NAME Q'TY No. NAME Q'TY
1 .LINK ASSY YN62D00017F1 1 1 1 1 .LINK ASSY YN62D00017F3 1 1 1
1-1 ..TRACK LINK R 46 46 46 1-1 ..TRACK LINK R 49 49 49
1-2 ..TRACK LINK L 46 46 46 1-2 ..TRACK LINK L 49 49 49
1-3 ..BUSHING 45 45 45 1-3 ..BUSHING 48 48 48
1-4 ..PIN 45 45 45 1-4 ..PIN 48 48 48
1-5 ..MASTER BUSHING 1 1 1 1-5 ..MASTER BUSHING 1 1 1
1-6 ..MASTER PIN 1 1 1 1-6 ..MASTER PIN 1 1 1
1-7 ..COLLAR 2 2 2 1-7 ..COLLAR 2 2 2
1-8 ..SEAL 90 90 90 1-8 ..SEAL 96 96 96
2 .SHOE 600mm 46 - - 2 .SHOE 600mm 49 - -
.SHOE 700mm - 46 - .SHOE 700mm - 49 -
.SHOE 800mm - - 46 .SHOE 800mm - - 49
3 .BOLT 2420Z1292 184 184 184 3 .BOLT 2420Z1292 196 196 196
4 .NUT 2420Z1293 184 184 184 4 .NUT 2420Z1293 196 196 196
5-15
5.4.2 UPPER ROLLER (SK200-8)
5.4.2.1 UPPER ROLLER ASSY
UPPER ROLLER ASSY No. YN64D00032F1

ITEM NAME Q’TY REMARKS
1 ROLLER ASSY 4 YN64D01068F1
2 CAPSCREW (SEMS SCREW) 4 M20×P2.5×100
3 NUT 4
4 WASHER 4
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
Fig. 5-11 Removing upper roller
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
(2) Installing upper roller (1)

1) To install the upper roller, turn up socket bolts (2)
toward the center of machine.
2) Insert it until collar comes in contact with support.
3) Fit it directing the countersinking mark of shaft

CENTER OF MACHINE
end upward.
4) Apply Loctite #262 on capscrew M20×100, and

tighten it to the specified torque.
: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
2 1 3,4
Fig. 5-12 Installing upper roller
5-16
5.4.2.4 MAINTENANCE STANDARD
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
5.4.3 LOWER ROLLER (SK200-8)
5.4.3.1 LOWER ROLLER ASSY
B5 Apply Loctite #262

T=397N.m (290 lbf.ft)

!
!

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) 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.

(2) Removing track guide

Remove capscrews (B5) and remove track guide Fig. 5-14 Preparation for removal
(B2).
: 27mm,
Weight of track guide : Approx. 25 kg (55 lbs)
ROLLER
SK200-8 STD YN01F00035F1

LOW
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
(3) Remove lower roller

Remove capscrews (2) and remove lower roller (1). B2,B5
LC
: 27 mm, Fig. 5-15 Installing track guide
Weight of lower roller : Approx. 33 kg (73 lbs)
Fig. 5-16 Installing lower roller
5-18
+ +
*
-
)
0
Fig. 5-17 Lower roller (Track roller)
Unit : mm (in)
REPAIRABLE SERVICE LIM-
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
5.4.4 IDLER ASSY (SK200-8)

"
!

%
!
"
!
&

" $
#
"
!#
" "$
Fig. 5-18 Idler assy
160(6.30)
C
F
D
E
B
A
Fig. 5-19 Front idler
Unit : mm (in)
REPAIRABLE SERVICE
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)
Idler rotation Rotates smoothly by hand Reassemble
5-20
5.4.5 IDLER ADJUSTER ASSY (SK200-8)

" ! % # ' & $

"

"

# #
#
#$

"$
Fig. 5-20 Idler adjuster assy
$%
! $
#
"$&
No. ITEM STANDARD VALUE

A Installed length of spring 429 mm (16.9 in)
B Free length of spring Approx. 540.1 mm (21.3 in)
C Stroke 51.8 mm (2.04 in)
D Set length 716 mm (28.2 in)
E Outside view of piston Nor scoring and rusting
F 59 N•m (43 lbf•ft)
grease nipple
X
E
C
A, B F
X D Y
INSTALL A SPRING WHOSE STARTING POINT AT BRACKET SIDE TO BE 35 DEGREE.
BRACKET
DETAIL Y
SECTION XX
Fig. 5-21
5-21
5.4.6 SPROCKET (SK200-8)
5.4.6.1 MAINTENANCE STANDARD (YN51D01003P1)
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.
C O.D. of sprocket bottom ø 586 (23.1) ø 578 (22.8) ø 576 (22.7)
pair or replace.
5-22

(RELEVANT UPPER FRAME) (SK200-8)
5.5.1 OPERATOR SEAT (SK200-8, SK330-8)
5.5.1.1 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).
Fig. 5-23 Disassembling and Assembling seat
Install it in reverse procedure of removing according to
the tightening torque table.
A4
A5

A2

# & $%

$% '#($ &' A6

!"# $& )(# %($
A1
Reference : Movement on rail

A3
Upper rail …… Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm (0.26in)]
A5
Lower rail …… Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm (0.19in)]
Amount of adjustment of seat height
[Up; 23mm (0.07in), down; 37mm (0.16in)] Fig. 5-24 Disassembling and Assembling armrest
5-23
5.5.2 CAB (SK200-8, SK330-8)
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
RELAY BOX
ASSY
Fig. 5-27 Move switch cover assy

(7) Remove cab attaching bolt
1) 5 capscrews (A1) M12×65 and 1 capscrew (A3)
M12×30. (Mark ) B4
2) 2 nuts (B4) M16 (Mark )

(8) Slinging cab
1) Remove two plastic plugs at the front of the ceil-
ing of the cab. Then place a wire sling with eye A3
rings and a hook around the cab, as shown in
Fig. 5-29.
A1
2) Then lift up slowly avoiding interference with sur-
roundings.
Fig. 5-28 Removing and installing cab mounting
Wire with hook ;
bolts.
Length 1.5 m (4ft-11in)×Dia. 8 mm (0.315 in)×3
pcs.
Weight of cab ; Approx. 250 kg (550 lbs)
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)
Fig. 5-29 Slinging cab
5-25
5.5.3 BATTERY (SK200-8)
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.
(2) Remove battery cover (1) and (2)

Loosen nut (7) M10 and remove battery cover (1)
and (2).
But only Asia specification equips cover (1).
: 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
Follow the battery removal order.

Start removing battery from grounding side, and finish
attaching to grounding side. If this order is missed,
short-circuits may occur.
(4) Remove battery (B1)

A2
1) Loosen 2 capscrews (4) M10×235. A4
A3
: 17 mm
3
2) Remove plate (3). 4
3) Remove battery (B1). B1
Fig. 5-31 Removing and installing battery
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
5.5.4 GUARD (SK200-8)

(1) Remove guard in the following procedure. 7
Remove the guards in the order of 2
6
(11)→(5)→(6)→(7)→(2)→(21)→(23)→(3)→(4)→ 1
22
(22) and (1). 5
(2) All the locked cover, open them using starter key.
11
23
4
21
Fig. 5-32 Arrangement of guard assy
5.5.4.2 REMOVE GUARD

(1) Remove bonnet assy (11) 2
3
1) Unlock catches (2) and unlatch catches (2), (3), 11
and open bonnet (11).
2) Remove four nuts (7) M12.
3) Remove bonnet (11).
: 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
Fig. 5-34 Removing guard (5)
5-27
(3) Remove guard (6) and guard assy (3).

41a
1) Remove 4 sems bolts (35) M12×25. 35
2) Remove a sems bolt (41a) M12×25. 6
35
3) Remove guard (6).
4) Remove a sems bolt(41b) M12×25.
41b
5) Remove guard assy (3).
: 19 mm D
3
(4) Remove stay (7)
1) Remove 2 sems bolts (41) M12×25.
3) Remove stay (7). 41
: 19 mm
43
A
Fig. 5-36 Removing stay (7)
(5) Remove guard (2)
41
2) Remove connector for right side deck light. 2
Deck light
: 19 mm

(6) Remove panel assy (21) 21
1) Unlock panel assy (21).
2) Remove 4 nuts (4) M10.
3) Remove panel assy (21).
: 17 mm 4
Fig. 5-38 Removing panel assy (21)
5-28
(7) Remove panel assy (23)

23
2) Remove panel assy (23). 4
: 17 mm

22
1) Unlock and open panel assembly (22).
: 17 mm

(9) Remove guard assy (16) and guard (14), (15), (17).
41
1) Remove 9 sems bolts (41) M12×25 and a sems 17
41
bolt (6A) M12×30 and guard assy (17), (15), (16),
41
(14) in order. 14 41
16 41
6A
: 19 mm 41 41
41
41
15
Fig. 5-41 Removing guard assy (16) and guard (14),

(15), (17).
(10)Remove pillar (11)
C
1) Remove 4 sems bolts (42) M12×30 and remove
pillar. 11
: 19 mm 42
Fig. 5-42 Removing pillar (11)
5-29
(11)Remove beam (4)

41
1) Loosen 6 sems bolts (41) M12×25.
2) Remove beam (4).
: 19 mm
Weight : 8 kg (18 lbs) 4
10
12
Fig. 5-43 Removing and installing of beam (4)

(12)Remove pillar (10), (12)
Remove battery relay box in advance and remove
pillar (10). (See Chapter 23) 10

2) Loosen 2 sems bolts (43) M12×40. 12
3) Loosen a sems bolt (51) M12×35.
42
: 19 mm 51
43
4) Remove pillar (10), (12).
Weight : Pillar (10) : 12 kg (26 lbs)
Fig. 5-44 Removing and installing of pillar (10),(12)

(13)Remove guard assy (18) and (13) 41
1) Loosen 4 capscrews (33) M12×20, and remove 19
guard assy (18).
2) Loosen 2 sems bolts (42) M12×20, and remove 18
guard assy (13). 13
E
33
: 19 mm
33
(14)Remove guard (19)

Loosen 6 sems bolts (41) M12×25, and remove
E
guard (19). 42
Fig. 5-45 Removing and installing of guard assy

and guard
5-30
(15)Remove cover (2)

1) While air cleaner is removed, loosen hose clamp
3
of engine intake and disconnect the hose.
2) Loosen 6 sems bolts (6) M12×25, and remove
cover (2).
: 19 mm 6
(16)Remove guard assy (1)

guard assy (1).
6
: 19 mm 2
Weight : 20 kg (44 lbs) 1 6
(17)Remove guard assy (3)

6
guard assy (3).
6
: 19 mm
Weight : 15 kg 6
Fig. 5-46 Removing and installing of cover and

guard assy
(18)Remove plate (20)
plate (20).
: 19 mm
Weight : 15 kg (33 lbs) B
41
41
20
41
Fig. 5-47 Removing and installing of plate (20)
5-31
(19)Remove cover assy (1)

1) Unlock the locks and open cover (1-2).
3) Remove cover assy (1).
: 19 mm
Weight : 30 kg
41
1-2
(20)Remove other brackets, as required.
Fig. 5-48 Remove cover assy (1)
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
Unit : N.m (lbf.ft)

Size Capscrew Sems bolt
M8 - 23.5 (17.3)
M10 - 46.1 (34.0)
M12 121 (90) 79.4 (58.6)
5-32
5.5.5 FUEL TANK (SK200-8, SK330-8)

(1) Draining fuel. (See Fig. 5-50)
1) Unlock cap (B2) with a starter key and open it.
2) Loosen valve (A8) under the tank.
3) Draining fuel
Capacity of tank : 367 L (97 gal) … SK200-8
580 L (153 gal) … SK330-8
(2) Remove stay (7) and guard (2). $
"
(See 5.5.4 GUARD (SK200-8))
Remove stay (3) and guard (2). !
(See 5.11.2 GUARD (SK330-8)) %
(3) Remove the connector for level sensor (A4).
Fig. 5-49 Removing fuel hose (7), (24)
(See Fig. 5-50)
(4) Remove fuel hose
1) Loosen clip (16),(23) and draw out hoses (24)
and (7).
2) Put in plugs that match the hose bore.
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).
Record the shim locations.

A3
A1
A8
Fig. 5-50 Removing fuel tank
5-33
Tank attaching bolt (A1) M16 × 40 (SK200-8)
M16 × 45 (SK330-8)
: 24 mm, Apply Loctite #262

If the gap (looseness) between tank mount and frame

exceeds 1 mm (0.04 inch), adjust the gap with shim
(A3) and tighten capscrew (A1) to install the tank.
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
5.6 WEIGHT OF COMPONENTS (SK200-8)

Unit ; kg (lb)
Model
SK200 - 8 SK210LC - 8
Item
Machine complete 20,200 (44,500) 20,600 (45,400)
1. Upper frame assy (Assembly of following :) 9,500 (21,000) ←
1.1 Upper frame 1,770 (3,900) ←
1.2 Counter weight (Semi-weighted) 4,640 (10,230) ←
1.3 Cab 260 (570) ←
1.4 Engine *540 (1,190) ←
1.5 Hydraulic oil tank *150 (330) ←
1.6 Fuel tank *110 (240) ←
1.7 Slewing motor (including reduction unit) *210 (460) ←
1.8 Control valve *230 (510) ←
1.9 Boom cylinder *170 (375) × 2 ←
1.10 Pin (for mounting boom) 70 (150) ←
1.11 Pump *130 (290) ←
1.12 Radiator (including intercooler) *90 (200) ←
2. Lower frame assy (Assembly of following :) 6,730 (14,840) 7,130 (15,720)
2.1 Lower frame 2,260 (4,980) 2,420 (5,340)
2.2 Slewing bearing 250 (550) ←
2.3 Travel motor (including reduction unit) 260 (570) × 2 ←
2.4 Upper roller 20 (44) × 2 ←
2.5 Lower roller 30 (66) × 14 30 (66) × 16
2.6 Front idler 110 (240) × 2 ←
2.7 Idler adjuster 100 (220) × 2 ←
2.8 Sprocket 50 (110) × 2 ←
2.9 Swivel joint *30 (66) ←
2.10 Track link with 600 mm (23.6 in) shoes assy 1,260 (2,780) × 2 1,350 (2,980) × 2
Track link with 700 mm (27.6 in) shoes assy 1,470 (3,240) × 2 1,560 (3,440) × 2
2.10.1 Track link assy 510 (1,120) × 2 540 (1,190) × 2
3. Attachment (Assembly of following / STD :) 3,420 (7,540) ←
{5.65 m (18ft-6in) Boom + 2.94 m (9ft-8in) Arm + 0.80m (1 cu•yd) Bucket}
3
3.1 Bucket assy (STD) 640 (1,410) ←

3.2 STD Arm assy (Assembly of following :) 1,050 (2,315) ←
3.2.1 STD Arm 660 (1,455) ←
3.2.2 Bucket cylinder *140 (310) ←
3.2.3 Idler link 20 (44) × 2 ←
3.2.4 Bucket link 90 (198) ←
3.2.5 Pin (2 pcs. for mounting bucket cylinder / 2 pcs. for mounting bucket) 100 (220) ←
3.3 Boom assy (Assembly of following :) 1,730 (3,815) ←
3.3.1 Boom 1,310 (2,890) ←
3.3.2 Arm cylinder *255 (560) ←
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 80 (180) ←
5-35
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) ←
Marks * show dry weight.
5-36
5.7 BOOM (SK330-8)

5.7.1 BOOM DIMENSIONAL DRAWING
d4
J
I
d3 K
d1
D C
H G B
E
F
K
A
J
d2
SECTION K-K
Fig. 5-51 Boom dimensional drawing
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
5.7.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section ASIA, OCEANIA
A
C
Fig. 5-52 Clearance of pin and bushing on boom section
ASIA Unit : mm (in)

tolerance level
+ 0.020 + 0.226 + 0.246
ø 110 (+0.0008) (+0.0089) (+0.0097)
A Boom foot LC02B01373P1
(4.331) - 0.020 + 0.098 + 0.078
(-0.0008) (+0.0039) (+0.0031)
+ 0.222 + 0.262
0
(+0.087) (0.0103)
B LC02B01344P1
(Head side) (3.937) + 0.105 + 0.0105 More
(-0.0016) Replace
(+0.0041) (+0.0041) than 3.0
bushing
+ 0.020 + 0.230 + 0.250 2.5 (0.12)
or pin
Boom cylinder (+0.0008) (+0.0091) (+0.0098) (0.10)
C LC02B01345P1
(Rod side) - 0.020 + 0.105 + 0.085
ø 110 (-0.0008) (+0.0041) (+0.0033)
(4.331) + 0.030 + 0.250 + 0.280
Arm cylinder (+0.0012) (+0.0098) (+0.0110)
D LC02B01444P1
(Head side) - 0.030 + 0.050 + 0.020
(-0.0012) (+0.0020) (+0.0008)
5-38

tolerance level
+ 0.020 + 0.226 + 0.246
ø 110 (+0.0008) (+0.0089) (+0.0097)
A Boom foot LC02B01373P1
(4.331) - 0.020 + 0.098 + 0.078
(-0.0008) (+0.0039) (+0.0031)
+ 0.222 + 0.262
0
(+0.087) (0.0103)
B LC02B01344P1
(Head side) (3.937) + 0.105 + 0.0105 More
(-0.0016) Replace
(+0.0041) (+0.0041) than 3.0
bushing
+ 0.230 + 0.250 2.5 (0.12)
or pin
Boom cylinder (+0.0091) (+0.0098) (0.10)
C LC02B01345P1
(Rod side) + 0.020 + 0.105 + 0.085
ø 110 (+0.0008) (+0.0041) (+0.0033)
(4.331) - 0.020 + 0.226 + 0.246
Arm cylinder (-0.0008) (+0.0089) (+0.0097)
D LC02B01337P1
(Head side) + 0.098 + 0.078
(+0.0039) (+0.00031)
5-39
(2) Clearance in thrust direction on the boom cylinder installation section
D
D C
A
L3 L3' X3
B A
PL3
X1 L1
SECTION C-C
X4
L4 PL4
PL2 PL2
PL1
SECTION D-D SECTION A-A
X2 L2 L2 X2
SECTION B-B
Fig. 5-53 Clearance in thrust direction on the boom cylinder installation section
Unit : mm (in)
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
5.8 ARM (SK330-8)

5.8.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
SECTION Y-Y SECTION Z-Z
Fig. 5-54 ARM DIMENSIONAL DRAWING
3.30 m (10ft-10in) LC12B00457F1 (ASIA)

ARM LC12B00383F1 (OCE) Unit : mm (ft-in)
Code NAME DIMENSION Code NAME DIMENSION
C Arm length 3,300 (10'10") N Bracket inner width 146 (5.75")
D R1,010 (3'4") O Bracket inner width 136 (5.35")
and bracket
D1 I.D of boss ø120 (4.72") P Idler link dimension 696 (27.4")
D2 I.D of boss ø95 (3.74") Q Bucket link dimension 686 (27.0")
D4 I.D of boss ø125 (4.92") R 44 (1.73")
center
E R2,429.5 (7'12") d1 Pin dia. ø90 (3.54")
and bracket
F R515 (20.3") d2 Pin dia. ø80 (3.15")
and boss
G 735.5 (29.0") d3 Pin dia. ø110 (4.38")
bracket
H 280 (11.0") d4 Pin dia. ø110 (4.33")
bracket
K Arm top end boss width 368 (14.5") d5 Pin dia. ø90 (3.54")
L Arm link section boss width 390 (15.4")
M Boss width 400 (15.75")
5-41
5.8.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing ASIA, OCEANIA
E F
D, D'
B
C
G
Fig. 5-55 Clearance of pin and bushing on arm section
ASIA Unit : mm (in)

Pin dia.
+0.272 +0.332
(+0.0107) (+0.0131)
A Arm point
–0.020 +0.095 +0.115
ø90 (-0.0008) (+0.0037) (+0.0045)
LC12B01783P1
(3.5433) –0.060 +0.298 +0.358
Bucket link (-0.0024) (+0.0117) (+0.0141)
B
(Bucket side) +0.168 +0.188
(+0.0066) (+0.0074)
0 +0.229 +0.269
Idler link
ø80 (0) (+0.0090) (+0.0106)
C (Connected part LC12B01784P1
(3.1496) –0.040 +0.158 +0.158
of arm) (+0.0062) (+0.0062)
(-0.0016)
+0.299 +0.359
Bucket link (+0.0118) (+0.0141) Replace
D 2.5 3.0
(Idler link side) 0 +0.170 +0.170 bushing
(0.10) (0.01)
(0) (+0.0067) (+0.0067) or pin
LC12B01789P1
ø90 –0.060 +0.310
Bucket cylinder (3.5433) (-0.0024) (+0.0122)
D'
(Rod side) +0.250 +0.050
(+0.0098) (+0.0020)
Bucket cylinder +0.030 +0.050 +0.280
E LC12B01790P1
(Head side) (+0.0012) (+0.002) (+0.0110)
Arm cylinder –0.030 +0.020
F LC02B01444P1 (+0.0008)
(Rod side) (-0.0012)
ø110 +0.020 +0.288 +0.308
Arm foot
(4.331) (+0.0008) (+0.0113) (+0.0121)
–0.020 +0.190 +0.170
of boom)
(-0.0008) (+0.0075) (+0.0067)
5-42

Pin dia.
+0.272 +0.332
(+0.0107) (+0.0131)
A Arm point
–0.020 +0.095 +0.115
ø90 (-0.0008) (+0.0037) (+0.0045)
LC12B01657P1
(3.5433) –0.060 +0.217 +0.277
Bucket link (-0.0024) (+0.0085) (+0.0109)
B
(Bucket side) +0.071 +0.091
(+0.0028) (+0.0036)
+0.222 +0.262
Idler link
ø80 (+0.0087) (+0.0103)
C (Connected part LC12B01613P1
(3.1496) +0.079 +0.079
of arm) (+0.0031) (+0.0031)
0 +0.219 +0.259
Bucket link (0) (+0.0086) (+0.0102)
D
(Idler link side) –0.040 +0.034 +0.034
Replace
(-0.0016) (+0.0013) (+0.0013) 2.5 3.0
LC12B01614P1 bushing
+0.235 +0.275 (0.10) (0.01)
or pin
Bucket cylinder ø90 (+0.0093) (+0.0108)
D'
(Rod side) (3.5433) +0.074 +0.074
(+0.0029) (+0.0029)
+0.238 +0.258
E LC12B01461P1
(Head side) +0.077 +0.057
(+0.0030) (+0.0022)
+0.020 +0.226 +0.246
Arm cylinder (+0.0008) (+0.0089) (+0.0097)
F LC02B01337P1
(Rod side) –0.020 +0.098 +0.078
ø110 (-0.0008) (+0.0039) (+0.0031)
(4.331) +0.200 +0.220
Arm foot
(+0.0079) (+0.0087)
+0.099 +0.079
of boom)
(+0.0039) (+0.0031)
5-43
(2) Clearance of arm and cylinder installing sections in thrust direction
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
L3
L1 X3
X1
X5
L5 PL5
X6 L6
PL1
SECTION E-E
PL3
SECTION A-A
SECTION C-C
L2 X4 L4
X2
PL6
SECTION F-F
PL2 X7 L7
X4' L4'
SECTION B-B PL4 PL7
SECTION D-D,D'-D' SECTION G-G
Fig. 5-56 Clearance of arm and cylinder installing sections in thrust direction
5-44
Unit : mm (in)
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
5.9 BUCKET (SK330-8)

5.9.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket

Fig. 5-57 Bucket dimensional drawing
No. NAME No. NAME

A Distance between pin and bracket G Outer width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug Io Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.
5.9.2 BUCKET DIMENSIONAL TABLE
Unit : mm (ft-in)
Type GD bucket (General Duty)
[STD]
1.20 m3 1.60 m3 1.80 m3
Capacity 1.40 m3
(1.57 cu•yd) (2.09 cu•yd) (2.35 cu•yd)
(1.83 cu•yd)
Part No. LC61B00115F1 LC61B00052F1 LC61B00118F1 LC61B00057F1
A R517 (20.4") ← ← ←
B R1,690 (5'7") ← ← ←
C 1,238 (4'1") 1,060 (3'6") 1,388 (4'7") 1,620 (5'4")
D 444 (17.5") ← ← ←
E 382 (15.0") ← ← ←
F 1,415 (4'8") 1,240 (4'1") 1,565 (5'2") 1,683 (5'6")
G 1,122 (3'8") 936 (36.9") 1,272 (4'2") 1,496 (4'11")
H 1,238 (4'1") 1,060 (3'6") 1,388 (4'7") 1,620 (5'4")
I 280.5 (11") 316 (12.4") 318 (12.5") 377 (14.8")
IO 280.5 (11") 315 (12.4") 318 (12.5") 376 (14.8")
d1 ø 105 (4.13") ← ← ←
d2 ø 90 (3.54") ← ← ←
5-46
5.9.3 LUG SECTION DIMENSIONAL DRAWING
LS12B01054P1
28 (1.10")
19
(0.748")
VIEW I
SHIM t=1
(Five shims are installed
at shipping) Insert this pin flush with surface
SECTION AA
Fig. 5-58 Dimension of lug section
Unit : mm (ft-in)
Lug plate thickness
Screw hole P.C.D

Boss outer radius
Plate thickness
Boss outer dia.

Spring pin dia.
Pin hole dia.
Boss width.
Screw dia.
Capacity of
Hole dia.
Type of Part No. of

bucket
bucket bucket
m3 (cu.yd)
A B D E F G H J M N
1.40 (1.83) LC61B00115F1
1.20 (1.57) LC61B00052F1 90 28 105 16 105 19 190 12 150
GD bucket M20
1.60 (2.09) LC61B00118F1 (3.54") (1.10") (4.13") (0.63") (4.13") (0.748") (7.48") (0.472") (5.91")
1.80 (2.35) LC61B00057F1
5-47
5.9.4 BOSS SECTION DIMENSIONAL DRAWING
)
gh
ou
thr
rill
(D
G
Fig. 5-59 Dimension of boss section
Unit : mm (ft-in)
Capacity of
Type of Part No. of Part No.
bucket øA øB E F øG
bucket bucket of boss
m3 (cu•yd)
1.40 (1.83) LC61B00115F1
1.20 (1.57) LC61B00052F1 139.8 103.8 15 40 21
GD bucket LS12B01054P1
1.60 (2.09) LC61B00118F1 (5.50") (4.09") (0.591") (1.58") (0.827")
1.80 (2.35) LC61B00057F1
5-48
5.10 LOWER PARTS (SK330-8)

5.10.1 CRAWLER (SK330-8)
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
5.10.2 UPPER ROLLER (SK330-8)
5.10.2.1 UPPER ROLLER ASSY
Upper roller assy LC64D00003F1

Item Name Q’ty Remarks
1 Roller assy 4 24100N7035F3
2 Capscrew 4 M20×150
3 Washer 8
4 Nut 4
5.10.2.2 REMOVING
(1) Preparation for removal " ! !
Remove crawler (Above mentioned).
(2) Removing upper roller (1)

1) Remove nuts on support tightening section, and
also remove capscrew (2) M20 × 150.
: 30 mm
Fig. 5-61 Removing upper roller
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.
3) Apply Loctite #262 on capscrew M20×150, and

tighten it to the specified torque.
: 30 mm
Fig. 5-62 Installing upper roller
5-50
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
(2.5591) -0.040 — 0.8 (0.0315) Replace bushing.

(-0.0016)
+ 0.030
Interference between roller ø 70 Interference Clearance
Hole
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
5.10.3 LOWER ROLLER (SK330-8)
5.10.3.1 LOWER ROLLER ASSY

" 1
! # 2 Apply loctite #262
T=731N.m (540 lbf.ft)
Fig. 5-63 Lower roller assy
5.10.3.2 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
Fig. 5-65 Installing track guide
(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
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.
: 19 mm, Tightening torque : 59 N•m (43 lbf•ft)
5-52
C C
G
A
E
B
Fig. 5-66 Lower roller (Track roller)
Unit : mm (in)
Repairable lev-
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
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
5.10.4 IDLER ASSY (SK330-8)

8

6

'
2

' 7
5
!
3 I
"# $%&
'$%
4 VIEW I
$%& 1
()$%& * +
'#& ',-
Fig. 5-67 Idler assy
204 (8.03")
C
F
E
D
A
B
Fig. 5-68 Front idler
Unit : mm (in)
Repairable
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
Unit : mm (in)
Repairable
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
5.10.5 IDLER ADJUSTER ASSY (SK330-8)

3 4 5 10 2 1 6 7 8
! "#

$ ()*
%$ +,)*-
$ (

$

$ +,)*- ,)* 9
$ .)
Fig. 5-69 Idler adjuster assy
&$ ./)*-
' ) *
)* %

No. Item Standard value

A Installed length of spring 554 mm (21.8 in)
About. 685 mm
B Free length of spring
(27.0 in)
C Stroke 53 mm (2.09 in)
D Set length 797 mm (31.4 in)
Nor scoring and
E Outside view of piston
rusting
F 59 N•m (43 lbf•ft)
grease nipple
C F
A, B
D
5-56
5.10.6 SPROCKET (SK330-8)
5.10.6.1 MAINTENANCE STANDARD (LC51D01008P1)
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
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.
C O.D. of sprocket bottom ø 664.05 (26.1) ø 656 (25.8) ø 654 (25.7)
pair or replace.
5-57

(RELEVANT UPPER FRAME) (SK330-8)
5.11.1 BATTERY (SK330-8)
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.
(2) Remove battery cover (A2)

Loosen nut (A7) M10 and remove battery cover
(A2).
: 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
Follow the battery removal order.

Start removing battery from grounding side, and finish +!
attaching to grounding side. If this order is missed,
short-circuits may occur.
Fig. 5-72 Removing and installing battery cable
5-58
(4) Remove battery (B1)

A7
1) Loosen 2 capscrews (A4) M10×235. A2
: 17 mm
2) Remove plate (A3).
3) Remove battery (B1).
A4
A3
B1
Fig. 5-73 Removing and installing battery
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
5.11.2 GUARD (SK330-8)

(1) Remove guard in the following procedure. 3
1 2
Remove the guards in the order of
(11)→(7)→(8)→(5)→(3)→(2)→(21)→(23)→(22)→ 8
7
(6) and (1). 22
(2) All the locked cover, open them using starter key.
5 11
23
6
21
Fig. 5-74 Arrangement of guard assy
5.11.2.2 REMOVE GUARD

(1) Remove bonnet assy (11)

1) Unlock catches (2) and unlatch catches (2), (3),
and open bonnet (11). !
2) Remove four nuts (7) M12.

3) Remove bonnet (11).
: 19 mm
%
Fig. 5-75 Removing bonnet assy (11)
(2) Remove guard (7) %
1) Remove 3 sems bolts (38) M12×25 on upper !&
side. !'
2) Remove 4 sems bolts (39) M12×25 on the side.

!'
3) Remove guard (7)
: 19 mm
5-60
(3) Remove guard (8) and guard assy (5).

!"
&
2) Remove a sems bolt (39) M12×30.
3) Remove guard (8). #
!'
4) Remove 6 sems bolts (39) M12×30. !'
5) Remove guard assy (5). !"
!" !'
: 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)
3) Remove stay (3).
38
: 19 mm
Weight : 8.6 kg (19 lbs)
40
Fig. 5-78 Removing stay (3)

(5) Remove guard (2)
39
2) Remove connector for right side deck light. 2
Deck light
: 19 mm

(6) Remove panel assy (21) 21
1) Unlock panel assy (21).
: 17 mm 4
5-61

"
: 17 mm
!
22
1) Unlock and open panel assembly (22).
: 17 mm

(9) Remove guard assy (17) and guard (15), (16).
1) Remove 7 sems bolts (38) M12×25 and guard
assy (15), (17), (16) in order.
#
: 19 mm
Weight : !&
guard (15) : 6.5 kg (14 lbs)
guard (16) : 3.5 kg (7.7 lbs)
guard assy (17) : 2 kg (4.4 lbs)
%
$
!&
!&
Fig. 5-83 Removing guard assy (17) and guard (15),

(16).
5-62
(10)Remove beam (11), pillar (10), panel (4) "

!'
beam (11).
3) Remove panel (4), pillar (10) in order.
: 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

5
beam (6). 5

6
: 19 mm
3) Remove pillar (9), (12).
Weight :
pillar (9) : 13 kg (29 lbs)
pillar (12) : 5 kg (11 lbs)
beam (9) : 19 kg (42 lbs) 13
12
38
39
39
39
Fig. 5-85 Removing and installing of beam (6), pillar

(9),(12)
(12)Remove plate (49), guard assy (13)
!'
2) Remove plate (49).
: 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)
: 19 mm
5) Remove guard assy (13)
5-63
(13)Remove guard assy (1) and (2)

#
1) While air cleaner is removed, loosen hose clamp
of engine intake and disconnect the hose.
3) Remove guard assy (2),(1) in order.
: 19 mm
Weight :
guard assy (1) : 20 kg (44 lbs) 5
Fig. 5-87 Removing and installing of guard assy

(1),(2)
(14)Remove guard assy (4), guard (3) 5
1) Loosen 7 sems bolts (5) M12×30. "
: 19 mm
3
2) Remove guard assy (4), guard (3)
Weight :
guard (3) : 11 kg (24 lbs)
Fig. 5-88 Removing and installing of guard assy (4)

and guard (3)
(15)Remove plate (18)
39
plate (18).
39
: 19 mm
Weight : 2.9 kg (6.4 lbs)
18
39
Fig. 5-89 Removing and installing of plate (18)
5-64
(16)Remove cover assy (1)

1) Unlock the locks and open cover (1-2).
3) Remove cover assy (1).
: 19 mm
Weight : 30 kg
39
1-2
(17)Remove other brackets, as required.
Fig. 5-90 Remove cover assy (1)
Unit : N.m (lbf.ft)

Size Nut Sems bolt
M8 - 23.5 (17.3)
M10 46.1 (34.0) 46.1 (34.0)
M12 - 79.4 (58.6)
5-65
5.12 WEIGHT OF COMPONENTS (SK330-8)

Unit ; kg (lb)
Model
SK330 - 8 SK350LC - 8
Item
Machine complete 33,800 (74,500) 34,600 (76,300)
1. Upper frame assy (Assembly of following :) 15,800 (34,840) ←
1.1 Upper frame 2,950 (6,500) ←
1.2 Counter weight
Counter weight (Semi-weighted) 8,130 (17,920) ←
Counter weight (weighted) 9,700 (21,380) ←
1.3 Cab 235 (520) ←
1.4 Engine *699 (1,540) ←
1.5 Hydraulic oil tank *189 (420) ←
1.6 Fuel tank *199 (440) ←
1.7 Slewing motor (including reduction unit) *456 (1,000) ←
1.8 Control valve *231 (510) ←
1.9 Boom cylinder *266 (590) × 2 ←
1.10 Pin (for mounting boom) 83 (180) ←
1.11 Pump *155 (340) ←
1.12 Radiator (including intercooler) *206 (450) ←
2. Lower frame assy (Assembly of following :) 11,300 (24,900) 12,000 (26,460)
2.1 Lower frame 4,070 (8,970) 4,300 (9,480)
2.2 Slewing bearing 545 (1,200) ←
2.3 Travel motor (including reduction unit) 397 (880) × 2 ←
2.4 Upper roller 40 (90) × 2 ←
2.5 Lower roller 57 (125) × 14 57 (125) × 18
2.6 Front idler 176 (390) × 2 ←
2.7 Idler adjuster 186 (410) × 2 ←
2.8 Sprocket 75 (165) × 2 ←
2.9 Swivel joint *24 (50) ←
2.10 Track guide 39 (86) × 2 39 (86) × 6
2.11 Track link with 600 mm (23.6 in) shoes assy 1,870 (4,120) × 2 2,000 (4,410) × 2
2.11.1 Track link assy 840 (1,850) × 2 900 (1,980) × 2
3. Attachment (Assembly of following / STD :) 6,590 (14,530) ←
{6.50 m (21ft-4in) Boom + 3.30 m (10ft-10in) Arm + 1.40 m (1.83 cu•yd)
3
Bucket}
3.1 Bucket assy (STD) 1,080 (2,380) ←
3.2 STD Arm assy (Assembly of following :) 1,900 (4,190) ←
3.2.1 STD Arm 1,250 (2,760) ←
3.2.2 Bucket cylinder *266 (590) ←
3.2.3 Idler link 33 (73) × 2 ←
3.2.4 Bucket link 142 (313) ←
3.2.5 Pin (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
Unit ; kg (lb)
Model
SK330 - 8 SK350LC - 8
Item
4. Lubricant and water (Assembly of following :) 862 (1,900) ←
4.1 Hydraulic oil 310 (684) ←
4.2 Engine oil 28 (62) ←
4.3 Fuel 484 (1,070) ←
4.4 Water 44 (97) ←
Marks * show dry weight.
5-67
[MEMO]
5-68
6-1
6-2
6.1 CHECK-UP & MAINTENANCE

6.1.1 EVERYDAY CHECK-UP
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.
1. Check the engine for any oil, fuel or coolant leakage.

Repair as required.
2. Check the area around the engine and radiator for any accumulated material and remove as required.
3. Check the hydraulic equipment, hydraulic oil tank, hoses, and joints for oil leakage, and repair as required.
4. Check the travel system, such as the crawler, idlers, and sprockets, for any damage or wear, and the bolts for
looseness.
5. Check the attachments, cylinders, linkages and hoses for any cracks, wear or looseness and repair as required.
6. Check the door, cover, steps and handrails for damage, and the bolts for looseness. Repair and tighten bolts as
required.
7. Verify that the gauges and the monitor panel (gauge cluster) function properly.
8. Check rear view mirror for abnormality, and if abnormality is found, repair it.
Clean the surface of mirror and adjust the angle so that the rear sight is visible from the operator seat.
9. Check seat belt and attaching metal for possible damage and if damaged, replace it with new one.
6-3
6.1.2 CHECKING BEFORE STARTING ENGINE

The following checkup should be performed once before the first engine startup in a day.
A. Checking Coolant Level for Shortage and Making Up
• Do not open radiator cap if not required.

Check coolant level of the reserve tank (1) when LOW ENG WATER
LEVEL
engine is cooled down.
• Never remove radiator cap when engine is hot. S
Allow engine to cool down before removing radi-
ator cap.
The coolant level check switch is provided on the upper

part of radiator upper tank.
When the engine is running and the engine switch is on,
if warning is displayed on the multi-display, loosen the
radiator cap and supply coolant to the neck of radiator.
(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
B. Checking Oil Level of Engine Oil Pan and Making Up
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
• Make sure the machine is on firm level when

checking engine oil level.
• Always make sure to check engine oil level be-
fore starting the engine.
• Keep the engine to standstill for at least 30 min-
H
utes, when checking engine oil level after work-
ing.
L
(1) Release catch of bonnet, open engine hood on
the rear side of machine and lock it with stay.
(2) Pull out oil level gauge (G) and wipe oil with a
clean cloth.
(3) Insert oil level gauge (G) in oil pan fully.
(4) When the level is in the range of H – L of oil level
gauge (G) it is proper. If the level is insufficient
for L level, make up engine oil for the shortage
through oil filler cap (F).
change it ahead of schedule without depending
on the periodic change interval.
For oil in use, refer to 6.2, 6.3.
(5) When the oil level is H level or higher, drains ex-
cess engine oil through drain valve (P) and
check the oil level again.
(6) If the oil level is proper, insert level gauge (G)
securely, close engine hood and lock it with bon-
net catch.
6-5
C. Checking Fuel Level and Making Up
• Use diesel fuel only and stop engine before refill-

ing.
• Do not overflow fuel while refilling. It may cause
1
damage to the fuel system and cause oil spout-
ing. Clean up all spilled fuel to prevent fire.
• Dispose of all hazardous waste in accordance
with government environmental laws and regula-
tions.
• It is possible to operate machine for 2 days (8 hours

a day) in general use when the tank is full. Be sure to
fill it up to the brim after the work in 2nd day was fin-
ished. But do not supply with fuel to the level more
than necessary (to the top end of tank). There is a
possibility of overflowing because the fuel expands
as the outside air temperature rises.
• Use specified diesel oil for fuel.
This engine is equipped with electronic control high
pressure fuel injection system to obtain the features
like excellent fuel consumption and emission in clean
condition. This system requires the parts in high pre-
cision and high lubricating ability. Therefore if low
viscosity fuel in low lubricating ability is used, the du-
rability may be notably lowered.
(1) Check fuel level with fuel gauge by turning starter

switch on. The fuel level is low when the fuel gauge
reads close to E point.
(2) Stop engine with starter key, remove filler cap (1) of
fuel tank and make it up with fuel making sure of the
level.
When strainer is fitted to filler port, do not remove
the strainer for making up.
(3) When dirt is adhered on strainer (2), take out the
strainer and clean it with light oil or air gun, and then
fit it to filler port again.
(4) Refer to "6.2 & 6.3" for fuel tank capacity.
(5) After refueling, tighten filler cap (1) securely.
6-6
D. Fuel Filter Drain

Draining water collected in fuel filter the fuel filter is used to separate water contaminated in fuel.
When warning "DRAIN WATER SEPA" is displayed, or water is collected in fuel tank, drain water.
(1) The fuel filter (1) is installed in front of counter-
weight on the right rear side of machine. 4 DRAIN WATER SEPA
(2) Open side door on the right side.
(3) Put container for drain oil under drain hose (2).
(4) Loosen drain plug (3) and air bleed plug (4) and
1
drain water collected in fuel filter (1) in the contain-
er.
(5) After draining, tighten drain plug (3) and air bleed
plug (4) securely. 3
(6) Lock side door on the right side.
2
6-7
E. Check Hydraulic Oil Level
Hydraulic Oil Level Check Position
It is very danger because the inside of hydraulic

tank is heated and pressurized.
When removing filler port plug, stop engine and re-
move breather top end cap (1) and then release
pressure from hydraulic oil tank by pressing the
valve head.
For safe operation on inclines, the hydraulic oil lev-
el must be maintained between "Proper Level" and
"Upper Limit" mark.
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)
Avoid overfilling. It causes damages on hydraulic

equipment or oil spouting.
For make up procedure of hydraulic oil, refer to section

"Change Hydraulic Oil" of OPERATION MANUAL.
6-8
F. Checking Belt Tension
Rotating parts can cause injury.

Keep away from fan and belt when engine is run-
ning.
Stop engine before servicing.
Check the fan and alternator belt for insufficient ten-

sion, wear, and damage.
Insufficient belt tension may cause battery charge fail-
ure, engine overheating, or abnormal belt wear. If too
much tension is applied to the belt, the bearings or belt
may be damaged prematurely.
Apply a force of 98 N {22 lb} to the center of belt be-
tween pulleys, and measure the belt deflection. The ta-
ble below shows normal condition.
SK200-8
Belt Deflection Force

Alternator, Fan 11~14 mm (0.4~0.5") 98 N (22 lb)
Air-conditioner 6~7 mm (0.2~0.3") 28 N (6.3 lb)
SK330-8
Belt Deflection Force

B C
Alternator (A) 14~18 mm (0.6~0.7") 98 N (22 lb)
Fan (B) 8~10 mm (0.3~0.4") 98 N (22 lb)
Air-conditioner (C) 5~7 mm (0.2~0.3") 27 N (6.1 lb)
See the section "250 HOUR (3-MONTH) INSPECTION

& MAINTENANCE PROCEDURE" of OPERATION
MANUAL for details on the inspection and adjustment
procedure for the belt.
6-9
6.2 LUBRICANT, FUEL & COOLANT SPECIFICATIONS (SK200-8)

6.2.1 For Asia
The following chart provides information on the specification of oils, grease, fuels and coolant to be used in various
climates and working conditions.
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
6.2.2 For Oceania

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
(4.8 Gal)
DH-1 [L level] SAE
15 Liters SAE 15W-40
15W-40 SAE 15W-40
(4.0 Gal)
"service GL-4"
Travel motor 5.3 Liter X 2
1.0 kg EP GREASE
unit (Housing)
(KOBELCO BRAND)
2 places EP GREASE
Operating lever
(Pilot valve)
8.6 kg
Swing gear
(19 lbs)
ASTM D-975 No.2
ASTM D-975
(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
(20 L)
Handling method of long life hydraulic oil

When changing and replenishing hydraulic oil, make sure to use oil specified by KOBELCO.
The use of unspecified hydraulic oil or the use of mixed oil causes deterioration of oil resulting in shortening life of oil.
The above hydraulic oil change time is 5,000 hours.
Specified oil :
Maker : Shell
Brands : Shell Tellus Oil S46
Shell Tellus Oil ST32
Be sure to select hydraulic oil adaptable to the ambient temperature.
6-11
6.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS (SK330-8)

6.3.1 For Asia
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
(6.9 Gal)
DH-1 [L level]
(5.3 Gal)
Travel motor 9.5 Liter X 2 "service GL-4"
1.7 kg EP GREASE
unit (Housing)
(KOBELCO BRAND)
2 places EP GREASE
Operating lever
(Pilot valve)
28.7 kg
Swing gear
(63.2 lb)
ASTM D-975 No.2
ASTM D-975
(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
(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
6.3.2 For Oceania

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
(6.9 Gal)
DH-1 [L level]
(5.3 Gal)
"service GL-4"
Travel motor 9.5 Liter X 2
1.7 kg EP GREASE
unit (Housing)
(KOBELCO BRAND)
2 places EP GREASE
Operating lever
(Pilot valve)
28.7 kg
Swing gear
(63.2 lb)
ASTM D-975 No.2
ASTM D-975
(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
(20 L)
Handling method of long life hydraulic oil

When changing and replenishing hydraulic oil, make sure to use oil specified by KOBELCO.
The use of unspecified hydraulic oil or the use of mixed oil causes deterioration of oil resulting in shortening life of oil.
The above hydraulic oil change time is 5,000 hours.
Specified oil :
Maker : Shell
Brands : Shell Tellus Oil S46
Shell Tellus Oil ST32
Be sure to select hydraulic oil adaptable to the ambient temperature.
6-13
6.4 MAINTENANCE PARTS (SK200-8)

6.4.1 For Asia
A. Filters & Elements, and Bucket

Replace parts, such as filters and elements, during the periodical maintenance or before the service life.
The machine can be used economically if the parts are changed properly and timely.
When you place an order of parts, confirm the parts number on parts manual.
Table6-1 Maintenance Parts Table
System Part Number Parts Name Q’ty Replacement Interval
Return filter element kit After 50 hours (first change)
YN52V01008R600 1
(STD. Breaker) Every 1000 hours (from 2nd
change)
Hydraulic oil tank (ZD11G19000) (O-ring) 1 (Breaker specification : Every
250 hours)
YW50V00004F7 Suction strainer 1
Every 2000 hours
(ZD11G19000) (O-ring) 1
After 6 times of cleaning or one
YN11P00029S003 Element (Outer) 1
year whichever comes first
For machines equipped with W
(double) element the inner ele-
Air cleaner
ment must be replaced together
YN11P00029S002 Element (Inner) 1
with the outer element.
Replace the inner element with
new one.
After 50 hours (first change)
Engine oil filter YN30T01001P1 Cartridge 1
Every 250 hours
Fuel filter YN30T01002P1 Cartridge 1 Every 500 hours
Fuel pre-filter YN21P01036S002 Element 1 Every 500 hours
YN50V01015P3 Air-con filter (Outer) 1 Every 10 times cleanings

Air conditioner When heavy clogging of filter oc-
YN50V01014P1 Air-con filter (Inner) 1 curs, clean or replace
Pilot line filter YN50V00020F1 Line filter 1 Every 2000 hours (Cleaning)
2412N289D11 Side cutter 1
ZS13C24070 Bolt 8
Bucket (STD) When required
ZN13C24019 Nut 8
B12N0006E1 Tooth 5
B12N0006E2 Rubber lock pin 5
Items enclosed in parenthesis ( ) are the parts to be

changed at the same time.
6-14
6.4.2 For Oceania

YN52V01008R600 1
change)
250 hours)
YW50V00004F7 Suction strainer 1
Every 2000 hours
(ZD11G19000) (O-ring) 1
YN11P00029S003 Element (Outer) 1
Air cleaner
YN11P00029S002 Element (Inner) 1
new one.
Every 500 hours

ZS13C24070 Bolt 8
ZN13C24019 Nut 8
B12N0006E1 Tooth 5
B12N0006E2 Rubber lock pin 5

6-15
6.5 MAINTENANCE PARTS (SK330-8)

6.5.1 For Asia

LS52V01001R300 1
change)
250 hours)
LC50V00004F1 Suction strainer 1
Every 2000 hours
(ZD11G22000) (O-ring) 1
LC11P00018S003 Element (Outer) 1
Air cleaner
LC11P00018S002 Element (Inner) 1
new one.
Every 250 hours

2412J351D1 Side cutter 1
ZS13C24065 Bolt 10
ZN13C24019 Nut 10
LC69B00001S1 Tooth 5
LC69B00001S2 Rubber lock pin 5

6-16
6.5.2 For Oceania

LS52V01001R300 1
change)
250 hours)
LC50V00004F1 Suction strainer 1
Every 2000 hours
(ZD11G22000) (O-ring) 1
LC11P00018S003 Element (Outer) 1
Air cleaner
LC11P00018S002 Element (Inner) 1
new one.
Every 500 hours

ZS13C24065 Bolt 10
ZN13C24019 Nut 10
LC69B00001S1 Tooth 5
LC69B00001S2 Rubber lock pin 5

6-17
6.6 USE OF BIO-DEGRADABLE OILS

When using Bio-degradable Oil (BIO OIL), refer to the following infomation.
A. Recommended Oil
Maker Mobil
Brand MOBIL EAL Envirosyn 46H
B. Precaution for the Use of Oil

1. When filling the former machine in which mineral oil is charged with BIO oil, try to flush the machine three times.
The mineral oil will be left in the circuit of the machine without flushing, resulting in the reduction of effect of bio-
degradation ability.
2. When you use BIO OIL, slewing and travel parking brake performance will be reduced because of lower friction
factor of BIO OIL compared to that of mineral oil.
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.
D. Bio Oil Change Interval

The BIO oil change interval is 2,000 hours.
6-18
6.7 INSPECTION & MAINTENANCE CHART (For Asia)

Follow the chart below for recommended intervals of regular inspection and maintenance procedures. Perform in-
spection and maintenance according to the calendar time or operation time shown by the hour meter, whichever
comes first.
See the inspection and maintenance procedure mentioned below for details.
Symbols and their meanings :
: Necessary regular inspection item to hour meter

: Only first replacing is performed
: inspection and/or maintenance is needed
LLC : KOBELCO genuine antifreeze/coolant.

System
When Interval (Hours on Hourmeter) Lubricant, etc.

Maintenance to Perform
required (Replacing part)
8H 50H 120H 250H 500H 1,000H 2,000H
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
Change After 6 times of cleaning or one O Outer, inner element

Coolant level and Check level O

cleaning of cooling sys- Change/
O LLC
tem cleaning
Hoses in cooling system O
Cleaning of radiator/oil cooler core/
O
intercooler and fin
Check O
Check belt tensioner *1
Adjust O
(First)
Radiator cap Clean O

Checking for rubber hose of in-
O
take system
Checking of engine mount brack-
O
et for tightening
6-19
System

8H 50H 120H 250H 500H 1,000H 2,000H
*2 Checking and adjustment of valve *1

O
clearance (First)
*2 Checking and adjustment of com-
O
pression pressure
*2 Checking of intake and exhaust *1
O
manifold for tightening (First)
*2 Checking of oil pan and other ac- *1
O
cessories for tightening (First)
*2 Checking of installing turbo charg- *1
O
er for tightening (First)
*2 Checking of turbo charger rotor
O
and impeller for rotating
O
for looseness
*2 Checking of turbo charger for lu-
O O
brication
*2 Checking and cleaning of stator
O
brush and commutator
*2 Checking of oil pan and for intru-
O
sion of water and fuel
Engine
*2 Checking of fan mounting bolt for

O
tightening
*2 Checking of thermostat for func-
O
tion
*2 Checking of starter for function O
*2 Checking of stability, exhaust col-
O
or and noise
*2 Checking of heater plug/intake air
O
heater (Starting aid)
*2 Checking of alternator for function O
*2 Checking of each pipe joint for
O
tightening
*2 Checking of exhaust pipe and
muffler for installation looseness O
and damage
*2 Checking and cleaning of alterna-
O
tor brush (If equipped)
Checking leakage of fuel system O
Checking engine oil leakage O
Check engine electrical O
Contact our dealer/distributor for checking and adjust-

ment shown by asterisk *2.
6-20
System
8H 50H 120H 250H 500H 1,000H 2,000H
Check/fuel level O
Fuel system
Drain water and depos-

Fuel tank O
its
Clean cap and strainer O
Check oil
O
level
Hydraulic
O Hydraulic oil
oil
Change 600H O
Hydraulic
Hydraulic system
(Breaker)
tank Suction
Clean O Strainer
strainer
*1 O
Return filter (Breaker at-
O Element
(First)
tachment)
Check for oil leaks O

Check hoses/lines O
Pilot line filter Clean O
Check oil
O Extreme gear oil
Swing reduction oil lev- level
SAE #90
el & fill *1
Change O GL-4
(First)
Grease slewing ring O EP grease
Check slewing ring & pinion gear O

Upper frame
Change grease in slewing ring

O EP grease
grease bath
Check slewing brake O
Greasing of control lever push rod
O EP grease
and universal joint
Check bolts/torque (Slewing ring) O
*1
Check bolts/torque (Counterweight) O
(First)
Grease swing reduction unit O

Check oil
O Extreme gear oil
Travel reduction unit oil level
SAE #90
level & fill *1
Change O GL-4
(First)
Adjust track tension O

Lower frame

Check lines for damage O
Check steps & handrails O
Check frame structure O
Check tracks & links O
Check sprocket wear O
Check idler wear O
Lower frame
Check roller wear O
Check track tension O
6-21
System

8H 50H 120H 250H 500H 1,000H 2,000H
Grease for pins O EP grease

Attachment
Reversing backhoe bucket O

Bucket clearance O
Check bucket teeth and side cutters O
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 Refrigerant O
Check A/C condenser
Air condi- O
and clean
tioner
Clean O
Filter
Change After 10 times cleaning is done
Accessories
Check wiper washer fluid level O

Check O
O
Seat belt
Change (3
years)
6-22
6.8 INSPECTION & MAINTENANCE CHART (For Oceania)

Follow the chart below for recommended intervals of regular inspection and maintenance procedures. Perform in-
spection and maintenance according to the calendar time or operation time shown by the hour meter, whichever
comes first.
See the inspection and maintenance procedure mentioned below for details.
Symbols and their meanings :
: Necessary regular inspection item to hour meter

: Only first replacing is performed
: inspection and/or maintenance is needed
LLC : KOBELCO genuine antifreeze/coolant.
When
System
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 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
Change After 6 times of cleaning or one O Outer, inner element

Coolant level and Check level O

cleaning of cooling Change/
O LLC
system cleaning
Hoses in cooling system O
Cleaning of radiator/oil cooler core/
O
intercooler and fin
Check O
Check belt tensioner *1
Adjust O
(First)
Radiator cap Clean O

Checking for rubber hose of in-
O
take system
Checking of engine mount
O
bracket for tightening
6-23
When
System

(Replacing part)
quired 8H 50H 120H 250H 500H 1,000H 2,000H 5,000H
*2 Checking and adjustment of *1

O
valve clearance (First)
*2 Checking and adjustment of
O
compression pressure
*2 Checking of intake and exhaust *1
O
manifold for tightening (First)
*2 Checking of oil pan and other ac- *1
O
cessories for tightening (First)
*2 Checking of installing turbo *1
O
charger for tightening (First)
O
and impeller for rotating
O
for looseness
*2 Checking of turbo charger for lu-
O O
brication
*2 Checking and cleaning of stator
O
brush and commutator
*2 Checking of oil pan and for intru-
O
sion of water and fuel
Engine
*2 Checking of fan mounting bolt

O
for tightening
*2 Checking of thermostat for func-
O
tion
*2 Checking of starter for function O
*2 Checking of stability, exhaust
O
color and noise
*2 Checking of heater plug/intake
O
air heater (Starting aid)
*2 Checking of alternator for func-
O
tion
*2 Checking of each pipe joint for
O
tightening
*2 Checking of exhaust pipe and
muffler for installation looseness O
and damage
*2 Checking and cleaning of alter-
O
nator brush (If equipped)
Checking leakage of fuel system O
Checking engine oil leakage O
Check engine electrical O
Contact our dealer/distributor for checking and adjust-

ment shown by asterisk *2.
6-24
System When
(Replacing part)
quired 8H 50H 120H 250H 500H 1,000H 2,000H 5,000H
Check/fuel level O
Fuel system
Drain water and de-

O
Fuel tank posits
Clean cap and strain-
O
er
Check oil
O
level
Hydrau-
O Hydraulic oil
lic oil
Change 1,000H O
(Breaker)
Hydraulic
Hydraulic system
tank Suction
Clean O Strainer
strainer
O
*1
Return filter (Breaker O Element
(First) attach-
ment)

Check hoses/lines O
Pilot line filter Clean O
Check oil
O Extreme gear oil
Swing reduction oil level
SAE #90
level & fill *1
Change O GL-4
(First)
Grease slewing ring O EP grease
Check slewing ring & pinion gear O

Upper frame
Change grease in slewing ring

O EP grease
grease bath
Check slewing brake O
Greasing of control lever push rod
O EP grease
and universal joint
Check bolts/torque (Slewing ring) O
Check bolts/torque (Counter- *1
O
weight) (First)
Grease swing reduction unit O

Check oil
O Extreme gear oil
Travel reduction unit level
SAE #90
oil level & fill *1
Change O GL-4
(First)
Adjust track tension O

Lower frame

Check lines for damage O
Check steps & handrails O
Check tracks & links O
Check sprocket wear O
6-25
When
Lower frame System

(Replacing part)
quired 8H 50H 120H 250H 500H 1,000H 2,000H 5,000H
Check idler wear O

Check roller wear O
Check track tension O

*3
Grease for pins O O O
(50H)
EP grease
*3
Grease bucket pins O O
Attachment
(50H)
Reversing backhoe bucket O
Bucket clearance O
Check bucket teeth and side cut-
O
ters
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 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
6.9 PERFORMANCE INSPECTION STANDARD TABLE (SK200-8)
The mode is already "S" mode when power is thrown.

Unless otherwise specified, measure it on "H" mode.
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
H mode Hi idle 2000 + 30 - 30 Full throttle (HI idle)
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
ATT 34.3 (4970) + 0.7 (+100) - 0.5 (-73) MR1 Boom up

P2 a2
P1 a1
Boost 37.8 (5480) + 1.0 (+145) - 0.5 (-73) MR1
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
High pressure circuit
H 39.7 (5760) 0 - 5.9 (-855) OR3 Boom up

Over load relief valve pressure
R 39.7 (5760) 0 - 5.9 (-855) OR8 Arm out

Main pump
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-580) (psi) OR2 Bucket dump
Bucket a1
H 39.7 (5760) 0 - 5.9 (-855) OR1 Bucket digging
RH 29.0 (4205) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 29.0 (4205) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 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
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
Operating time of cylin- In 3.0 ~ 3.6

Arm sec (At no load)
der Out 2.3 ~ 2.9
Digging 2.2 ~ 2.8
Bucket
Dumping 1.7 ~ 2.3
RH
Swing speed 4.2 ~ 5.4 sec / 1 rev
LH
1st speed Iron shoe 19.5 ~ 21.5
Travel speed sec / 20 m
2nd speed Iron shoe 11.9 ~ 13.1
Amount of travel devia-
2nd speed 0 ~ 240 mm / 20 m
tion
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance
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
6.10 PERFORMANCE INSPECTION STANDARD TABLE (SK330-8)
The mode is already "S" mode when power is thrown.

Unless otherwise specified, measure it on "H" mode.
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)
H mode Lo idle 1000 + 25 - 25 LOW throttle

Measure the engine
Engine speed
H mode Hi idle 2100 + 30 - 70 Full throttle (HI idle)
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
ATT 34.3 (4970) + 0.7 (+100) - 0.5 (-73) MR1 Boom up

P2 a2
P1 a1
Boost 37.8 (5480) + 1.0 (+145) - 0.5 (-73) MR1 Boom up
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
High pressure circuit
H 39.7 (5760) 0 - 5.9 (-855) OR3 Boom up

Over load relief valve pressure
R 39.7 (5760) 0 - 5.9 (-855) OR8 Arm out

Main pump
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-580) (psi) OR2 Bucket dump
Bucket a1
H 39.7 (5760) 0 - 5.9 (-855) OR1 Bucket digging
RH 29.0 (4205) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 29.0 (4205) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 35.8 (5190) 0 - 2.0 (-290) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 35.8 (5190) 0 - 2.0 (-290) RH and LH
RV —
6-29
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
Down 2.1 ~ 2.7

Operating time of cylin-
In 3.4 ~ 4.0
der Arm sec (At no load)
Out 2.9 ~ 3.5
(At no load)
Digging 2.7 ~ 3.3
Bucket
Dumping 1.9 ~ 2.5
RH
Swing speed 17.1 ~ 19.1 sec / 3 rev
LH
1st speed Iron shoe 19.6 ~ 24.6
Travel speed sec / 20 m
2nd speed Iron shoe 12.3 ~ 14.3
Amount of travel devia-
2nd speed 0 ~ 240 mm / 20 m
tion
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance
58 ~ 98 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 120
ATT amount of drift Boom cylinder 4.2 mm / 5min (At no load)
Arm cylinder 6
Amount of horizontal play at the bucket tooth 27 ~ 53 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in 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.
7.1 WORKING RANGES (SK200-8)

A. Backhoe Attachment
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
A Maximum digging reach 9,420 9,900 10,340

Maximum digging reach at ground
A’ 9,240 9,730 10,170
level
* B Maximum digging depth 6,160 6,700 7,260
* C Maximum digging height 9,510 9,720 9,750
* D Maximum damping clearance 6,680 6,910 6,970
* E Minimum damping clearance 2,980 2,430 1,870
* F Max. vertical wall digging depth 5,570 6,100 6,470
G Minimum swing radius 3,560 3,540 3,480
* H Height at min. swing radius 7,750 7,680 7,720
* J 8 feet level digging depth 5,950 6,520 7,080
K Horizontal digging Stroke 4,080 5,270 6,080
L stroke at ground level Minimum 2,980 2,270 1,900
Marked * dimensions do not include height of shoe lug
7-3
7. DATA 1.
B. Face Shovel Attachment
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

A’ 9,360 9,850 10,290
level
* D’ Maximum damping clearance (45°) 6,480 6,760 6,880
* H Max. height at min. slewing radius 7,750 7,680 7,720
7-4
7. DATA 1.
7.2 WORKING RANGES (SK330-8)

A. Backhoe Attachment
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
A Maximum digging reach 10,350 10,610 11,260 11,970

A’ 10,140 10,400 11.060 11,790
level
* B Maximum digging depth 6,510 6,860 7,560 8,410
* C Maximum digging height 10,280 10,260 10,580 10,700
* D Maximum damping clearance 7,050 7,000 7,370 7,530
* E Minimum damping clearance 3,730 3,320 2,620 1,770
* F Max. vertical wall digging depth 5,280 5,840 6,610 7,150
G Minimum swing radius 4,480 4,450 4,370 4,430
* H Height at min. swing radius 8,810 8,750 8,640 8,650
* J 8 feet level digging depth 6,310 6,670 7,400 8,270
K Horizontal digging Stroke 3,400 4,210 5,820 7,210
L stroke at ground level Minimum 4,290 3,660 2,700 2,020
7-5
7. DATA 1.
B. Face Shovel Attachment
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’ 10,550 11,210 11,930
level
* D’ Maximum damping clearance (45°) 6,810 6,940 7,400
* H Max. height at min. slewing radius 8,750 8,640 8,650
7-6
8-1
8-2

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HYD.

Technical Service Group,

Book Code No. S6OA00801ZE03

2. CONSTRUCTION & FUNCTION

3. MECHATRO CONTROL SYSTEM

4.9 ENGINE MOUNTING (SK330-8).............................................................................. 4-35

6. CHECK-UP & SERVICE

8. DATA (CIRCUIT DIAGRAM)

8.4 ELECTRIC CIRCUIT DIAGRAM (SK200-8, SK330-8) ............................................. 8-6

New style control valve Low fuel consumption

Counter New shape and design

Appearance of cab has no change

New design instrument panel

New style control valve Low fuel consumption

Counter New shape and design

Appearance of cab has no change

New design instrument panel

2.1 NAME OF COMPONENTS

SHOE AND TRACK LINK

AIR CLEANER TRACK GUIDE

LOWER ROLLER BATTERY

UPPER ROLLER ENGINE

2.2 SPECIFICATIONS AND PERFORMANCE

2.2.1.1 SPEED AND CLIMBING CAPABILITY

Area & Model

Engine model HINO J05E-TA

2.2.1.3 HYDRAULIC COMPONENTS

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

2.2.2.1 SPEED AND CLIMBING CAPABILITY

Area & Model

Engine model HINO J08E-TM

2.2.2.3 HYDRAULIC COMPONENTS

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

2.3 OPERATOR CAB NOMENCLATURE (SK200-8, SK330-8)

No. NAME No. NAME

2.3.2 GAUGE CLUSTER

GROUP No. NAME

2.3.3 LOCATION OF SWITCHES AND METERS

No. NAME No. NAME

2.4 SUMMARY OF MECHATRO CONTROL SYSTEM

&    

 %     $

MAIN CONTROL VALVE

ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

SWING MOTOR PARKING RELEASE

TRAVEL MOTOR 1,2 SPEED SELECT

SAFETY LOCK LEVER

TRAVEL 1,2 SPEED

2.4.2 UNLOAD VALVE CONTROL

PILOT SECONDARY PRESSURE

2.4.3 POSITIVE CONTROL & P-Q CONTROL

(LEFT) (RIGHT) PILOT PILOT

PILOT SECONDARY PRESSURE

(1) Positive control

POSITIVE CONTROL P-Q CONTROL

PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

PILOT PRESSURE PUMP DELIVERY PRESSURE

2.4.4 BOOM UP CONFLUX CONTROL

BOOM UP PILOT SECONDARY PRESSURE

BOOM UP PILOT SECONDARY PRESSURE

BOOM UP PILOT SECONDARY PRESSURE

2.4.5 ARM IN RECIRCULATION & CONFLUX CONTROL

ARM IN PILOT SECONDARY PRESSURE

&

% $